High Temperature Additive

Architecture for 65% Efficiency

DE-FE0031611

GE Gas Power
Conference presenter
PI: Richard DiCintio
Scott Johnson
PM: Carlos Miranda
Key Contributors: Ben Lacy, Srikanth Kottilingam, Brad
VanTassel, Evan Dozier, Tim Moricca

FECM / NETL Spring R&D Project Review Meeting

Pittsburgh, PA
May 2024

© 2024 GE Vernova and/or its affiliates. All rights reserved. 1

© 2023 GE Vernova and/or its affiliates. All rights reserved.
This material is based upon work supported by the Department of Energy under Award Number DE-FE0031611

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any
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GE-NETL Partnership Leads to Record Performance
Advanced Cores & Castings
Micro-channel cooling

Advanced sealing Ceramic Matrix Composites

Low / Ultra-Low k TBC

High Temperature Additive Unsteady Aerodynamics

High Temperature Rotor Last Stage Blades

Micromixer + Axial Fuel Staging

Advanced Combustion

57% to 64%+ Combined Cycle Efficiency in 15 years!

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Agenda

▪ Impact of Additive at GE
▪ Industrial Gas Turbine Terminology
▪ Phase I Objectives
▪ Phase II Key Technology Activities
▪ Phase II Validation Testing
▪ Phase II Next Steps

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Impact of Additive at GE

Performance Improved
• Removes traditional mfg. constraints Processing
• Enables “near surface” cooling & cooling air
Sciences
reduction

Speed to Market
More Capable
• Model to part directly
• Quick prototypes Alloys
• ~18-month cycle

Cost Advanced
• Eliminate casting tooling Product
• Metal only where needed
Designs
• Reduction of component counts

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 Advanced Manufacturing Works – Greenville, SC

Merging design and manufacturing technology to deliver better products

Additive
• >25,000 parts shipped
• 1st GT parts produced/fielded

Ceramics
• 1st fielded CMCs
• Thermal coatings

Process optimization
• Automation/Digital
• HGP Special Processes
• Reduced cost and lead time

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Industrial Gas Turbine Terminology

STAGE 1
TURBINE
STAGE 1
SHROUD
TURBINE VANE
STAGE 1
TRANSITION PIECE TURBINE
BLADE STAGE 2
TURBINE VANE
COMBUSTION SYSTEM &
LINER

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Turbine Vane Conventional Cooling Fundamentals

Internal Cooling Flow Circuit Surface/External Film Cooling

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Project Objectives & Technical Approach
Overall Objective
Develop a feasible conceptual design for advanced additive turbine inlet components that enable 65% CC efficiency
through analytical methods and feature print trials.

Technical Approach

Phase 1 – Discovery (July 2018 – Jan 2020)

Phase 2 – Demonstration (Jan 2020 – Sept 2024)
▪ Generate advanced wall architecture and airfoil
▪ Generate high efficiency component design, enabled by additive
concepts enabled by additive manufacturing
manufacturing, using state-of-the-art tools and methods.
▪ Identify and evaluate additive methods and materials
▪ Demonstrate manufacturing readiness level for additive
that enable desired geometry through coupon print
manufacturing modalities through extensive print trials and post
trials
print inspection.
▪ Downselect a primary concept and additive
▪ Validate individual wall architecture and cooling concepts with
method/material plus a backup to carry forward into
laboratory environment testing.
potential Phase II project
▪ Demonstrate technology readiness level for component design at
▪ Develop test plan for Phase II execution
representative gas turbine conditions in combustion validation
rig.
Program Objectives: Phase I – Discovery
Conceptual Design & Feasibility
Near-wall Microchannels
Recirculating Trailing Edge
Advanced Film Shapes

Airfoil Compartmentalization
& Impingement Reuse
Axial Film Flow
for Leading Edge

Adaptive Cooling
Advanced H-Bumps

Program focus: high-temperature alloys, new additive modalities, geometry enabled by

additive, and manufacturing capability
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Phase II Key Technology Activities
Cooling Technology
Initial scope of thermal correlations for additive cooling features.

Wall Architecture Technology Bench Testing

Correlations of model to printed feature size for different additive modalities.
Flow testing of cooling features, total and by feature.

Additive Process Capability and Control

Powder removal on production viable designs.
Repeatability demonstration/ dimensional control.

Additive Material Properties

Properties for several modalities.

Detailed Design
Heat transfer and structural mechanical.

All activities listed above are complete

© 2023 GE Vernova and/or its affiliates. All rights reserved. 11
 Phase II Validation Testing
Testing Summary
Tested over 3 days, ~20 fired hours.
No test issues, all key instrumentation preserved.

Testing Envelope
Gas: 2700°F, 2900°F, 3100°F and 3200°F within +/- 5°F
Coolant: 660°F, 760°F with short excursion to 830°F within +/- 10°F

Objectives Achieved
Collected 75 data points.
Test Cell
Generated Baseline Airfoil Cooling Effectiveness Curve by Gas Temperature,
Vernova Advanced Research
Coolant Temperature, Coolant Flow and Gas Flow sweeps.
Niskayuna NY

General Trends
Consistently colder metal temperatures than Baseline for same conditions.

© 2023 GE Vernova and/or its affiliates. All rights reserved. 12

Next Steps
Data Collection
Manufacturing Trial
Baseline and Technology test articles to be cut for further
Commissioning inspection, cold flow and metallurgical processing.
TC depth and TBC thickness to be measured.

Baseline
Data Analysis
Revisiting Heat Transfer models for Technology and Baseline test
articles.
Data-matching models to include as tested cooling flows, TBC
thickness and operating conditions.
Technology Comparing heat transfer model prediction to TC data.

Test articles in excellent

condition post-test
© 2023 GE Vernova and/or its affiliates. All rights reserved. 13
QUESTIONS?

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© 2023 GE Vernova and/or its affiliates. All rights reserved.
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