Hot Section Material Systems Testing and Development for Advanced Power Systems

72892-Although materials and coatings are being developed for use in syngas-fueled turbine engines, no test system is available today to effectively measure their capabilities under representative engine conditions. This project will design a low-cost test rig that can be used to understand how trace contaminants in a coal-derived synthesis gas (syngas) fueled combustion environment interact with advanced turbine blade materials and coatings. The degradation processes that may be studied with this rig include deposition, erosion, and corrosion from heavy metals or particulates and gaseous species such as SOx, alkali compounds, or HCl. The rig also will allow for the study of thermal and mechanical loads on the test specimens, emissions measurements, and will simulate actual engine conditions. In Phase I, a conceptual design and analysis were conducted of the rig test section to demonstrate that desired test conditions (thermal gradient and heat flux) could be achieved, and that the proposed rig is viable. The test chamber was designed to test multiple specimens concurrently with the specimens loaded statically. An instrumentation plan was developed to address the need to monitor specimen temperature and identify whether coating spallation occurs. In Phase II, an analytical verification of the test section design will be performed. In addition, the combustion system that supports the test rig will be designed and built. Commercial Applications and Other Benefits as described by awardee: Higher performance and lower emission requirements are driving the need for advanced turbine thermal barrier coatings for industrial gas turbines, land-based aeroderivative power turbines, and military aero engines. These applications require accurate representation of turbine engine pressures, temperatures, and air velocities in order to evaluate candidate coatings with confidence. The proposed rig should enable versatile and accurate testing in a very affordable and efficient manner to support new turbine designs.