SAMULET Project 1 - High Efficiency Turbomachinery
Lead Research Organisation:
Cranfield University
Department Name: Sch of Applied Sciences
Abstract
Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.
Organisations
Publications
Chen J
(2012)
An investigation into the correlation between nano-impact resistance and erosion performance of EB-PVD thermal barrier coatings on thermal ageing
in Surface and Coatings Technology
Wellman R
(2010)
CMAS corrosion of EB PVD TBCs: Identifying the minimum level to initiate damage
in International Journal of Refractory Metals and Hard Materials
Craig M
(2015)
CMAS degradation of EB-PVD TBCs: The effect of basicity
in Surface and Coatings Technology
Wellman R
(2009)
Effect of microstructure and temperature on the erosion rates and mechanisms of modified EB PVD TBCs
in Wear
Wang X
(2010)
Evolution of stress and morphology in thermal barrier coatings
in Surface and Coatings Technology
Aurelie Van De Put (Author)
(2009)
Hf addition by sputtering in _-NiPtAl bond coating for TBC systems and its effect on thermal cycling behaviour
Chirivi L
(2013)
Influence of Surface Finish on the Cyclic Oxidation Lifetime of an EB-PVD TBC, Deposited on PtAl and Pt-diffused Bondcoats
in Oxidation of Metals
Nicholls J
(2010)
Shreir's Corrosion
Ndamka N
(2016)
The degradation of thermal barrier coatings by molten deposits: introducing the concept of basicity
in Materials at High Temperatures
Sumner J
(2013)
Type II Hot Corrosion: Kinetics Studies of CMSX-4
in Oxidation of Metals
| Description | Note - This project was extended and completed on 30/11/13. A major aim of the SAMULET 1 was to reduce the lifecycle costs and environmental impact of gas turbines by improving the efficiency of turbomachinery. Cranfield university's involvement in this TSB project was in the development of new high temperature coating systems (WP 1.1) and in the understanding of ice accretion on the fan blades (WP: 1.9). In WP 1.1, two new high temperature coating systems have been developed, life performance assessed and transferred into Rolls Royces supply chain as a route to commercial manufacture. These are 1. a new bondcoat for a thermal barrier coating system and 2. a corrosion protection coating system. Both coating systems achieved the aim of increasing blade lifetime by at least a factor of x2. Further, the aim was to develop methods to assess the durability of high temperature coating systems under cyclic oxidation, hot corrosion and corrosion-fatigue conditions. Probablistic life models, capable of predicting the 'risk of failure', have been developed for aerofoil component geometries, thus extending further Cranfield's research into high temperature probablistic lifetime modelling. Hence the achievements were: 1. Establishment of a risk based lifing methodology for thermal barrier coatings based on the statistical analysis of cyclic oxidation data. 2. Identification of improvements to current bondcoat technologies and manufacturing methods offering an improvement in thermal barrier coating lifetime by a factor of x2. These improvements include control of trace sulphur and phosporus levels and the optimisation of the bondcoat surface finish prior to the deposition of the zirconia based thermal barrier top coat. 3. Development of a new NiPtCr diffusion coating resistant to type II hot corrosion and underplatform corrosion giving a x3 increase in component life. In WP 1.9, the behaviour of ice at different temperatures has been studied; how this affects the ice's properties, its accretion and shedding behaviour. This icing behaviour has been modelled and CFD and FE analysis have been used to validate these ice shedding models. |
| Exploitation Route | The major success of this SAMULET programme may be measured by the 'take-up' of the technologies by Rolls Royce and its supply chain. This has specifically been addressed by the exploitation report produced by Rolls Royce for the TSB. Extracting from this report, the coating benefits of this work, when fully commercialised, would be worth £100M over a 10 year base for engines of the Trent family. While the better understanding of icing mechanics, would allow new system designs saving £1M on new engines to be built. Additionally, this SAMULET programme has seen a transfer of young talented engineers and experienced research staff into industry, support the aero-engine market sector. The primary route to expoitation is through Rolls Royce plc and its supply chain. The new, improved bondcoat technology, increases current blade life by a factor of x2. This benefit, if implimented, would allow Rolls Royce to increase turbine entry temperature, whilst achieving the same projected engine life,thus increasing the available power and reducing emissions such as CO2, due to an increase in thermal efficiency and the associated savings on fuel burn. Understanding ice build up and shedding, will allow systems to be developed with Rolls Royce that limit ice accretion, mitigating the potential damage to fan blades and the compressor due to ballistic impact as a result of ice shedding. In terms of the exploitation of academic outputs, the PI and both CoI's have been asked to present keynote papers in their specialist research areas. Research papers have been published in peer reviewed journals and as a result of such communications new research proposals have been developed and funded. |
| Sectors | Aerospace, Defence and Marine,Energy,Environment,Manufacturing, including Industrial Biotechology,Transport |
| Description | Low K thermal barrier coatings are now specified for the Trent 1000 family of Rolls Royce engines. This TBC system benefits from the new bondcoat technologies developed in this programme. Within the programme stochastic models for lifing TBCs were developed that included both compositional and manufacturing variables. These models have been implimented within Rolls Royce as part of a lifing stratergy for TBCs. Since this research, methodologies to assess both erosion and CMAS damage have been further developed, through the understanding of materials behaviour and processing variables, allowing extension of the models to encompass new ceramic/new bondcoat combinations. Subsequent to this grant, the methods developed to co-dope and sequential dope TBCs with lanthenide additions has allowed self diagnostic, temperature sensing TBCs to be developed. |
| First Year Of Impact | 2014 |
| Sector | Aerospace, Defence and Marine,Energy,Manufacturing, including Industrial Biotechology,Transport |
| Impact Types | Societal,Economic |
| Description | Advanced Surface Protection for Improved Renewable Energy (ASPIRE) |
| Amount | £199,996 (GBP) |
| Funding ID | 16895-122151 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 01/2013 |
| End | 12/2015 |
| Description | Flexible and Efficient Power Plant |
| Amount | £1,997,000 (GBP) |
| Funding ID | EP/K021095/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 08/2013 |
| End | 02/2018 |
| Description | MALIT - Material and Lifing Improvements in Turbines |
| Amount | £1,189,000 (GBP) |
| Funding ID | 113180 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 09/2018 |
| End | 08/2022 |
| Description | Multi-layered CMAS Resistant Thermal Barrier Coatings |
| Amount | £79,896 (GBP) |
| Funding ID | STC 32729 |
| Organisation | Rolls Royce Group Plc |
| Sector | Private |
| Country | United Kingdom |
| Start | 06/2018 |
| End | 12/2018 |
| Description | Multi-layered CMAS Resistant Thermal Barrier Coatings (phase 2) |
| Amount | £62,180 (GBP) |
| Funding ID | STC 32872 |
| Organisation | Rolls Royce Group Plc |
| Sector | Private |
| Country | United Kingdom |
| Start | 04/2019 |
| End | 12/2019 |
| Description | New Bondcoat Technologies |
| Amount | £62,000 (GBP) |
| Funding ID | 50022704223 |
| Organisation | Rolls Royce Group Plc |
| Sector | Private |
| Country | United Kingdom |
| Start | 09/2013 |
| End | 07/2014 |
| Description | New Bondcoat Technologies |
| Amount | £62,000 (GBP) |
| Funding ID | 50022704223 |
| Organisation | Rolls Royce Group Plc |
| Sector | Private |
| Country | United Kingdom |
| Start | 09/2013 |
| End | 07/2014 |
| Description | Samulet 2: CMAS and Volcanic Ash Resistant Coatings |
| Amount | £202,000 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 01/2009 |
| End | 12/2013 |