Advanced Materials and Manufacturing Technology Developments for Extreme Environment Gas Turbine Applications

Abstract

Abstract Electrical power generation is becoming increasingly reliant on gas turbines with multiple fuel capability, with research advances focusing on increased efficiency/power output and reduced emissions. Increasing gas turbine efficiency primarily requires higher operating temperatures and reduced coolant flow in the turbine flow path, which makes it challenging to increase component performance, as these will encounter high stresses and large temperature gradients. Current nickel-based alloys, which operate at operate at extreme environments, are exposed to stress caused by temperature or static/dynamic loading like creep and fatigue, oxidation and corrosion, wear, and damage due to vibrations. Higher turbine inlet temperatures are currently managed with internal/film cooling and thermal/environmental barrier coatings for hot section parts. Comprehensive solutions are needed to translate to achieve ultrahigh efficiencies, lower parts cost, reduced scrape rate, and life cycle savings. The paper discusses material developments coupled with innovative manufacturing approaches to be married with advanced design strategies to realize the needed improvements for hot gas path components. The case studies for combustion and turbine components will be presented to demonstrate the structure property relationships and improved component performance at lower cost.