Structural Metallic Systems For Advanced Gas Turbine Applications
Lead Research Organisation:
University of Birmingham
Department Name: Metallurgy and Materials
Abstract
Dwindling resources and climate change are forcing engineering designers to utilise materials and energy supplies withever-greater efficiency. It is argued that cuts in CO2 emissions of between 60-90% must be achieved if irreversibleclimate change is to be avoided.At present, almost all aircraft propulsion and over 1/3 of the UK's total generating capacity rely on gas turbines. Theirflexibility and efficiency compared with the alternatives mean that their use in power generation is predicted todramatically increase for the foreseeable future. Similarly, a substantial growth in air travel is also predicted withpassenger numbers forecast to double or triple by 2050. Achieving drastic reductions in the emissions from gas turbines,without bring national economic activity to a standstill, requires urgent activity on a very wide number of fronts. This isparticularly important for the UK. It has Europe's largest gas turbine industry, second only to the US, including majorengine makers, such as Rolls-Royce, Alstom and Siemens, together with approximately 3,000 companies supplyingalloys, high integrity components, such as discs, blades and shafts, as well as coatings and seals. The industry as awhole employs over 400,000 people and generates 2 billion in exports in the power sector alone.The aim of this programme is to meet this challenge by identifying and developing materials based on refractory metals,such as Mo and Co alloys, while carrying out shorter term research to extend the usefulness of Ni-based alloys. Thework will involve a coordinated programme of materials development and processing, microstructural and defectmodelling, characterisation and prediction of these high temperature materials designed to answer the fundamentalquestions that will enable their potential to be fully realised.To generate a critical mass of researchers, the programme brings together academics from 6 universities with expertise inthe necessary areas, together with Rolls-Royce plc to ensure the research is appropriate and to establish a route forexploitation.The success of the UK high-value engineering sector is an area in which improved public understanding is needed toimprove the perception of metallurgical engineering generally and to engender enthusiasm to encourage more youngpeople into science and engineering. To address this, a significant programme of public engagement has been designedto run alongside this research programme
Planned Impact
This programme addresses a national grand challenge, the reduction of emissions in energy production, by developing disruptive materials technologies for increasing the operating temperature of gas turbines. The beneficiaries will be: * UK gas turbine industry, including supply chain: By enabling the primary end-user in this programme, Rolls-Royce, to remain competitive as power generation, aero and land, becomes increasingly constrained by environmental legislation; * UK policy makers: By both informing UK government and enabling it to meet national, EU and international commitments without compromising the economic viability of UK industry; * UK population: By limiting potential damage through dangerous climate change whilst simultaneously minimising the impact on standard of living. UK aerospace and energy industry * To ensure a critical mass of researchers, this programme builds upon the established and highly successful UTP framework between Cambridge, Swansea and Birmingham and involves other institutions where specific expertise exists (Sheffield, Cranfield & Imperial College).* Maximum impact requires: 1. RR will manage the involvement of companies in the supply chain to enable the development of suitable manufacturing techniques.. 2. The application of the materials in land-based turbines, using the established relationship between RR and Alstom. * Active technical engagement with RR will build upon existing links between academic staff and RR staff. Each project in the programme will have a nominated technical specialist at RR who will attend regular technical review meetings held in the universities. Annual Gate Reviews will be held to assess development of materials and the involvement of appropriate commercial partners. Materials identified as suitable for adoption by industry at the end of the programme will have a RR technical representative assigned to champion their development and deployment. * The Programme will be managed by an Operations Board (made up of representatives from RR, EPSRC & each university). This will review developments in the individual projects & assign responsibilities within both RR & universities for uptake of technologies into industry. * A dedicated website will be run from University of Cambridge to capture and maintain new knowledge as well as enabling easy dissemination of technical information within the partnership. * A formal collaboration agreement will be put in place before the programme. * Issues associated with the manufacture and the supply chain will be addressed by the appropriate partners in collaboration with the relevant funding agencies. UK policy makers * Oversight of progress and developments on the programme, as well as coordination with other activities, will be achieved through attendance of the Governance and Operations Boards by members of the Energy Materials Working Group, EPSRC and TSB. * EPSRC & TSB will provide assistance in the delivery of the new materials into the industrial sector through the identification of suitable funding mechanisms to support their continued development beyond this programme. UK population * On-line material will be developed to give a basic understanding of the problems and applications as well as enabling those interested to follow the progress of the project. * This will be done in collaboration with the Naked Scientists , who produce science highly popular radio programmes and podcasts. It is hoped to contribute toward recruiting more undergraduates into engineering and physical sciences.
Publications
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Flint T
(2018)
Prediction of grain structure evolution during rapid solidification of high energy density beam induced re-melting
in Materials & Design
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Wang S
(2019)
Investigation on Fatigue Threshold Testing Methods in a Near Lamellar TiAl Alloy.
in Materials (Basel, Switzerland)
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Taylor M
(2010)
A chromia forming thermal barrier coating system
in Materials and Corrosion
![publication icon](/resources/img/placeholder-60x60.png)
Taylor M
(2014)
The oxidation characteristics of the nickel-based superalloy, RR1000, at temperatures of 700-900°C
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Cruchley S
(2014)
Cautionary note on use of focused ion beam sectioning as technique for characterising oxidation damage in Ni based superalloys
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Taylor M
(2014)
The effect of bond coat oxidation on the microstructure and endurance of a thermal barrier coating system
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Rosser J
(2014)
Steam oxidation of Super 304H and shot-peened Super 304H
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Sato A
(2014)
Characterisation of oxide scale formation on a new single crystal superalloy for power generation applications
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Cruchley S
(2015)
Effect of prior oxidation on high cycle fatigue performance of RR1000 and role of oxidation in fatigue crack initiation
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Baris A
(2017)
Observation of crack microstructure in oxides and its correlation to oxidation and hydrogen-uptake by 3D FIB Tomography - case of Zr-ZrO 2 in reactor
in Materials at High Temperatures
![publication icon](/resources/img/placeholder-60x60.png)
Guo Y
(2017)
Spatial variation of microtexture in linear friction welded Ti-6Al-4V
in Materials Characterization
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Ding R
(2015)
Electron microscopy study of direct laser deposited IN718
in Materials Characterization
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Turner R
(2018)
Neutron tomography methods applied to a nickel-based superalloy additive manufacture build
in Materials Letters
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Mine Y
(2012)
Effect of lamellar spacing on fatigue crack growth behaviour of a TiAl-based aluminide with lamellar microstructure
in Materials Science and Engineering: A
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Htwe Y
(2018)
Anisotropy of < a > slip behaviour in single-colony lamellar structures of Ti-6Al-4V
in Materials Science and Engineering: A
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Oluwasegun K
(2014)
Micro-tensile strength of a welded turbine disc superalloy
in Materials Science and Engineering: A
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Ding R
(2009)
The role of Hf and TiC additions in the mechanical properties and microstructure of NbAlV alloys
in Materials Science and Engineering: A
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Ye R
(2020)
Microstructure and microhardness of dissimilar weldment of Ni-based superalloys IN718-IN713LC
in Materials Science and Engineering: A
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Guo Y
(2013)
Microstructure and microhardness of Ti6246 linear friction weld
in Materials Science and Engineering: A
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Yang J
(2014)
Lamellar orientation effect on fatigue crack propagation threshold in coarse grained Ti46Al8Nb
in Materials Science and Technology
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Daus F
(2013)
Mechanical and microstructural assessments of RR1000 to IN718 inertia welds - effects of welding parameters
in Materials Science and Technology
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Cruchley S
(2014)
Characterisation of subsurface oxidation damage in Ni based superalloy, RR1000
in Materials Science and Technology
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Ding R
(2013)
Influence of carbides on the strength and toughness of a niobium alloy
in Materials Science and Technology
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Li H
(2013)
High temperature fatigue of friction welded joints in dissimilar nickel based superalloys
in Materials Science and Technology
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Jiang H
(2011)
Microstructure and properties of hot isostatically pressed powder and extruded Ti25V15Cr2Al0·2C
in Materials Science and Technology
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Hu D
(2010)
Tensile Ductility of Cast TiAl Alloys
in Materials Science Forum
![publication icon](/resources/img/placeholder-60x60.png)
Schulz F
(2018)
Influence of Tertiary Gamma Prime (?') Size Evolution on Dwell Fatigue Crack Growth Behavior in CG RR1000
in Metallurgical and Materials Transactions A
![publication icon](/resources/img/placeholder-60x60.png)
Christofidou K
(2018)
On the Effect of Nb on the Microstructure and Properties of Next Generation Polycrystalline Powder Metallurgy Ni-Based Superalloys
in Metallurgical and Materials Transactions A
![publication icon](/resources/img/placeholder-60x60.png)
Turner R
(2015)
An Improved Method of Capturing the Surface Boundary of a Ti-6Al-4V Fusion Weld Bead for Finite Element Modeling
in Metallurgical and Materials Transactions B
![publication icon](/resources/img/placeholder-60x60.png)
Turner R
(2016)
An Integrated Modeling Approach for Predicting Process Maps of Residual Stress and Distortion in a Laser Weld: A Combined CFD-FE Methodology
in Metallurgical and Materials Transactions B
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Edmonds I
(2009)
The Role of the ?' Precipitate Dispersion in Forming a Protective Scale on Ni-Based Superalloys at 750 °C
in Oxidation of Metals
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Smith P
(2013)
The Oxidation and Interdiffusion of a Chromia Forming Multilayered TBC System
in Oxidation of Metals
![publication icon](/resources/img/placeholder-60x60.png)
Jackson R
(2011)
Oxidation Study of an EB-PVD MCrAlY Thermal Barrier Coating System
in Oxidation of Metals
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Ding R
(2012)
Transmission electron microscopy of deformed Ti-6Al-4 V micro-cantilevers
in Philosophical Magazine
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Basoalto HC
(2018)
A computational study on the three-dimensional printability of precipitate-strengthened nickel-based superalloys.
in Proceedings. Mathematical, physical, and engineering sciences
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Khoshkhou D
(2016)
Three-dimensional displacement mapping of diffused Pt thermal barrier coatings via synchrotron X-ray computed tomography and digital volume correlation
in Scripta Materialia
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Evans H
(2013)
A mechanism for stress-aided grain boundary oxidation ahead of cracks
in Scripta Materialia
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Mine Y
(2019)
Fatigue crack growth behaviour in single-colony lamellar structure of Ti-6Al-4V
in Scripta Materialia
![publication icon](/resources/img/placeholder-60x60.png)
Panwisawas C
(2015)
On the role of thermal fluid dynamics into the evolution of porosity during selective laser melting
in Scripta Materialia
![publication icon](/resources/img/placeholder-60x60.png)
Kitaguchi H
(2015)
An atom probe tomography study of the oxide-metal interface of an oxide intrusion ahead of a crack in a polycrystalline Ni-based superalloy
in Scripta Materialia
![publication icon](/resources/img/placeholder-60x60.png)
Yang C
(2012)
Effect of boron concentration on phase transformation texture in as-solidified Ti44Al8NbxB
in Scripta Materialia
![publication icon](/resources/img/placeholder-60x60.png)
Evans H
(2011)
Oxidation failure of TBC systems: An assessment of mechanisms
in Surface and Coatings Technology
![publication icon](/resources/img/placeholder-60x60.png)
Kitaguchi HS
(2019)
Mesoscopic quantitative chemical analyses using STEM-EDX in current and next generation polycrystalline Ni-based superalloys.
in Ultramicroscopy
Description | Fundamental understanding of processing-microstructure-property correlations has allowed: new alloys to be introduced; life extension of existing components to be supported; and, new joining methods to be introduced into the arduous environment of a gas turbine aero-engine. |
Exploitation Route | The joining techniques could find applications in other sectors of transportation and power generation industries. The new alloys also have applications to other areas such as their use in turbo-chargers for automotive transportation. Also, the lifing methodologies developed have applicability to land- based power generation. |
Sectors | Aerospace, Defence and Marine,Energy,Transport |
Description | Fundamental studies have allowed the incorporation of new alloys TiAl into the up-rated version of a new engine (2015) and to be introduced into service in the near future. They have also facilitated the use of new joining techniques for engines which are now flying (2014-2015). Finally they have allowed life extension methodologies which are expected to save many millions of pounds to the engine fleet over the next 30 years in service. In addition this Strategic Partnership allowed the University of Birmingham to bid for the RPIF HTRC project with Rolls-Royce. |
First Year Of Impact | 2013 |
Sector | Aerospace, Defence and Marine |
Impact Types | Economic |
Description | ATI |
Amount | £13,000,000 (GBP) |
Funding ID | TS/L008831/1 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 04/2014 |
End | 03/2017 |
Description | ATI |
Amount | £16,000,000 (GBP) |
Funding ID | TS/N001222/1 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 07/2016 |
End | 06/2018 |
Description | ATI |
Amount | £2,300,000 (GBP) |
Funding ID | TS/N010825/1 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 04/2016 |
End | 03/2019 |
Description | EPSRC Programme Grant |
Amount | £2,000,000 (GBP) |
Funding ID | EP/P00878/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 09/2016 |
End | 08/2020 |
Description | FP7 |
Amount | £1,009,357 (GBP) |
Organisation | European Union |
Sector | Public |
Country | European Union (EU) |
Start | 06/2011 |
End | 06/2016 |
Description | H2020 |
Amount | £1,500,000 (GBP) |
Organisation | European Union |
Sector | Public |
Country | European Union (EU) |
Start | 04/2016 |
End | 03/2019 |
Description | Research Grant |
Amount | £9,000,000 (GBP) |
Funding ID | EP/M005607/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 10/2014 |
End | 09/2019 |
Description | Rolls-Royce Plc |
Amount | £1,111,400 (GBP) |
Organisation | Rolls Royce Group Plc |
Sector | Private |
Country | United Kingdom |
Start | 01/2010 |
Description | University Technology Centre with TIMET |
Amount | £1,000,000 (GBP) |
Organisation | Timet UK Ltd |
Sector | Private |
Country | United Kingdom |
Start | 04/2012 |
End | 09/2017 |