ENGINEERING ABSTRACTS

JOHN W. SAWYER

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ENGIAEERING ABSTRACTS

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1956 Modern Plant Survey Some Experiences in Vessels Equipped with Two-Stroke Cycle Harland and Wolff Opposed Piston Diesel Engines using Boiler Oil Metallurgical Designing for Strength Ultrasonic Welding Tool Life Increased with New Steel Packless Stuffing Boxes-Pro and Con Surface Finish Inspection Methods Power and the Future Fire Resistant Hydraulic Fluids Materials for Nuclear Power Reactors How Additives Can Make Your Residual Fuels Burn Better, Cleaner Engine Research The Influence of Combustion on the Thermal Efficiency of Simple Gas-Turbine Cycles Fire Fighting with Combustion Products Nuclear Effects on Electronic Components A Design Guide to Industrial Fasteners Fin Stabilizers for Ships Research at Pametrada Lightweight Mech-Hydro Locomotive for Train X The High Temperature Turbo-Jet Engine Where Reactor Development Stands Today 25,000 Hours of Free Piston Engine Operation High Temperature Brazing

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"1956 Modem Plant Survey"-B.G.A. Skrotzki: Power, V. 100, n. 9B, Mid Sept. 1956, pp. 35-62. Data are presented on steam, gas turbine and hydro plants w i n g operations, under con- struction or in planning stages. Material includes: design survey of new steam central station installation; industrial institutional plants 250 psi and over; industrial and institutional plants less than 250 psi; stationary gas turbines in central station and industry: stationary gas turbines. small auxiliary and experimental: hydroelectric plants in the United States h d Canada. Survey shows about 1,270 steam gen- erators with total capacity 53.8 million lb. per hr. purchased in 1955 and early 1956. Some 63 steam turbines were installed with capacity of 815 mw. Largest boiler reported has capacity of 1,050,OOO lb. per hr. Survey lists 413 gas turbines; 23 are Houdry and other process units and 390 are electrical and mechanical drive. These have a total nameplate rating of 1,855.OOO kw. Largest gas turbine was a 40,000 kw planned by Swedish Power Board. Cycles for gas turbine include 349 open, 14 closed, 25 free piston, 2 semi-closed and 2 equi-pressure.

"Some Experiences in Vessels Equipped with Two-Stroke Cycle Harland and Wolff Opposed Piston Diesel Engines using Boiler Oil"-A. G. Arnold: Institute of Marine Engineers Trans- actions V. LXVIII. n. 7. July 1956, pp. 201-245. Results of seventy-five voyages between the United Kingdom and The Far East made by nine vessels. Ehgmes in aII vessels had 750 mm bore with a combined stroke of ZOO0 mm. Two cylinder liners were removed, after 13,000

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hours. due to cracking and not as a result of wear. Wear rates of liners are plotted for several vessels. Chrome hardened liners were tried but did not give results expected. Exhaust piston yoke on one engine was cracked and had to be replaced. Exhaust pistons. coating of piston crowns piston rings. scavenge belts, scavenge belt fires, lubrication. cylinder oil, boiler oil. maintenance charges, supercharging and trials are discussed. A 350 KW gas turbine driven emergency generator set was installed in these vessels. Photographs, curves, tables. drawings, indicator diagrams and discussions of the paper are included.

83-56 “Metallurgical Designing for Strength”-C. Zener; Westinghouse Engmeer, V. 16, n. 5, Sept. 1956, pp. 146-151. Design techniques are being developed to provide new metals and alloys to meet specific requirements. A new high-temperature alloy for steam turbines was recently developed using these techniques. Atomic structures and deformation are described. Design principles now available to the metallurgist are outlined. These new principles will result in the development of new materials at less cost and in shorter times.

84-56 “Ultrasonic Welding”-J. Byron Jones and James J. Powers, Jr.; The Welding Engineer, V. 36. n. 8, August 1956, pp. 761-766. Dissimilar metals can be bonded by introduction of ultrasonic energy into the metals at the areas to be in contact. Application of heat, aside from that generated by the vibratory motions, is not re- quired. Strength and deformation of weld zones are shown. Discussion includes: basic problems in ultrasonic welding; welding systems; con- trollable welding variables; factors associated with mechanism of ultrasonic welding; present status of sheet-to-sheet welding. Feasible uses include: foil-thickness material bonding; foil thick materials bonded to heavy plate, rod or tube; welding of sintered aluminum powder products; welding of copper in gages up to 0.040 in.: hermetic sealing of small containers, squeeze tubes, impact extrusions. References.

85-56 ‘Tool Life Increased with New Steel”-J. Y. Riedel; Metal Progress, V. 70, n. 2, August 1956, pp. 69-71. A tool steel has been developed that has improved shock resistance and service life. This steel is improved for both hot and cold work applications. The nominal com- position of this steel is 0.50%, C, 0.70‘h Mn, 0.27:$ Si, 3.255 Cr, and 1.WL Mo. When fully annealed, machinibility is about 95% that of a 1% carbon steel. This steel, as a notching die, enabled production of 10,OOO pieces where dies of other materials produced only 30 pieces.

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Punches made from this steel produced an av- erage of 5,500 holes while other punches produced from 300 to 1,500 holes per punch. In hot riveting on boilers rivet sets ran to nearly 2,500 before recupping while standard rivet sets ran no more dhan 300 rivets.

86-56 “Packless’ Stuffing Boxes-Pro and Con”-Igor J. Karassik; Power Engineering, V. 60, n. 9, Sept. 1956, pp. 90-92. The weakest point of high speed boiler feed pumps is the packing. Present designs can now be made so that high pressure pumps can run from 60,000 to 120,000 hours between complete overhauls. However, packing requirements are to shut pumps down every 6 to 18 months for repacking. Mechanical seals and packless stuffing boxes are being investigated. They have both been tried. The packless stuffing box is the most promising at the present. In this unit a labyrinth breakdown bushing is substituted for conventional packinq. Pumps operating in speed range from 6,000 to 9,OOO rpm make the packless stuffing box more attractive than packing.

87-56 “Surface Finish Inspection Methods”-C. H. Good: The Tool Engineer, V. XXXVII, n. 2, Au- gust 1956, pp. 93-97. Methods and equipment for measuring and evaluating surface finish are presented. Instruments and methods include: reflectivity meter, air gaging, microscow, stylus techniques. Limitations of these are described. Various inspection techniques are summarized in tabular form. Illustrations, photographs and charts.

88-56 “Power and the Future”-T. W. F. Brown; North East Coast Institution of Engineers and Ship- builders Transactions, V. 72, n. 8, July 1956, pp. 373-388. Power available and predicted for future is discussed. Sources include the earth and sun. Radiation is a direct use of sun while indirect uses include hydro-electric, wind and lightning. Tidal power, hydrocarbon fuels and nuclear power are reviewed. Efficiencies of various prime movers for converting heat energy to mechanical power are shown.

89-56 “Fire Resistant Hydraulic Fluids”-R. Q. Sharpe: Product Engineering, V. 27, n. 8, Au- gust 1956, pp. 162-166. More hydraulic systems for actuating machines are being designed to use fire resistant fluids. Many hydraulic and lu- bricating oils have a flash point of 375°F or greater and a fire point of 425°F. When lines fail under high pressure, oil can be atomized and readily result in a flash fire. Fire resistant fluids available include: water glycol mixtures; non-aqueous type such as tri-cresyl phosphate, chlorinated hydrocarbons, fluorinated hydrocarbons; water soluble oil emulsions. Proper- ties of fire resistant fluids compared with pe- troleum oil. Tables and references.

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90-56 “Materials for Nuclear Power Reactors”-John M. Warde; Materials & Methods, V. 44, n. 2, August 1956, pp. 121-144. Material selection factors and materials for reactors are discussed. Data presented on structural materials including aluminum, stainless steel, nickel and nickel base alloys, zirconium, magnesium, molybde- num, titanium, graphite, silicon, carbide, cer- mets, plastics and elastomers. Shielding, controls, coolants, fuels, and fertile materials are reviewed. Properties of some materials are in tables. Illustrations and curves shown. Future outlook for power indicates that by 2,000 A.D. nuclear plants will be producing more power than aU other sources combined at present time.

“HOW Additives Can Make Your Residual Fuels Burn Better, Cleaner”-R. S. Norris; Power, V. 100, n. 8, Aug. 1956, pp. 120-121. Residual fuels contain most of the compounds of sulfur, vanadium and sodium. These compounds are harm- ful to certain parts of boilers, gas turbines and diesel engines. Diesel cylinder liners and piston ring wear rates are as much as three times as high when burning residual fuel. Vanadium and sodium compounds are corrosive in a liquid state. Certain additives for residual fuels hold promise for use in diesels, gas turbines and boilers. These additives are known as BARSAD. They have been used in the following applications with residual fuels: 20 diesel ships for 18 months; a 650 psi, 825”F, 150,OOO 1b.-per-hr. boiler; and a C-2 cargo vessel.

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92-56 “Engine Research”-Automobile Engineer: V. 46, n. 7, July 1956, pp. 254-263. Discussion of engine research including: diesel engine devel- opments, high-speed sampling valves, fuel-line pressure measuring units, blowing rig. cold starting rig, traversing thermocouple, heat flow. residual fuel, injector temperature measure- ment and Alcock viscous flow air meter.

”The Influence of Combustion on the Thermal J3Eciency of Simple Gas-Turbine Cycles”-L. S. Dzung: The Brown Boveri Review, V. 43, n. 3/4, MarIApr. 1956, pp. 63-78. The entire problem of combustion, both internal and external to the medium circuit, is discussed. Thermo- dynamic principles, diabatic process without combustion, liquid fuel, dependence of basic process on medium, reaction parameters and numerical examples are presented. Bibliog- raphy.

“Fire Fighting with Combustion Products”-- The Marine Engineer and Naval Architect; V. 79, n. 958. August 1956, pp. 276-278. A fire fighting system consisting of an inert gas generator has been developed for extinguishing fires in cargo holds and machinery spaces. The unit as developed includes: horizontal combustion chamber, with water jacketed fire brick lining; an oil burner with fuel and air regulators: cool-

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ing chamber; water cooled diesel driving an air blower; generator for supplying power for ac- cessory units. Diesel oil is used for fuel The gas generator package is 9 f t . long, 4 ft. wide and 7 ft. high. Fuel consumption to meet requirements for a ship’s hold of 115,OOO cu. f t . is 25 gallons per hour. This system as installed on the motorship Oti costs about $21,000 and has been approved by Ministry of Transport.

“Nuclear Effects on Electronic Components”- Charles C. Robinson: Electrical Manufacturing, V. 58, n. 2, August 1956, pp. 96-99, 268. 270, 272. Important nuclear effects on electronic components are being investigated under a recently awarded Air Force contract. Wire insulation has reduced resistance proportional to radiation intensity. Gases may be liberated and rupture containers of oil filled and oil impregnated parts. Resistors change values from 5 to 15 per cent. Radiation, particularly gamma radiation. may cause phototubes to indicate false. Current tests under this program are designed to in&- cate changes in components during periods of irradiation. Results of this work will be pre- pared in a form suitable for use by the engineer in selecting an appropriate component for specific needs. References.

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96-56 “A Design Guide to Industrial Fasteners“- Julius Soled; Machine Design. V. 28. n. 17, Au- gust 23,1956, pp. 105-135. Seven basic categories of fasteners are presented: inserts. nuts. pins. retaining rings, rivets. Screws, bolts, studs and washers. The items are illustrated, form, design features. materials. sizes, and applications are discussed. Standard and proprietary items are included.

97-56 “Fin Stabilizers for Shps”-M. D. Martin; Bu- reau of Ships Journal, V. 5. n. 5, Sept 1956. pp. 15-21. A hydrofoil fin type stabilizer has been installed on the USS Gyatt (DDG-712). The installation cost approximately $38O,OOO and is the first for the US. Navy. The stabilizer is expected to have sufficient capacity to reduce rolling motions of the ship from 26” or more from the vertical to 1%” either side of the vertical. Main components of the power plant include electric motor. hydraulic pump and strdr- ing servo system. Advantages of the stabilizer: aids in replenishing at sea; aids in navigation: improves crew efficiency. safety and comfort: aids in guided and ballistic missile handling and launching.

98-56 “Research at Pametrada”-The Oil Engine and Gas Turbine; V. XXIV. n. 276, August 1956. p. 164. High temperature development and design work is being done gas turbines operating at 1200” C. The test turbine is a single stage machine. Temperature distribution tests on the combustion chamber vary from plus 21°C to minus 33°C from the mean. Torch igniters are used. Blades

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tested include zircon plus 2.5 per cent chromic oxide. A silicon carbide has been tested as blade material and found superior to zircon-chromic oxide. Blade cooling utilizes a two liquid system. The hollow blades are sealed with sodium potassium liquid metal. The test unit has been operated for twelve hours at maximum temperature without its rotor, Other development work includes flexible ducting, sprayers, fuel systems, air cooled combustion chambers, heat exchanger, materials, water cooled blades, turbine casings. A design of a 10,OOOshp marine engine includes a maximum temperature of 1204°C and a specific fuel consumption of 0.39 Ib. per shp-hr.

“Lightweight Mech-Hydro Locomotive for Train X”-Arnold B. Newell; Diesel Progress, August 1956. pp. 23-25. A new locomotive power package has been manufactured. It consists of a 1,OOO hp diesel engine. hydraulic transmission, drive shaft and axle drives. The power package is so designed that it is easily removed and replaced. The transmission, Baldwin-May- bach. is fully automatic. It is comprised of a permanently filled hydraulic torque convertor, a four-speed gear box. including three pairs of helical gears operating together with over- running clutches. There are four ahead speeds and reverse. The engine is a V-type, operating at 1,500 rpm, bore 7.3 in. and stroke 7.9 in. A spherical combustion chamber is located in the center of each cylinder head.

“The High Temperature Turbo-Jet Engine”- D. G. Ainlay: The Journal of The Royal Aero- nautical Society. V. 60, n. 549, Sept. 1956, pp. 563-589. High temperature operation and its re- lated problems is discussed in relation to the future progress in turbo-jet engines. Greatest single problem is that of highly stressed blades in the turbine. Possible solutions include development of new material that could operate at higher temperatures or devising means of cooling existing materials. Thus gas temperatures could be raised while blade temperatures would remain at levels now found in existing engines. Methods of cooling blades include: liquid cooling where heat is absorbed by an ex- pendable amount of liquid without reusing the liquid; combined liquid-air method where heat is removed from blades by a liquid which is then circulated and cooled in an air heat exchanger; air cooling where air is forced directly through inner portions of the turbine blades. These cooling methods are illustrated. Design and development of various types of cooled blades are presented. Basic requirements for efficient internal cooling, cooling characteristics of typical internally air-cooled blades, summary of practicability of air-cooling, choice of turbine design are discussed. Many problems are yet to be solved in blade cooling. At present an experimental air-cooled turbine at gas temperatures up to 1,400”C has been operated at

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N.G.T.E. A rise in engine temperatures of at least 15O0-Uw)”C should be expected. Discussions references, drawings, curves and photographs.

“Where Reactor Development Stands Today”-- James A. Lane; Nucleonics, V. 14, a 8, August 1956, pp. 30-37. Some 45 reactors are in use. These exclude units used for aircraft propulsion and P u production. Estimates show about 172 reactors wiU be in use by 1960. Programs of the U.S., Russia and Britain are disc.ussed. The US. power-reactor program is tabulated. Cost of power from nuclear sources and conventional methods, diesel and steam, compared. Feasibility studies of power reactors with various coolants and moderators are listed with estimated dates of established technical feasibility. References.

“25,000 Hours of Free Piston Engine Opera- tion”-Gregory Flynn, Jr.; SAE Journal, V. 64, n. 10, Sept. 1956, pp. 64-70. The following free piston engines account for some 25,000 hours operation: Muntz P-42 air compressor; Sigma P-13 air compressor; GM-14 gasifier; GMR 4-4 (Hyprex) gasifier. Main problems include: cylinder wear; diesel piston ring wear, scuffing, and breakage; compressor piston ring wear, scuffing and breakage; intake valve failures; oil leakage past seals resulting in valve deposits and airbox fires; piston ring groove deposits: high piston cooling oil consumption. Consider- able running time has been accumulated on bunker “C” fuel with the GM-14 gasifier. This engine showed great improvement over earlier free piston engines. After 4,500 hours at full load valve blades showed no evidence of fa- tigue failure. During this engine test no shut- downs were caused by injector seal leakage, precombustion chamber failures or intake valve failures. A 4,500 hr. test can now be run with more than 90‘; availability. The GM-14 engine will be a contender for commercial power gen- eration.

“High Temperature Brazing”-Robert M. Evans; Battelle Technical Review, V. 5, n. 8, August 1956, pp. 8-12. Processes using filler metals that melt above 1,600”F. and techniques for joining assemblies to operate in temperatures above 1,000”F. are discussed. High temperature brazing has been used: to fix turbine blades of gas turbines to rotors; in manufacture of heat exchangers for high temperature corro- sion-resistant service; for production of Diesel components and metal to ceramic seals. Appli- cations where greater use of brazing may take place include: aircraft engine parts, fuel systems, sandwich structures, heat exchangers; missile fuel systems, precision parts, temperature controls, burner assemblies and exhaust chambers; mechanical power valves, piping, turbine blades, nozzles, preheaters, boilers; nuclear power heat exchangers, fuel elements, pressure systems and controls.

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