Advanced Turbo-generators for 1-1000 kW Variable-load Aero-Missions

"Preliminary analysis and simulations show a novel, recuperated, open Brayton cycle gas turbine should achieve system specific mass (including the generator and power conditioning) below 5 kg/kWE and efficiency of 35-50% over the range of 1-1000 kW withextremely low thermal and acoustic signatures at altitudes from sea level to 14 km. The dual-spindle compressor will enable high efficiency over a very wide load range, from idle to full power, with response time of 3-10 s after a 15-minute warm-up,making the system well suited to pulse-mode as well as continuous operation. The design integrates advanced features in the Si3N4 turbine, superalloy microtube recuperator, 2-stage compressor with intercooling, micro-jet combustor, high-speed generator,bearings, and power conditioning. The engine will be compatible with most liquid and gaseous fuels and achieve very low emissions. The Phase I is expected to include off-design engine calculations and simulations, detailed CFD and FEA turbine bladeoptimizations, analysis of factors in erosion of Si3N4 turbine blades, NOX decomposition kinetics analysis, superalloy vacuum brazing experiments, initial spindle design for a 10 kW unit, and tests of a model spindle at turbine tip speeds over 400 m/s.Manufacturing cost analyses will also be an important part of both Phase I and Phase II. Initial applications will be for aerospace and air-platform ballistic missile defense power sources where mass