FINAL REPORT

University Turbine Systems Research Program Summary and Directory

(Formerly the Advanced Gas Turbine Systems Research Program) September 1992 – June 2003

Prepared by

Lawrence P. Golan Principal Investigator

Richard A. Wenglarz

Program Manager

July 2004

DOE Award Number DE-FC21-92MC29061

Submitted by

Clemson University Research Foundation Clemson University 300 Brackett Hall

Clemson University Clemson, South Carolina 29634

The UTSR will execute research supporting the long term health of the U.S. turbine industry while respecting the education mission of universities – learning at the highest level.

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DISCLAIMER

“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 agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.”

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ABSTRACT

The South Carolina Institute for Energy Studies (SCIES), administratively housed at Clemson University, has participated in the advancement of combustion turbine technology for over a decade. The University Turbine Systems Research Program, previously referred to as the Advanced Gas Turbine Systems Research (AGTSR) program, has been administered by SCIES for the U.S. DOE during the 1992-2003 timeframe. The structure of the program is based on a concept presented to the DOE by Clemson University. Under the supervision of the DOE National Energy Technology Laboratory (NETL), the UTSR consortium brings together the engineering departments at leading U.S. universities and U.S. combustion turbine developers to provide a solid base of knowledge for the future generations of land-based gas turbines. In the UTSR program, an Industrial Review Board (IRB) (Appendix C) of gas turbine companies and related organizations defines needed gas turbine research. SCIES prepares yearly requests for university proposals to address the research needs identified by the IRB organizations. IRB technical representatives evaluate the university proposals and review progress reports from the awarded university projects. To accelerate technology transfer technical workshops are held to provide opportunities for university, industry and government officials to share comments and improve quality and relevancy of the research. To provide educational growth at the Universities, in addition to sponsored research, the UTSR provides faculty and student fellowships. The basis for all activities – research, technology transfer, and education - is the DOE Turbine Program Plan and identification, through UTSR consortium group processes, technology needed to meet Program Goals that can be appropriately researched at Performing Member Universities. Since inception in 1992, seventy-five (75) UTSR university projects (Appendix K) were awarded in the areas of gas turbine combustion, aerodynamics/heat transfer, and materials. Currently, as many as 15-20 universities are under contract at any one time. This final report contains a complete listing of all research projects (closed and current), descriptions of selected research successes (Appendix L), all IRB and DOE/NETL personnel (Appendix E) involved, SCIES’ contributors (Appendix E), all Faculty Fellows (Appendix I) and Student Fellows (Appendix H).

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FORWARD The twentieth century has taught us that energy demand is one true indicator of growth--economic, population, and technological. How best to meet this ever-increasing demand is an issue of obvious importance. In the 1990's, the fastest-growing means of electrical power generation in the United States was based on the gas turbine. Recognizing the need for gas turbines with improved efficiency, decreased emissions, and enhanced economic viability, the U.S. Department of Energy's (DOE) National Energy Technology Laboratory (NETL) initiated the Advanced Turbine Systems (ATS) program in 1992. The investment the DOE and the NETL made between 1992 and 2003 towards these critical endeavors has enabled the success of the University Turbine Systems Research (UTSR) program, formerly known as the AGTSR program. The UTSR program is ongoing and continues to broach the issues of gas turbine efficiency, environmental performance, and economic viability in the context of alternate, high-hydrogen fuels, including coal-based fuels. The success of the UTSR program would not have been possible by government funding alone. The South Carolina Institute for Energy Studies (SCIES) at Clemson University, led by Dr. Lawrence Golan, has administered the ATS program since its inception. Through his vision, leadership, and dedication, Dr. Golan has brought together representatives and experts from government, industry, and academia to meet the DOE goals for the UTSR program. In so doing, he has helped to direct the technical and educational growth of one part of the energy industry. On behalf of all those involved with the UTSR program, I thank Larry for his outstanding efforts. G. Phillip Anderson Chairman, UTSR Industrial Review Board

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FINAL REPORT: ACTIVITIES 1992-2003 TABLE OF CONTENTS

Title Page....................................................................................................................................... 1

Disclaimer...................................................................................................................................... 2

Abstract ......................................................................................................................................... 3

Forward ......................................................................................................................................... 4

Table of Contents.......................................................................................................................... 5

Executive Summary ..................................................................................................................... 6 • Organization of UTSR (Consortium of Government, Industry, Academia, coordinated by SCIES) • Areas of Research (To support ATS goals)

Experimental Summary ............................................................................................................... 9

Review of UTSR activities from 1992-2003 .............................................................................10 • Background • What has UTSR Accomplished? • UTSR Operations • Special Studies

o University Facilities Survey o Regional Stakeholders Meeting o Economic Impact Study

Results and Discussion ................................................................................................................17 • Overview of Success Stories • Technical Accomplishments: Materials, Combustion/Instrumentation, Aerodynamics/Heat Transfer

Conclusions ..................................................................................................................................26

• Benefits of UTSR organization/structure • Benefits due to turbine technology development

Appendices ...................................................................................................................................29 A. List of Performing Member Universities .........................................................................30 B. List of States Represented by Performing Member Universities .....................................31 C. Industrial Review Board Focal Point Personnel...............................................................32 D. Industrial Review Board Technical Contact Persons .......................................................34 E. DOE Personnel .................................................................................................................38 E. SCIES Personnel .............................................................................................................38 F. General Focus of UTSR Research Areas .........................................................................39 G. UTSR Workshop History .................................................................................................40 H. UTSR Student Interns/Fellows.........................................................................................41 I. UTSR Faculty Fellowship Program .................................................................................46 J. UTSR Professor/Student Inventory..................................................................................48 K. List of UTSR Research Projects.......................................................................................54 L. UTSR Success Stories ......................................................................................................67 M. List of UTSR Project Publications ...................................................................................96 N. UTSR By-Laws .............................................................................................................. 128 O. UTSR Subcontract Funding By State............................................................................. 134

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EXECUTIVE SUMMARY

The U.S. Department of Energy (DOE) National Energy Laboratory (NETL) initiated the Advanced Turbine Systems (ATS) program in 1992. The South Carolina Institute for Energy Studies (SCIES) managed/coordinated this program for NETL since inception. The program was conceived by Clemson University under the leadership of Dr. Lawrence P. Golan. Though they have been updated, the original program supported the development of utility scale combined cycle power systems (>400 MW) and industrial scale turbines (<20 MW) with the following goals:

• High efficiency: greater than 60 percent for utility scale systems and 15 percent improvement in efficiency for industrial systems

• Ultra clean: nitrogen oxide emissions at less than 9 ppm, CO and UHC less than 20 ppm • Economical: 10 percent decreased cost of electricity • Fuel flexibility: primary focus on natural gas initially with clean gas from coal and

biomass in the future Development of these high efficiency, ultra clean turbine systems required significant advances in high temperature materials science, understanding of combustion phenomena, and innovative cooling techniques to maintain integrity of turbine components. Such necessary technology advancements are basic to the needs of the entire gas turbine industry. In 1992 the Advanced Gas Turbine Systems Research (AGTSR) consortium was encouraged by the DOE to use university research to accelerate basic turbine technology development, to provide non-proprietary research to support the ATS program, and to provide training in gas turbine technologies for U.S. students. Though the program name has changed in recent times (University Turbine Systems Research, UTSR), the central purpose of the program continues. UTSR ORGANIZATION UTSR activities have grown to encompass research, education, and technology transfer.. Still true to its founding purpose the program has significantly matured from its inception in 1992. As funding agency for the program, the DOE National Energy Technology Laboratory (NETL) operates in an advisory capacity providing overall review and program guidance. UTSR research is defined by an Industrial Review Board (Appendix C) and is conducted by Performing Member Universities (Appendix A). The membership of the IRB consists of: EPRI Rolls-Royce ExxonMobil Siemens Westinghouse Cinergy Solar Turbines General Electric Southern Company Services Parker Hannifin Woodward Pratt & Whitney

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with GTI acting in an advisory role. Where mutual interest exists, UTSR coordinates activities with the national labs and other federal agencies such as the Department of Defense and NASA. Gas turbine research needs defined by the IRB are used for an annual Request for Proposal (RFP) that is released to the 105 member Performing Member Universities located in 40 of the 50 states (Appendix B). Proposals from the universities are reviewed by the IRB and awards made to the highest ranked proposals. Definition of research topics and selection of awards by the IRB keeps the research program relevant. Coordination with industry and review of the university project reports by the IRB companies also accelerates the technology transfer The UTSR uses workshops to further facilitate early discussion and release of research progress, promote interaction and teaming among research groups, and to assist in defining industry research needs. Personnel from industry, universities, and government attend these workshops. Numerous workshops (Appendix G) and specialty meetings have been conducted by the UTSR in the areas of combustion, aerodynamics/heat transfer, and materials. When appropriate, the UTSR has also led specialty meetings. The educational aspects of the UTSR included Faculty Fellowships (Appendix I) and Industrial Internships (Appendix H). Nine Faculty Fellowships involved interactions with visits of faculty from UTSR Performing Member Universities to IRB companies. Short reports describing the faculty fellowship activities and results are available from the UTSR. One hundred twenty five (125) Industrial Internships have involved work placement of students from UTSR Performing Member Universities at IRB companies for periods from 10 to 12 weeks. After graduation, most of the Interns have taken permanent positions in the gas turbine industry. The IRB companies consider the Industrial Internship program to be highly beneficial to their organizations. AREAS OF RESEARCH TO SUPPORT ATS GOALS Seventy-four (74) UTSR university research projects (Appendix J) have been awarded through the year 2003. Awards have been for projects in three primary turbine technology areas; combustion, aero/heat transfer, and materials. The following items summarize recent university topics in these three technology areas. Combustion

- active and passive control of instabilities in low emissions turbine combustors - improved methods to predict combustor instabilities - improved computer code to predict emissions/design combustors - fuel composition effects on combustor instability and flashback

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- infrared sensor for combustor temperature measurements - probe to measure/improve fuel-air mixing for NOx control

Materials

- instrumentation for non-destructive evaluation of thermal barrier coatings (TBC) - improved TBC durability through better bond coats - higher temperature TBC for improved turbine performance - determination of factors that control TBC failures - analyses/measurements for TBC life prediction - materials selection for turbine flow path steam environments produced by

emissions control

Aero-Heat Transfer

- use of water mist cooling to reduce air cooling requirements and thereby improve turbine performance

- reduction of rotor tip aerodynamic losses - improved blade/vane internal cooling - airfoil clocking for increased aerodynamic performance and durability - better representation of airfoil in-service roughness for aero/cooling design - aero/heat transfer data in airfoil passages to evaluate/validate CFD models - improved analyses/design of airfoil endwalls

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EXPERIMENTAL SUMMARY

The UTSR has developed a high quality, technically and geographically diverse base of university research capable of supporting the U.S. land based gas turbine industry. A total of 75 research projects focused on three relevant areas of combustion, materials, and aero-heat transfer (Appendix F) were conducted. The research laboratories used to conduct the projects were located at Performing Member Universities. To the current time, the UTSR has only augmented existing university facilities to the quality level required to conduct the research a specific university has proposed. Each of the 75 UTSR research projects are conducted in separate labs with separate test procedures and protocols. These experimental procedures are described in the project final reports. The South Carolina Institute for Energy Studies (SCIES) to date has conducted no research. SCIES makes its contribution by effectively and efficiently being the administrative arm for the UTSR coordinating the participation of academia, government, and industry; and, by acting as the direct project manager of each UTSR funded research project. Experimental summaries of individual UTSR research projects may be found in the reports those projects published (see UTSR Presentations & Publications Library, Appendix M).

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REVIEW OF UTSR ACTIVITIES FOR 1992-2003 BACKGROUND The South Carolina Institute for Energy Studies provides the central administration for the University Turbine Systems Research (UTSR) program. The UTSR consortium cuts across university boundaries to create teams of excellence. Key features of the UTSR are:

♦ Researchers are spread out geographically. ♦ Researchers are encouraged to move temporarily to establish test sites rather than

build unnecessary new ones. ♦ Electronic communications are exploited. ♦ Specialty meetings are held for peer review, ♦ DOE peer review requirements are accomplished through an annual program

review, and ♦ Currently, besides peer review, the annual program review meeting engages the

UTSR community in facilitated process improvement sessions, education, and identification of new research topics.

The distribution of researchers throughout the U.S. maximizes potential contact of the researchers to each other and with major research sites. With DOE oversight and industry guidance the program is managed by SCIES with a focus on quality, relevance, and timeliness of the research. The quality of the research is assured by university peer review at workshops and through the publication process. Relevance of this research is assured by the definition of the research needs provided by industry – followed by the selection of the research to be accomplished and subsequent critique of results by the Industrial Review Board. Finally, timeliness is assured by industry and DOE interest and continued contact with Performing Member institutions throughout the life of a project. The universities realize that for success, competition to win research awards is necessary as is cooperation after awards are made. At inception the UTSR had eleven Performing Member (Appendix A) Universities. Over the contract period the UTSR Performing Member base has grown to 105 members located in 40 states. The complete listing of academic institutions and the states involved in UTSR are shown in Appendix A and B, respectively. The Industrial Review Board (IRB) consists of ten major U.S. firms that are OEM’s, users, or component manufacturers. The ten companies supporting UTSR are General Electric, EPRI, Parker Hannifin, Pratt & Whitney, Ramgen, Rolls-Royce, Siemens Westinghouse, Solar Turbines, Southern Company Services, Woodward. The university members determine how and where to conduct the research recommended by the industry. The IRB provides corporate leaders to define the thrust of the research program and technical experts to evaluate the university research proposals and review technical reports. For a complete listing of IRB Focal Points, refer to Appendix C and for a listing of the industry experts, contributing to research, reviews and evaluations, refer to Appendix D. SCIES’

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responsibility was to be the linkage between all three groups: universities, government, and industry. The research program is broadly segmented into three discipline areas – combustion, aero/heat transfer, and materials. The prime thrust of the research is been to improve efficiency, reduce emissions and improve engine and system performance. The sub-areas focus in each research area is shown Appendix F. WHAT HAS UTSR ACCOMPLISHED? In the first year or two the UTSR focused solely on research. As the program matured research continued to be the key element of the program; however, workshops, student internships, faculty fellows, and special studies were added. Refer to Appendix G, H, and I for complete listing of Workshops, Student Interns, and Faculty Fellows. UTSR accomplishments can be grouped into 3 areas:

philosophical - personnel - technical From the philosophical point of view UTSR has changed the way gas turbine research and maybe university research in general is accomplished. Prior to UTSR it would not be uncommon for a university researcher to work with a funding agency on a one-on-one basis. With UTSR programs this is not the typical way research is accomplished – cooperation is the key. As reported to SCIES, the universities believe that they have had at least a four-fold increase in university-to-university-to-industry-to-government interaction. Meaningful relationships beyond these should continue outside the UTSR/ATS as university-industry-government research personnel become more and more familiar with each other’s capabilities. This is a major accomplishment as it maximized use of existing facilities, produced better trained/educated university students and resulted in well informed up-to-date faculty available to improve the education process. From the perspective of personnel, UTSR was a resource for training competent professional staff. The accomplishments included:

• the majority of Student Summer Interns joined OEM companies as employees • one intern is now a professor • nine Faculty Fellowships provided in-depth training for university professors • approximately 300 graduate and undergraduate students were involved in the

research program (Appendix J, UTSR Professor/Student Inventory) • approximately 120 university faculty were involved in the program (Appendix J),

and, • approximately 110 area experts from industry assisted in developing program

technology needs. Combined, approximately 600 individuals, a majority of which were university personnel, were involved in UTSR. Some individuals have suggested that the training of

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competent professional staff in the university environment is the most important facet of UTSR. The reason being that these individuals are the future for the gas turbine industry.

From the research perspective the UTSR research community has had numerous contributions to the land-based gas turbine technology. These contributions, referred to as UTSR Success Stories, are separately described in the Results and Discussion section of this report under the title “Overview of Success Stories” with a more complete listing in Appendix L. These Success Stories were the result of the 75 sponsored UTSR research projects (Appendix K). Beyond the Success Stories directly contributing to the advancement of land-based gas turbine technology, the UTSR professors contributed to an increase in basic science via publications in other journals and conferences. The listing of professor reports reported to SCIES is shown under UTSR Publications (Appendix M). As can be quickly observed, the 329 contributions to the basic open literature is extremely extensive. This information is directly transferable to other important areas beyond land-based gas turbines. UTSR OPERATIONS The UTSR consortium is charged with providing support to the DOE/NETL turbine program by conducting research and other activities on longer range technology development issues defined by industrial participants and approved by NETL. The operations of UTSR are governed by a set of By-Laws (see Appendix N) for complete details). In summary the UTSR is open to all American colleges and universities with an accredited engineering curriculum. Universities that have a statement of interest on file with the UTSR are referred to as Performing Members and are eligible to receive the annual RFP and complete for research awards. The competition for UTSR research awards is very competitive with the distribution of dollar awards per state listed on Appendix O. U.S. gas turbine manufacturers are eligible for membership on the Industrial Review Board (IRB) and with payment of the appropriate membership fee have voting privileges. Other organizations could join the IRB with payment of the appropriate fee, but are not eligible for voting privileges. The IRB elects a Chair who leads all IRB activities. The Performing Member Universities are not eligible for membership on the IRB because of the obvious potential for conflict of interest. SPECIAL STUDIES Occasionally, situations have arisen wherein the UTSR has been tasked by the DOE to help with or conduct special studies. Three special studies conducted by the UTSR are (1) University Facilities Survey, (2) DOE-EE Regional Stakeholder Meetings, and (3) Economic Impact Study. A description of this work follows.

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University Facilities Survey The University Facilities survey confirmed that U.S. universities have the necessary laboratory equipment for conducting gas turbine power systems research. However, the survey showed that the universities lack capabilities for conducting full scale turbine tests, systems integration studies and long duration tests. The Facilities Survey confirmed the basic premise that UTSR could be based on “people power” and that it was not necessary to invest in new facilities to conduct needed research. Besides offering this confirmation, the survey also provided a mechanism for university researchers to initiate a dialogue to promote cooperation. By use of the survey researchers could team matching needed skills at differing universities to assemble expert teams with the latest equipment across universities. Regional Stakeholders Meeting At the time the Advanced Turbine Systems Program was evolving into the High Efficiency Engines and Turbine Program (ultimately UTSR), a series of regional meetings were held in order to get input on the HEET Program from various stakeholders around the country. The purpose of the meetings was to gather people with regional interests to obtain their input on how to implement the goals of the HEET program and increase regional impact and involvement. The meetings were typically attended by individuals representing power generators, turbine manufacturers, regional energy consortia, universities, the federal government, state governments, and consultants. Questionnaires were also used to supplement the meetings. The meetings were arranged to get separate input from each of the DOE-defined Regions in the U.S. SCIES ran the meetings for the Atlanta Region, the Philadelphia Region at Penn State University and held small meetings in the states of Connecticut and Louisiana following technical conferences which were held in those states. SCIES combined efforts with the National Association of State Energy Officials (NASEO) to cover the HEET Program in meetings that NASEO was already scheduled to conduct for the National Energy Technology Laboratory (NETL). The Denver Region and the Seattle Region were covered in the separate meetings in Portland, Oregon, and San Francisco, California. The Boston and Chicago Regions were covered by emailed questionnaires supplemented by telephone contact by a combination of NASEO and SCIES. Follow-up questionnaires were also sent to those who attended the Western Regional meetings. Of the inputs received from seven regions and two states, only one meeting was held separately for this purpose. Thus the entire effort was done at minimal cost to DOE and to those who provided the input. The following is a brief summary of the input received:

IGCC plants are worthwhile in states that use coal for power generation. For IGCC plants in those states:

o The intermediate and long term goals are worthwhile, but they are a stretch, particularly the timing.

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o IGCC plants must have low capital cost ($/kW) to compete with pulverized coal plants.

DOE should develop turbines for a wide range of non-standard fuels in addition to coal gas, e.g. biomass gasification

All states, even those not interested in coal, are interested in biomass. This suggests that DOE should link research and development efforts of the HEET Program which deals with syngas from coal, with those of the biomass gasification program.

Small hybrid systems, fueled with natural gas or coal-derived liquids, fit with almost all state and regional distributed generation (DG) plans.

There is strong support in all regions for development and field test of systems which show incremental improvements toward the long term goal.

Improved education of state and federal governments on the public benefits of HEET are necessary.

o Better define the scope and structure of HEET. o Get the importance of HEET understood so it gets full funding.

In each of the regional meetings a presentation was made describing the HEET

Program, as well as presentations from various stakeholders. Among the charts describing the HEET Program in each region, the following points were emphasized:

Purpose

o Provide gas turbine power generation technology essential to success of the DOE Vision 21 program

Performance Goal o Coal-based power system at 50% efficiency and a capital cost < $100/kW

based on gas turbine power generation NOx reduction < 3ppm Increase heat engine efficiency by 2-3% Improve RAM – 15% reduction in life cycle cost, limit degradation

to 2%/yr., 400 starts/yr. Unique Capabilities

o Fuel flexibility (market adaptability) o Adaptable to mandates for CO2 control/capture o Amendable to further reductions in NOx emissions o Scaleable

By 2008, develop advanced power systems capable of achieving 50% thermal efficiency at a capital cost of $1000/kWe or less for a coal-based plant

R&D Activities

o Simple/Combined Cycle Development o Advanced Systems Analysis o Hybrid Cycle Development o Technology Base Development

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Following the presentations the meeting attendees were asked for input in either facilities break-out sessions (Atlanta and Penn State), questions from the presenter during the general meeting, in a separate commentary sessions (Western Regions, Connecticut and Louisiana) or via a questionnaire supplemented by phone calls (Northeast and Midwest Regions). Economic Impact Study The ATS Economic Impact Study brought together a significant number of variables relating to the installation of advanced GTs over the period 1999 through 2010. Important factors included:

♦ forecasted growth of domestic GT orders ♦ time lags due to product commercialization ♦ time lags from GT order to commissioning ♦ selection of exiting GTs to use as reference units in determining energy usage ♦ likely propagation of ATS-initiated technologies ♦ likely penetration of ATS machines by the various customer segments

The actual PC computer model can be obtained from the South Carolina Institute for Energy Studies (SCIES). The “study” was conducted by the Windsor Group, Inc., Boston, MA and Oakhurst Associates, Ltd., Arlington, MA. Quantifying the social and economic benefits of the ATS program involved identifying discrete contributions such as increased efficiency (reduced fuel consumption), reduced emissions, lower O&M costs, ext., to the extent that readily acceptable models of the costs and benefits could be defined. With these contributions in mind, the model was extended to include the diffusion of the technology improvements within the manufacturer’s own product line and, to some extent, its appropriation by others. Actual benefits accrue from reduced costs in comparison with those arising from using machines that could not have benefited from the achievements of the ATS effort. Once the candidates for receiving benefits were identified, the study relied on a forecast of anticipated shipments over a meaningful period in which the ATS technology remains relevant. The benefits were then simply aggregated over the relevant horizon. Six customer segments were defined as indicated on Figure 1. Characteristics of a representative turbine model as indicated at the bottom of the illustration were used to quantify benefits. The overall conclusion of the Economic Impact Study was that the developed base technology would contribute to $1.1 billion in fuel saving (NPV at $3/MMBTU) and a reduction of 620,000 tons of NOx in the next decade.

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Figure 1

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RESULTS AND DISCUSSION

Overview of More Notable Research Progress and Significant Accomplishment The technical accomplishments listed below for the UTSR Program have resulted from its unique and effective structure for university research that did not exist before the DOE established these programs. The relevance and capabilities of university research to meet national and industry needs has been brought about by: • Increasing interactions between universities and industry which have stimulated

working relationships and projects beyond those of projects funded by UTSR • Increasing interactions between universities to work effectively together on research

projects, which was not typical previously • Increasing capabilities (e.g., experimental facilities and expertise) of academia in

areas of research needs of the US gas turbine industry • Stimulating new energy/gas turbine related university courses and an increased output

of university graduates, educated in skills and practiced in research needed by the US gas turbine industry

University Reports of Significant Progress The Appendix L, “University Reports of Progress” contains descriptions of projects reported to the DOE/NETL each month. Each month SCIES singles out one project for recognition prepares a summary report and submits it to the DOE/NETL. When one of these reports is judged to represent significant success, NETL in turn edits SCIES’ item and submits it as a “Success Story” to the DOE Secretary of Energy. Acknowledgement of Most Significant Research Outcomes UTSR funding justification is based on demonstrated contribution to the health of the turbine industry. For a university fundamental and basic research program, developing this justification can sometimes be challenging. Since the justification that counts most is actual use of research results by the U.S. turbine industry, this reality compounds the problem of documenting success. The inherent nature of good fundamental and basic research results is that it can be a tremendous advantage to turbine designers; but, the designers don’t have an obligation to share how the art developed in the UTSR program is being deployed in a specific manufacturer’s turbine design. Another aspect of the problem is that engineers and scientists in industry often gain insights from UTSR research but quickly forget the source of a new solution springing from that research, for among other reasons, the solution is so obvious once a footbridge of understanding is crossed. Therefore, UTSR industry members are continually reminded, to share non-proprietary applications of UTSR art so that the continued funding of the UTSR program is assured. This said, the following is a summary, as best that SCIES can ascertain, of the key research accomplishment in the UTSR since its inception:

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Technical Accomplishments – Materials 1. Advances in Non-Destructive Evaluation and Processing of TBCs (SRO30,

SRO73, SRO91) The University of Connecticut (UCONN) started a project (SRO30) in 1995 that produced two milestone results for the development of thermal barrier coatings (TBC): • Laser fluorescence (LF) was determined to be the most promising technique for non-

destructive evaluation (NDE) of TBCs • Ridges are produced at TBC bond coat grain boundaries by oxidation. Removal of

the ridges before applying the insulation layer can increase TBC lifetimes by a factor of three times

Significance: TBCs, originally developed for aircraft turbines with short maintenance intervals, had inadequate lifetimes and an unacceptable wide range of lifetime variability for land based turbines. This has impeded the full realization of the power and efficiency benefits of TBCs for industrial and utility turbines. The evaluations in the above project verified LF for NDE and provided the foundation for a later UTSR project at UCONN and the University of California at Santa Barbara (UCSB). That project (SRO73) started in 1999, to develop a prototype low cost and portable NDE instrument that is capable of inspecting manufactured parts and turbine parts in the field to determine residual life. The project uses laser techniques to measure stresses in coated laboratory specimens cycled to failure and coated engine parts from the field. Correlation of the laser signals with TBC stress degradation is used to assess remaining TBC life. Another UCSB project complements laser measurements of degrading materials properties with mechanistic modeling to predict remaining life. Both projects have demonstrated laser signal correlation with lifetime properties. Significance: The need is so great and the results from the earlier project were so promising that an instrument manufacturer and eight gas turbine related companies cooperated in the project and contributed substantial in-kind efforts and funding for the UCONN/UCSB project. The second major finding listed above for the first project described above provided an incentive for another UCONN project (SRO91) started in 2001 to improve durability of TBCs through manufacturing process modifications. UCONN research has shown that polishing to remove bond coat surface defects (e.g., roughness and embedded oxides) increases spallation lifetimes by a factor of four times. Significance: A gas turbine manufacturer has implemented and refined the UCONN findings and has achieved even greater improvements in TBC lifetimes.

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2. New Coating Application Technique for TBCs (SRO47) In a project (SRO47) initiated in 1996, Northwestern University (NU) advanced a new Small Particle Plasma Spray (SPPS) process to apply graded layers of coating materials to facilitate engineered TBC turbine coatings with specialized properties such as improved performance and durability. Experiments in the project showed that the SPPS process could apply a thin layer of oxygen diffusion blocking material on TBC bond coats and the diffusion blocking layer produced a factor of two lower internal oxidation rate of the bond coat. The project also showed that the SPPS process can produce TBC coatings that experience lower fatigue damage (through graded porosity). Significance: Internal oxidation of TBC bond coats produces internal stresses and is a major cause of TBC failures. Lower internal oxidation rates and lower fatigue damage demonstrated in this project indicates that the SPPS process offers promise for enabling longer TBC lifetimes in turbines. Two patents (#5,744,777 and #5,858,470) were issued concerning the SPPS process during the duration of the UTSR program. 3. Water Vapor Effects on Materials (SRO77) Oxide scales that are slow-growing and relatively impermeable to further oxygen penetration are the primary line of defense of turbine materials and coatings from accelerated oxidation and corrosion. High levels of water vapor from steam and water injection into turbines to reduce emissions or augment power have adversely affected part life. One cause has been the effect of steam in the hot gas stream on protective oxide formation on the turbine components. Effects of water vapor on oxidation and corrosion of components is also important for turbines operating with coal syngas, for which turbine expansion gases contain high water vapor levels. A University of Pittsburgh (UPT) project (SRO77) that started in 1999, conducted experiments and analyses to evaluate sources of water vapor induced degradation and to identify turbine alloys and coatings resistant to water vapor effects. The project has determined that turbine alloys that form chromium oxide scales should not be used for surface temperatures above 700 C (1290 F) in high water vapor environments. Of the alloys and coatings tested that form aluminum oxide scales, those that contain low levels of hafnium performed better in high water vapor environments. Two superior alloys and one coating that form aluminum oxide scales were identified for operation at surface temperatures above 700 C (1290 F). The thermal barrier coating that was tested did not experience significant degradation associated with water vapor effects. Significance: The UPT project has determined alloy and coating properties and specific materials for turbine components that operate in high water vapor environments, such as produced by water or steam injection for emissions control. Project results should also be beneficial for identifying turbine materials for operation with syngas.

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4. Corrosion Resistant TBCs for Turbine Using Syngas and Alternate Fuels (SRO42) A Cleveland State University (CSU) UTSR project (SRO42), initiated in 1996, has applied ceramic layers of various compositions on the top of TBCs for the purpose of protection from corrosion for alternate fuel applications. Tests showed high density, good adhesion, and crack resistance for the ceramic layers. No detrimental corrosion attack was observed in a 150 hour corrosion test at 900 C in molten sodium sulfate, a primary corrosive for turbines using alternate fuels. Significance: The project has shown the feasibility of using ceramic layers as corrosion barriers for TBCs for turbines operating with syngas and other alternate fuels. 5. New TBCs with Improved Performance and Durability (SRO81) A project (SRO81) started at the University of Connecticut (UCONN) in 2000 has evaluated over 130 candidate ceramics to identify new TBC materials with superior properties over conventional TBCs used in turbines. Goals are 25% improved insulation properties, a maximum use temperature up to 2900 F, and superior corrosion resistance. UCONN has shown that gadolinium zirconates (Gd-Zr) have over 30% lower thermal conductivity than the conventional TBC material and have the required property of not reacting with aluminum oxides, even at 500 F higher than turbine temperatures. Significance: The project has identified a new material for TBCs with two important superior properties over those for current TBCs used in turbines. If future work evaluating other characteristics of the new material determines other acceptable properties (e.g., lifetimes), then the Gd-Zr material might enable turbines to operate at much higher temperatures with reduced cooling penalties, resulting in much higher fuel efficiencies and substantial fuel savings. Potential benefits of meeting the program goals include over $2 billion in turbine fuel cost savings in a ten-year time frame and major reductions in CO2 emissions. Technical Accomplishments – Combustion/Instrumentation (SRO31, SRO75) 6. Control of Instabilities Associated with Low Emission Combustion (SRO31, SRO75) Instabilities in low emission combustors have forced removal of industrial and utility turbines from service because of excessive noise and structural failure. In a project (SRO31) starting in 1995, Georgia Tech (GT) has verified an active control approach to overcome instabilities in low emission turbine combustors. A factor of four reduction in combustor pressure oscillations was demonstrated for the GT active control system. Two patents on this technology have been awarded and a third is in process. Active control technology from the project is being transferred to most of the US turbine manufacturers.

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GT has worked with Siemens Westinghouse to scale-up the active control system for full-scale gas turbine combustors. A three-year contract was awarded by GE to GT to evaluate adapting the active control technology to GE combustors. A non-disclosure agreement has been signed with Rolls Royce (RR) to enable discussion of joint programs for implementing GT active control on RR combustors. NASA has purchased a GT “smart injector” used for active control and will test it on a gas turbine combustor at the United Technologies Research Center. Building on the success of the earlier program, another (GT) project (SRO75) started in 1999, which conducted experiments and analyses to determine the processes that drive combustor instabilities and to determine active and passive methods to suppress the instabilities. GT identified critical factors that affect the interactions between the flow and combustion process oscillations, which produce the instabilities. A method was found to determine the stability margin of combustors before experiencing problems in the field. Promising techniques were further advanced to actively control instabilities by modulating combustor fuel flow. Significance: Success in the these projects has resulted in three other separate GT projects with major gas turbine manufacturers, two in active control and one in modeling. Using project results, a semester long course in combustion instabilities was developed and offered to GT students and employees of a major gas turbine manufacturer through a live communication link. A combustion instabilities short course was also developed and offered at two gas turbine company sites. 7. Computer Codes to Design Turbine Combustors (SRO49) Cornell University (CLU) initiated a project (SRO49) in 1996 that developed an improved NOx and CO emissions prediction computer code for design of low emission turbine combustors. The code has shown a factor of forty reduction in computation times compared to previous codes. Comparisons of calculated emissions to those measured in a test combustor showed a very high level of prediction accuracy for the CLU code. Significance: Previous emissions chemistry prediction codes used to design turbine combustors have either been so complicated that computer run times are long and expensive, or inaccurate, if simplified to reduce run times. The CLU project has provided turbine combustor designers with a practical program to calculate emissions with a high degree of accuracy and at substantially reduced cost to use. 8. Sensors for Combustor Health and Performance (SR102) In a project (SR102), starting in 2002, Georgia Tech (GT) University has developed sensing strategies for monitoring gas turbine health and performance. The GT sensing approach extracts relevant combustor performance and status from the light and sound naturally produced by the combustion process. This relatively new project has already shown that the combustor flame CH to OH chemiluminescence (CL) ratio provides a practical measurement of the local fuel-air ratio in reacting gases. Experiments indicated

- 21 -

that measurement correlation parameters were nearly identical for three different combustors and were not sensitive to variations in natural gas fuel compositions. These results suggest that a CL sensor based on CH/OH ratio measurements would be widely applicable to many gas turbine combustors. Significance: Since key combustor performance metrics, such as NOx emissions and turbine inlet temperature pattern factor (which affects the materials durability of downstream turbine components) are very sensitive to local fuel-air ratios, the development of the CL ratio sensing technique by GT increases monitoring capabilities for reduced turbine pollutant emissions and increased hot section lifetimes. 9. Fuel/Air Mixedness Probe for Combustor Development (SRO74) In a project (SRO74), initiated in 1999, The University of California, Berkeley (UCB) experimentally evaluated diodes that operate with infrared light for measuring fuel-air mixedness in combustors. They offer the advantage of less than one-third of the cost of laser devices for measuring mixedness and are more compact and rugged. UCB experiments showed that fuel concentration is measurable with an infrared diode device at fuel-air ratios of gas turbine combustors. The results show promise for a reduced cost, compact and rugged diagnostic instrument for measuring fuel-air fluctuations in gas turbine premixers. Significance: Without thorough premixing of fuel in air, nitrogen oxide emissions from turbine combustors are unacceptable. Measurement of fuel-air mixedness is important for the development testing of advanced low emission combustors and could be used for monitoring and tuning emissions performance of operating commercial turbines. 10. Infrared Temperature Sensor (SRO44) Purdue University (PU) started a project (SRO44) in 1996 that advanced a miniature infrared sensor for measuring gas stream high temperatures. Laboratory tests at PU showed excellent performance of the PU sensor. The sensor capabilities were also demonstrated in combustor tests at General Electric, Siemens Westinghouse, Solar Turbines, and the United Technologies Research Center. In addition, the PU work contributed to two commercial products, a rapid scanning linear-array spectrometer offered En’Urga, Inc. and a turbine inlet temperature measurement sensor offered by Ametec, Inc. Significance: Because of the high sensitivity of NOx emissions to combustion temperatures, accurate temperature measurements are needed for turbine combustor development, combustor design model validation, and control of lean premixed low emission turbine combustors. Also, accurate measurement of gas temperatures facilitates turbine control to achieve acceptable hot section lifetimes, since a primary factor affecting durability of turbine parts downstream of turbine combustors is the turbine inlet temperature.

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2. Technical Accomplishments – Aerodynamics/Heat Transfer 11. Advanced Cooling of Turbine Components (SRO34) A project (SRO34), starting in 1995 at Clemson University (CU) performed experiments showing a scientific foundation for use of a fine water mist in steam for cooling high temperature turbine components. CU experiments demonstrated that addition of 1% water mist can enhance cooling performance by 50 to 100%, and in best cases, as much as 700%. Significance: The next generation of H class turbines (derived from ATS technology) uses steam cooling for components in the highest temperature turbine stages. The CU project indicates a potential for further improvements in cooling effectiveness (and resulting power and efficiency benefits) in these advanced turbines by addition of a fine water mist into the steam. The greatly enhanced cooling using mist also offers the potential for producing very low surface temperatures for turbine vanes and blades, which might be needed to control deposition and corrosion in future turbines that operate with syngas or other alternate fuels. 12. Rotor Blade Design to Improve Aerodynamic Performance (SRO79) Pennsylvania State University (PSU) researchers initiated a project (SRO79) in 1999 that evaluated methods to reduce aerodynamic inefficiencies associated with the gap between the tips of rotating turbine blades and adjacent stationary surfaces. Flow leakage through these gaps and associated tip vortices cause pressure losses and aerodynamic inefficiencies. Experiments showed that rotor blade convex side tip extensions are not effective, but concave side tip extensions weaken the tip vortex and reduce pressure losses. The project measurements showed that concave side tip extensions produced blade aerodynamic efficiency gains up to 5%. Significance: The tip extension method identified in the PSU project can result in a significant improvement in turbine stage efficiencies and provide designers with an approach to increase turbine fuel efficiencies. 13. Surface Roughness Characterization for Improved Airfoil Design (SR076) A project (SRO76) that started in 1999 at Mississippi State University (MSU) and the Air Force Institute of Technology (AFIT) evaluated the effects on vane and blade airfoil aerodynamic and cooling performance resulting from surface characteristics changes with turbine operation time. The surface changes are due to erosion, corrosion, deposition, and spallation of coatings from the parts and can degrade the airfoil aerodynamics and cooling from their initial finely tuned, as manufactured, levels. These surface degradation processes are even more severe for syngas turbine fuels.

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Past analyses of vanes and blades that had experienced service have shown that methods established by turbine manufacturers to characterize airfoil surface roughness for aerodynamic and heat transfer analyses are not universally appropriate. To better characterize surface degradations, MSU and the AFIT obtained over 70 vanes and blades from Solar Turbines, Siemens-Westinghouse, and Allied-Signal. These components had experienced service in turbines under a wide range of conditions. Two- and three- dimensional surface roughness measurements have been completed and the data were catalogued. The measured surface characteristics were then represented in heat transfer and aerodynamic experiments to quantify their effects on skin friction and heat transfer parameters used by turbine engineers for aerodynamic and cooling design of turbine airfoils. Significance: The surface degradation database obtained in the project provides better representation of real turbine surfaces to improve aerodynamics and heat transfer design of turbine vanes and blades. 14. Improved Cooling for Gas Turbine Airfoils (SRO11) Texas A&M (TAM) initiated a project (SRO11) in 1993 to experimentally and computationally evaluate the use of various internal surface features within cooling passages to initiate and sustain turbulence and thereby enhance cooling effectiveness. The evaluations showed that V-shaped, staggered rib turbulators provide a significant cooling advantage over conventional turbine rotor blade cooling schemes. The success of this project stimulated another TAM project to evaluate other internal surface features within channels to improve turbine blade cooling. Results indicated that dimples on the interior of cooling channels can improve cooling effectiveness by as much as a factor of two compared to smooth cooling channels. Significance: These projects have provided turbine engineers with new data for design of airfoil internal cooling passages and thereby improve the fuel efficiency of gas turbines. 15. Improved Computer Codes for Cooling Airfoils (SR100) Virginia Tech developed and used advanced analytical methods to predict high speed turbulent cooling flows encountered internally in turbine blades in a project (SR100) that started in 2002. Prediction capabilities were tested in experiments using stationary blades, blades with rotation and significant buoyancy forces across the cross-section of the coolant channels. The test results were used to verify the new analytical procedures. The project has established that LES (Large Eddy Simulation) computational approaches can be used to produce robust, repeatable, and accurate predictions of heat transfer in ribbed ducts used for cooling turbine blades. In this project, detached eddy-simulations have also been applied for the first time to predict heat transfer in ribbed duct and show favorable comparisons with LES at much lower cost.

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Significance: An Industrial Review Board member has recognized the outstanding progress and benefits of this project. The project has advanced and verified computation approaches for design of blade cooling that are more accurate and less expensive to use than previous methods. Better prediction capability being developed at Virginia Tech should allow lower factors of safety, which will result in increased efficiency. By using less coolant air, both aerodynamic losses and cooling losses can be decreased and turbine performance can be improved. Improved computer predictions for high rotation speeds will reduce expensive testing 16. Simplified Method for Evaluating Aerodynamic Interactions between Vane/Blade Rows (SR045) Reduction of efficiency losses due to aerodynamic interactions between adjacent rows of stationary vanes and rotating blades is one important remaining approach to improve gas turbine performance. Starting in 1996, a Massachusetts Institute of Technology (MIT) project (SRO45) coordinated with Solar Turbines and developed a relatively simple aerodynamics analysis approach to represent the unsteady effects on compressor rotor blades resulting from their relative motion with respect to the downstream stationary stator vanes. MIT has conducted computer aerodynamic analyses to show that this unsteadiness effect is negligible and the downstream stators can be represented by a time-average pressure profile for the conditions analyzed. Significance: The computer codes that are capable of aerodynamic analyses of the unsteady effects and complex geometry of adjacent airfoil rows require extensive manpower efforts to set up and require multiple computer runs at very long run times. Such analyses often need resources and time in excess of those available for a turbine development program. The MIT results suggest that multiple expensive computer runs representing adjacent blade-vane rows would not be necessary to determine rotor aerodynamic performance. Only a single run using a time-averaged downstream pressure profile would be needed.

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CONCLUSIONS

The benefits of the UTSR program can be divided into two categories: (1) benefits due to structure and organization and (2) contribution to the turbine technology base. BENEFITS DUE TO ORGANIZATION

• established a successful dialogue between industry, universities, and government that can continue beyond

• marshaled/focused U.S. university research on gas turbine industry research needs - the only focused group in the nation

• produced a cross cutting network of new technology usable by the gas turbine industry

• developed collaborations between government, industry and universities that accelerated research

• developed forms for rapid technology transition and entry into the gas turbine industry

• established a recognized centralized location for gas turbine technology inquiries • developed university student interest in and provided mechanism for preparations

for work in the gas turbine industry.

BENEFITS DUE TO TURBINE TECHNOLOGY DEVELOPMENT

Major issues for gas turbines in the years spanning the UTSR program have been: - Improved performance (higher power and efficiency) - Reduction in NOx emissions - Overcoming reliability issues that have arisen from some of the turbine advancements

used to achieve higher performance and lower NOx emissions The greatest gains in turbine performance have resulted from increases in turbine inlet gas temperatures. Two of the most significant technology approaches to achieve increased turbine inlet temperatures while enabling components to operate at acceptable materials temperatures have been thermal barrier coatings (TBC) and advanced cooling approaches. The university research in the UTSR program has made significant contributions to both TBC and cooling technologies for turbines. Most of the materials research projects were directed to advancing TBC coatings. Component cooling has been the most frequently addressed topic of any in the aerodynamics/heat transfer area. Significant accomplishments for TBC and airfoil cooling are described in a preceding section, Overview of Success Stories, and in the following Appendix of Success Stories. For example, a University of Connecticut project has screened over 130 ceramics to

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identify a promising new TBC material with improved insulation properties and is compatible with aluminum oxides that form on the bond coat needed for TBC adherence. Research at Texas A&M has evaluated and ranked features of internal channels within turbine airfoils that enhance turbulence and effectiveness of cooling flows and Virginia Tech has advanced computer techniques to cost effectively design internal cooling channels. Clemson University has shown a scientific foundation of using a small fraction (order of 1%) of fine water mist injected into steam coolant flows to enhance cooling performance by at least 50% and, in best cases, up to 700%. Accomplishments of other projects described in the Success Stories address not only higher temperature TBC and improved cooling but also additional approaches that increase turbine power and efficiency such as reduction of turbine aerodynamic losses and improved representation of surface roughness degradation for better aero and heat transfer design of airfoils. Lean premixed combustors are being developed to address the major issue of turbine NOx emissions. This combustion approach relies on thorough mixing of fuel and air under fuel lean conditions in a sufficiently short time to prevent premature ignition and damaging flashback from the main combustor chamber. As described in the Success Stories, the UTSR program has advanced computer codes for accurate and cost effective design of low emission combustors, probes and sensors to measure local fuel-air ratios (mixedness) in premixers, and temperature sensors for gases that might be used to monitor and control the high temperatures that produce NOx. In the earlier Success Stories Overview are an example of combustion computer code development at Cornell University and combustion sensor and probe development at the University of California, Berkeley and Purdue University. The use of TBC to improve turbine performance and lean premixed combustors to achieve low NOx emissions for turbine has introduced reliability issues. TBC were originally developed for aircraft turbines for which overhaul lifetimes on the order of a few thousand hours are sufficient. However, coating replacements overhaul lifetimes an order of magnitude longer are needed for industrial and utility land-based turbines. Since lean premixed, low emission combustors operate in the vicinity of their lean blowout limits, there have issues of combustion instabilities that have produced excessive noise, damaging vibrations, and resulting forced removal of turbines from service in some cases. Much of the UTSR research has addressed these reliability issues, as described below. The UTSR program has advanced new TBC coating application and processing techniques for improved TBC lifetimes. Success Story examples described in this report include research on a new SPPS coating application method at the Northwestern University and process improvement research at the University of Connecticut. Other Success Stories discuss UTSR research at the University of Connecticut and other universities that has advanced non-destructive evaluation (NDE) techniques. These techniques are suitable for coating inspection to identify manufacture imperfections and facilitate coating process development in addition to detecting coating degradation during turbine inspections to prevent service failures. Other materials reliability issues addressed in the Success Story examples include research at Cleveland State University to improve

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TBC corrosion resistance and research at the University of Pittsburgh to evaluate sources of water vapor degradation and identify the best materials for turbines that operate with steam or water injection for NOx control. Several UTSR programs such as at Georgia Tech, Virginia Tech, California University of Technology and Penn State University have addressed the major issue of combustion instabilities. As described in the Success Stories, Georgia Tech has developed a method of active combustion control that is being considered by several turbine manufacturers. The research at Virginia Tech, Cal Tech, and Penn State (in addition to Georgia Tech) have provided foundational analyses and data for understanding turbine combustion instabilities that could lead to improved active and passive control approaches.

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APPENDICES

A. List of Performing Member Universities B. List of States Represented by Performing Member Universities C. Industrial Review Board Focal Point Personnel D. Industrial Review Board Technical Contact Persons E. DOE/NETL Personnel E. SCIES Personnel F. General Focus of UTSR Research Areas G. List of Workshops H. Student Interns/Fellows I. Faculty Fellows J. UTSR Professor/Student Inventory K. List of UTSR Projects L. UTSR Success Stories M. List of UTSR Project Publications N. UTSR By-Laws O. UTSR Subcontract Funding By State

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Appendix A UTSR PERFORMING MEMBER UNIVERSITIES

1. Air Force Institute of Technology, Ohio 2. University of Alabama, Huntsville, Alabama 3. University of Alaska-Fairbanks, Alaska 4. Arizona State University, Arizona 5. Arkansas Tech University, Arkansas 6. University of Arkansas, Arkansas 7. Auburn University, Alabama 8. Boston University, MA 9. Brigham Young University, Utah 10. State University of NY @ Buffalo, New York 11. California Institute of Technology, California 12. University of California, Berkeley, California 13. University of California, Davis, California 14. University of California, Irvine, California 15. University of California, San Diego, California 16. University of California, Santa Barbara 17. Carnegie Mellon University, Pennsylvania 18. University of Central Florida, Florida 19. University of Cincinnati, , Ohio 20. Clarkson University, New York 21. Clemson University, South Carolina 22. Cleveland State University, Ohio 23. University of Colorado, Boulder, Colorado 24. Colorado State University, Colorado 25. University of Connecticut, Connecticut 26. Cornell University, New York 27. University of Dayton, Ohio 28. University of Delaware, Delaware 29. University of Denver, Colorado 30. Drexel University, Pennsylvania 31. Duke University, North Carolina 32. Embry Riddle Aeronautical University, Florida 33. Florida Atlantic University, Florida 34. Florida Institute of Technology, Florida 35. University of Florida, Florida 36. Georgia Tech, Georgia 37. University of Hawaii, Manoa, Hawaii 38. University of Houston, Texas 39. University of Idaho, Idaho 40. University of Illinois @ Chicago, Illinois 41. Iowa State University, Iowa 42. University of Iowa, Iowa 43. University of Kansas, Kansas 44. University of Kentucky, Kentucky 45. Lehigh University, Pennsylvania 46. Louisiana State University (LSU), Louisiana 47. University of Maryland, College Park, Maryland 48. University of Massachusetts, Amherst,

Massachusetts 49. University of Massachusetts, Lowell,

Massachusetts 50. Mercer University, Georgia 51. Michigan State University, Michigan 52. Michigan Technological University, Michigan 53. University of Michigan, Michigan

54. University of Minnesota, Minnesota 55. Mississippi State University, Mississippi 56. University of Missouri-Rolla, Missouri 57. Massachusetts Institute of Technology (MIT) ,

Massachusetts 58. University of New Orleans, Louisiana 59. State University of NY, Stoney Brook (SUNY),

New York 60. North Carolina State University, North Carolina 61. North Dakota, University of, North Dakota 62. Northeastern University, Massachusetts 63. Northwestern University, Illinois 64. University of Notre Dame, Indiana 65. Ohio State University, Ohio 66. University of Oklahoma, Oklahoma 67. Pennsylvania State University, Pennsylvania 68. University of Pittsburgh, Pennsylvania 69. Polytechnic University, NY 70. Princeton University, New Jersey 71. Purdue University, Indiana 72. Rensselaer Polytechnic Institute, NY 73. University of South Carolina, South Carolina 74. Southern University, Louisiana 75. University of Southern California, California 76. University of South Florida, Florida 77. Stanford University, California 78. Stevens Institute of Technology, New Jersey 79. Syracuse University, NY 80. Tennessee Technological University, Tennessee 81. University of Tennessee, Tennessee 82. University of Tennessee Space Institute (UTSI),

Tennessee 83. Texas A&M University, Texas 84. University of Texas, Arlington 85. University of Texas, Austin, Texas 86. University of Tulsa, Oklahoma 87. University of Utah, Utah 88. Valparaiso University, Indiana 89. Vanderbilt University, Tennessee 90. University of Virginia, Virginia 91. Virginia Polytechnic Institute (VPI), Virginia 92. Virginia Commonwealth University, Virginia 93. Washington State University, Washington 94. Washington University, Missouri 95. University of Washington, Washington 96. Wayne State University, Michigan 97. Western Michigan University, Michigan 98. West Virginia University, West Virginia 99. University of Wisconsin, Madison, Wisconsin 100. University of Wisconsin, Milwaukee, Wisconsin 101. Wichita State University, Kansas 102. Worcester Polytechnic Institute, Massachusetts 103. Wright State University, Ohio 104. University of Wyoming, Wyoming 105. Yale University, Connecticut

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Appendix B UTSR LIST OF STATES REPRESENTED BY PERFORMING MEMBER UNIVERSITIES

1. Alabama 2. Alaska 3. Arizona 4. Arkansas 5. California 6. Colorado 7. Connecticut 8. Delaware 9. Florida 10. Georgia 11. Hawaii 12. Idaho 13. Illinois 14. Indiana 15. Iowa 16. Kansas 17. Kentucky 18. Louisiana 19. Maryland 20. Massachusetts

21. Michigan 22. Minnesota 23. Mississippi 24. Missouri 25. New Jersey 26. New York 27. North Carolina 28. North Dakota 29. Ohio 30. Oklahoma 31. Pennsylvania 32. South Carolina 33. Tennessee 34. Texas 35. Utah 36. Virginia 37. Washington 38. West Virginia 39. Wisconsin 40. Wyoming

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Appendix C INDUSTRIAL REVIEW BOARD (IRB) FOCAL POINT PERSONNEL

Company Focal Point Time of Service

General Electric James Corman Manager, Advanced Programs Harold Miller Manager, Systems Engineering Ken Etkin Manager, Technology Planning & External Programs Kathryn Rominger Program Manager

1992-1996

1996-1998

1998-2000

2000-Current

Pratt & Whitney William Day Manager, Advanced Engine Programs Richard Tuthill Manager, Advanced Engine Programs

1992-2002

2002-Current Rolls-Royce Corporation

Sy Ali Director of Business Development, Energy & Marine Operations Robert Delaney Chief, Design Methods & Technology

1992-2001

2001-Current

Siemens Westinghouse

Ihor Diakunchak Advisory Engineer Gerard McQuiggan Manager, Gas Turbine Product Analysis

1992-2002

2002-Current

Solar Turbines George Padgett Eli Razinsky Manager, Aero/Thermal & Performance

1992-2001

2001-Current

EPRI Arthur Cohn Manager, Gas Turbine Programs Vis Viswanathan David Gandy Manager, Materials & Repair

1992-1999

2000-2001

2001-Current

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INDUSTRIAL REVIEW BOARD (IRB) FOCAL POINT PERSONNEL (concluded)

Parker Hannifin Corporation

Curt Scheuerman Michael Benjamin Technical Team Leader

1995-1997

1997-Current

Ramgen Power Systems

Robert Steele VP, Technical Development

2000-2002

Southern Company

Charles Boohaker Research Engineer

1998-Current

Woodward Governor Company

Frans Westenbrink Kelly Benson

2000-2001

2001-Current Honeywell David Winstanley

Len Meyer Chief Engineer for M&VP

1995-1997

1997-2002 ExxonMobil Phil Anderson

Materials Engineer 2003-Current

Cinergy Services Harold Stoker Principal Engineer

2004-Current

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Appendix D IRB TECHNICAL CONTACT PERSONNEL

Voting Members: GE - Power Generation Focal Point: Kathryn Rominger 518-385-0753

Sub Areas POC Phone Combustion (Instability) *Simon Sanderson 518-387-6296 Hukam Mongia 513-243-2552 (GEAE) Aero-Optimization Phil Beauchamp 518-385-4933 Ramani Mani 518-387-6341 Kevin Kirtley 518-387-5848

Phil Andrew 864-254-5334 Materials Curt Johnson (TBC’s) 518-387-6421 Warren Nelson 518-385-3660

Mike Henry 518-387-5799 *Steve Balsone 518-387-4141 Heat Transfer *Ron Bunker 518-387-5086 Richard Kehl RAM *Robert Orenstein 518-387-4103 Dynamics (Seals, Bearings) Imdad Imam 518-387-5043 Pratt & Whitney Focal Point: *Richard Tuthill 860-565-9809 Sub Areas POC Phone Heat Transfer Mike Blair 860-557-4407 Materials Kevin Schlichting 860-557-2442 Coatings Jeanine Marcin 860-565-4784 Mike Maloney 860-557-2076 Mladen Trubelja 860-565-0249

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Combustion Albert Veninger 860-557-2324 Aerodynamics Mike Blair 860-557-4407 Sensors & Controls Mark Zelesky 860-610-4326 Alternative Fuels Richard Tuthill 860-565-9809 Rolls Royce Corporation

Focal Point: *Robert Delaney 317-230-4624 Sub Areas POC Phone

Combustion *Mohan Razdan 317-230-6404 Aero-Optimization *Bob Delaney 317-230-4624 Heat Transfer *John Weaver 317-230-5398 Materials *William Brindley 317-230-8908 Dynamics *Dan Hoyniak 317-230-3312 Instrumentation, Sensors & Life *John Rothrock 317-230-3057 (old RAM) Siemens-Westinghouse Focal Point: *Gerry McQuiggan 407-736-5610 Sub Areas POC Phone Combustion, Instability Alternate Fuels, Anil Gulati 407-736-2346 Mike Koenig 407-736-5625 Sensors & Controls Tom Lippert 412-256-2440 Ramu Bandaru 407-736-5702 Materials, Thermal Allister James 407-736-7206 Barriers Ramesh Subramanian 407-736-5591

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Heat Transfer Sanjay Chopra 407-736-3679 Scott Nordlund 407-736-5108 Aerodynamics Matt Montgomery 561-776-5247 Seals Bearings Oran Bertsch 407-736-2464 Solar Turbines Focal Point: *Eli Razinsky 619-544-5635 Sub Areas POC Phone

Heat Transfer & Aero Hee Koo Moon 619-544-5226 Eli Razinsky 619-544-5198 Ulrich Stang 619-595-7573 Combustion/ Ken Smith 619-544-5539

Alternate Fuels Luke Cowell 619-544-5916 Materials Zaher Mutasim 619-544-5889 Associate Members: Cinergy Engineering and Construction Focal Point: Harold L. Stocker 317-838-6917

EPRI

Focal Point: *David Gandy 704-547-6198 ExxonMobil Focal Point: *G. Phillip Anderson 703-846-2229 Sub Areas POC Phone Combustion Richard Huntington 703-846-3021 Materials G. Phillip Anderson 703-846-2229

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Parker Hannifin Corporation Focal Point: Michael Benjamin 440-954-8105 Sub Areas POC Phone

Combustion *Adel Mansour 440-954-8171

Aero-Optimization *Erlendur Steinthorrsson 440-954-8115 Materials *Brad Hartley

Heat Transfer Adel Mansour 440-954-8171 *Erlendur Steinthorrsson 440-954-8115 Southern Company Focal Point: *Charles Boohaker 205-257-7537 Sub Areas POC Phone Combustion/Emissions Charles Boohaker 205-257-7537 Woodward Governor Company Focal Point: *Kelly Benson 970-498-3565 Sub-Areas POC Phone Kelly Benson 970-498-3921 Advisors:

DOE GRI Tom George 304-285-4825 Michael Romanco 773-399-5460 Rich Dennis 304-285-4515 Bruce Utz 412-386-5706

*Technical Contacts identified by Focal Points to send UTSR Proposals

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Appendix E DOE/NETL PERSONNEL

NAME

TITLE

DATES

Tom J. George Project Manager 2001 – Current Norman T. Holcombe Project Manager 1994-2001 Paul Micheli Product Manager 1992 – 1994 Bruce Utz Division Director 2001 - Current Richard A. Dennis Technology Manager 2001- Current Abbie W. Layne Technology Manager 1996 – 2001 Charles M. Zeh Technology Manager 1994 – 1996 Sandy H. Webb Technology Manager 1992 – 1994

SCIES PERSONNEL

Lawrence P. Golan, Ph. D. Director, PI 1992 – Current Robert By, Ph.D. Director 2004 – 2004 Glenda S. Black Unit Administrator 1992 – Current Roy P. Allen Program Manager 1992 – 1993 Daniel B. Fant, Ph. D. Program Manager 1994 – 1999 Richard A. Wenglarz, Ph. D Program Manager (Research) 2000 – Current William H. Day, Ph.D. Program Manager (Outreach) 2002 – Current Donna N. Partain Administrative Coordinator 1992 – Current Pamela R. Wilson Financial Coordinator 1992 – 1996 K. Dwight Dukes Financial Coordinator 1995 – 1996 Christina R. Talley Financial Coordinator 1996 – 2001 Leah S. Hucks Financial Coordinator 2001 – Current Kimberly A. Davenport Publications Specialist 1998 – Current

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Appendix F

GENERAL FOCUS OF UTSR RESEARCH AREAS

COMBUSTION RESEARCH

MATERIALS RESEARCH

AERO-HEAT TRANSFER RESEARCH

Permit higher turbine

inlet temperatures achieving cycle

efficiency benefits while lowering NOx,

CO, UHC and improving flame

stabilizations

Improve

performance and durability of

thermal barrier coating-substrate

materials

Enhance

performance and efficiency while

improving durability

Four Sub-Areas of

Work - lean

premixed/instability experiments

- advanced modeling - sensors and controls - catalytic

combustion

Three Sub-

Areas of Work - TBC modeling

and durability experiments

- New coating techniques

- Life prediction and non-destructive evaluations

Four Sub-Areas

of Work: - internal cooling

enhancement - external cooling

flows - aero

optimization - new design

methods

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Appendix G UTSR WORKSHOP HISTORY

Workshop Title

Dates Held Co-Host Location

Combustion Workshop I February 1994 Vanderbilt University Arthur Mellor

Nashville, TN

Combustion Workshop II March 1995 Purdue/Allison Engine Jay Gore

Indianapolis, IN

Heat Transfer Workshop March 1995 Clemson University Ting Wang

Hilton Head Island, SC

Materials Workshop I February 1996 DOE HQ Charleston, SC Combustion Workshop III March 1996 UC, Irvine

Scott Samuelsen Lake Arrowhead, CA

Sensors & Controls Workshop

April 1996 Oak Ridge National Laboratory

Clemson, SC

Heat Transfer Workshop II February 1997 Clemson University Jim Leylek, James Liburdi

Isle of Palms, SC

Combustion Workshop IV March 1997 Georgia Tech Ben Zinn

Atlanta, GA

Film-Cooling Short Course August 1997 Clemson University Clemson, SC Combustion Workshop V March 1998 UC, Berkeley

Robert Dibble Berkeley, CA

Metallics Workshop April 1998 Sevens Institute Woo Lee

Hoboken, NJ

TBC Winter Workshop January 1999 UC, Santa Barbara Carlos Levi

Santa Barbara, CA

Strategic Visioning Workshop

February 1999 DOE/Energetics, Inc. Abbie Layne

Austin, TX

Aero-Heat Transfer Workshop III

February 1999 University of TX, Austin David Bogard

Austin, TX

Combustion Workshop VI April 1999 Virginia Polytechnic Will Saunders

Blacksburg, VA

Combustion Workshop VII September 2000 UC, Berkeley Robert Dibble

Berkeley, CA

Aero-Heat Transfer Workshop IV

October 2000 University of Minnesota Terry Simon, Richard Goldstein

Minneapolis, MN

Combustion Workshop VIII July-August 2001 SCIES Charleston, SC Materials Workshop II October 2001 SCIES Greenville, SC Combustion Workshop IX August 2002 Penn State University

Dom Santavicca University Park, PA

Materials Workshop III October 2002 UCONN Maury Gell, Eric Jordan

Storrs, CT

Aero-Heat Transfer Workshop V

November 2002 LSU Sumanta Acharya

Baton Rouge, LA

- 40 -

Appendix H UTSR STUDENT INTERNS/FELLOWS

INTERN NAME YEAR WENT TO FROM PI CONTACT Degree Result/Hire Michael Chang 1995 UCBerkeley Oahn Nguyen 1995 AlliedSignal UCI Samuelsen MS Solar Turbines Steve LePera 1995 Allison Engine Virginia Tech Vandsburger MS 3-01 wkg on PhD @VT Yufeng Yu 1995 GE Carnegie Mellon Chyu PhD GE Power Gen Leonel Arellano 1995 Pratt & Whitney UCI Samuelsen MS Solar Turbines Neil Davis 1995 Solar Turbines UCI Samuelsen MS P&W Yakin Patel 1995 Westinghouse Central Florida Desai MS Westing/then Solar David Seager 1995 Clemson Brent Weyer 1995 Minnesota Patrick Wing 1995 Clarkson Bin Lian 1996 GE Michigan State Engeda PhD Intel Frank Carter* 1996 Allison Engine Oklahoma Agrawal ? Brenton Baugh 1996 AlliedSignal Wyoming Dellenback BS/MS Hewlett PackardBrian Graskow 1996 AlliedSignal U of Minnesota Simon grad wk in UK 4-01 Aaron Speight* 1996 Allison Engine USC Scott Little Chad Greer* 1996 Allison Engine Clemson Wang BS Arash Ateshkadi 1996 GE UCI Samuelsen PhD Pratt & Whitney Kris Robinson* 1996 GE-Greenville Clemson Wang BS Jason Jacobs 1996 Allison Engine Purdue Heister Devin Martin* 1996 Solar Turbines Clemson Wang BS Solar TurbinesRyan Noguchi 1996 Solar Turbines UCBerkeley Dibble MS Aerospace Corp. Randy Hibshman 1996 UTRC Virginia Tech Vandsburger MS GE-CRD Pratima Singh 1996 Westinghouse Penn State Santavicca BS MS different field Todd Thessen 1996 Parker Hannifin Wyoming Dellenback Nicholas Thayer 1996 UTRC Wyoming Dellenback Suresh Vilayanur 1996 Westinghouse UCI Samuelsen PhD Catalytica Charles Hale 1997 Allison Engine Purdue Plesniak PhD Raytheon in Arizona

- 41 -

Jeremy Hewton 1997 Allison Engine UC Davis Capece Jun Xu 1997 Allison Engine Cornell Pope PhD GE Power Systems Alberto Ayala 1997 GE UC Davis Capece PhD Asst Prof WVU Matthew Rice 1997 GE Clemson Wang MS May Leong 1997 GE UCI Samuelsen PhD UTRC Rajiv Mongia 1997 GE UCBerkeley Dibble PhD Solo Energy Ludwig Haber 1997 P&W/UTRC Virginia Tech Vandsburger PhD GRA @ VT 3-01 Andrew Bauer 1997 Pratt & Whitney U Buffalo-SUNY Taulbe MS working on PhD Joseph Yeh 1997 Pratt & Whitney Carnegie Mellon Chyu Texas Instrument Timothy Whitten 1997 Pratt & Whitney Clarkson LaFleur wkg on PhD probably-faculty pos 3-01 Christopher Hobbs 1997 Solar Turbines Virginia Tech Vandsburger BS grad stud at NCSt/3-01 John C. Lee 1997 Parker Hannifin U Washington Malte PhD Solar Turbines Ramakrishnan Pudupatty 1997 Solar Turbines Michigan State Lloyd MS Solar Turbines Adrian Stefanescu 1997 Westinghouse Cen Florida Kassab PhD Siemens-WestinghouseKevin McFarlan 1997 Westinghouse Arkansas Roe PhD 6/01 Prashanta Dutta 1997 Westinghouse USC Dutta Don Richmond 1998 Allied Signal U Washington Malte MSME cont education 4-01Erik Yen 1998 Allied Signal Carnegie Mellon Chyu na na Metin Muradogla 1998 Allison Engine Cornell Pope PhD wkng w/Pope post-doc-3-01 Robert Erickson 1998 Parker Hannifin Vanderbilt Mellor PhD 3-01 wkg w/Zinn @ GA tec Michael Davis 1998 Rolls Royce Allison N. Dakota Moen na na Kevin McFarlan 1998 Siemens Westinghouse Arkansas Roe PhD 6/01 Ye Ren 1998 Siemens Westinghouse Cen Florida Kassab wkg PhD 3-01 Siemens-Westinghouse John C. Lee 1998 Solar Turbines U Washington Malte PhD Solar Turbines John Torres 1998 Solar Turbines UCBerkeley Dibble MS Solo Energy Bryan Eisenhower 1998 UTRC Virginia Tech Vandsburger MS UTRC Ronald Wilber 1998 UTRC Penn State Santavicca MS 8/99 Charles Wadsworth 1999 GE Northwestern na naJustin Meyer 1999 GE Stevens Inst Tech Lee 3-01 PhD student w/Woo

- 42 -

Jack Griffin 1999 Pratt & Whitney Georgia Tech Carter MS 5-01 Factory Automation Sys Marcus McWaters 1999 Pratt & Whitney Texas A&M Bogard MS Int w/P&W better offer-Ford Stephen Oey 1999 Rolls Royce Allison Northeastern Taslim na na Donald Wicksall 1999 Rolls Royce/Allison Oklahoma Agrawal na naMichael Davis 1999 Rolls Royce/Allison N Dakota Moen na naJoseph Tapley 1999 Siemens Westinghouse Cen Florida Kapat na naKathryn Hawkins 1999 Siemens Westinghouse Washington St Ramaprian na naMark Higgins 1999 Siemens Westinghouse Washington St Ben Li na na Griffith Owen 1999 Solar Turbines Washington St Barry Hyman na na Scott Liljenberg 1999 Solar Turbines VPI Saunders UTRCRoss Fishman 1999 Woodward FST Arizonia State Chau na na Nathan Bolander 2000 Rolls Royce Allison Univ. of Wyoming Delaney BS 5/00 David Bryant 2000 Pratt & Whitney VA Tech Moore BS 5/01 Richard Langdon 2000 Woodward FST Univ.of SC Myers BS grad school fall 2000 Justin Meyer 2000 GE-AE Stevens Inst Tech Darolia MS PhD 5/2002 Michael Simonich 2000 Woodward FST Univ. of TX Myers BS grad school fall 2000 Allan Torsney 2000 Siemens Westinghouse Central Florida Hon Gjun Li BS Thiep Cao 2001 Siemens Westinghouse Michigan State Little MS-5/02 unknown at this time Jon Comeaux 2001 Woodward FST Univ. of N. Orleans Kalinovich SR grad. 12/01 Umeh Chukwueloka 2001 GE Embry-Riddle Dean MS-8/03 wkg/GE,wkg on MS @Rensselaer

Michael Durham 2001 Siemens Westinghouse Central Florida North MS-8/02 4/02-P/T @ Siemens thru CDI Staffing Co.

James Girard 2001 Solar Turbines UC, Berkeley Ken Smith Ph.D.-4/03 W/attend Tech. Univ., Vienna, 'til 1/03 Matthew Gold 2001 Solar Turbines SUNY, Stony Brook Mutasim MS-5/01 Sulzer Metco, Westbury, NY, Proc. Engr. Torben Grumstrup 2001 Pratt & Whitney Univ. Wyoming Jacques BS-12/02

on to grad sch, then wk in Alaska or out West

Adam Hendricks 2001 Pratt & Whitney/UTRC VA Tech K. Teerlika BS-5/02 w/pursue MS @ VA Tech Justin Meyer 2001 GE Aircraft Stevens Institute Darolia Ph.D. grad. 5/03 Justin Montgomery 2001 Rolls Royce Univ. Wyoming Welborn SR grad. 11/02 Nathan Tungseth 2001 Parker Hannifin Central Florida Patwari BS-12/01 Siemens Westinghouse

- 43 -

Steven Zygmunt 2001 Rolls Royce Univ. Wyoming Delaney BS-5/01 4/02-MS @ Penn State, degree 5/03 Samer Abdel-Wahab 2002 P&W, Cohen, 860-610-7973 VA Tech Uri Vandsburger MS rec MS ? Date--student 1/03 Ryan Edmonds 2002 Ramgen, Hinkley, 425-828-4919 Univ. Washington Phil Malte MSME-8/02 Ramgen Power Systems, Bellevue, WA Majid Feiz 2002 Woodward, Benson, 970-498-3565 Wichita State Behnam Bahr PhD grad May 2004-PhD Josh Foelber 2002 Rolls Royce, Gegg, 317-230-4850 Valparaiso Univ. Michael Barrett MS-5/02 Rolls-Royce, Indianapolis, IN Andrew Hyatt 2002 Solar Turbines, Smith, 619-544-5539 Univ. of Texas David Bogard MS-12/04 Shawna Liff 2002 Siemens, North, 407-736-2477 Northeastern U. M. Taslim SR grad 6/03 grad school fall 2003 for PhD James Losh 2002 Siemens, Entenmann, 407-736-2471 VA Tech William Saunders MS-12/04 may stay @VT for PhD Craig Russell 2002 GE, Sanderson, 518-387-6296 Vanderbilt Univ. Robert Pitz BE 5/03 GECRD Schenectady upon graduation

Todd Anderson 2003 Rolls-Royce, Sokhey, 317-230-6470, jack.sokhey@aadc.com BYU Bons SR

Joshua Bonds 2003 Siemens, Hadjinicolaou, 317-230-4591 Univ. Wyoming SR

David Thiep Cao 2003 Rolls-Royce, Weber, 317-230-4591, kurt.f.weber@rolls-royce.com Michigan State MS

Charles Cates 2003

Rolls-Royce, Wellborn, 317-230-4706, steven.r.wellborn@rolls-royce.com VCU MS

Brandon Clifton 2003 Siemens, Ramer VA Tech BS Ace Precision (Siemens supplier)

Loren Crook 2003 Woodward, Benson, 970-498-3921, kbenso@woodward.com Univ. Wyoming SR

Robert Draper 2003 Ramgen, Steele, 425-828-4919, x288, rsteele@ramgen.com Michigan State MS Ramgen

Kevin Duffy 2003 Solar, Damle, 619-237-8215, damle_sachin-v@solarturbines.com VA Tech MS

Kevin Eisemann 2003 P&W, Blair, 860-557-4407, michael.blair@pw.utc.com VA Tech SR

Justin Evans 2003 P&W, Blair, 860-557-4407, michael.blair@pw.utc.com Univ. N. Dakota SR

- 44 -

Majid Feiz 2003 Woodward, Benson, 970-498-3921, kbenso@woodward.com Wichita State PhD

Homayoon Feiz 2003 Parker, Steinthorsson, 440-954-8115, esteinthorsson@parker.com GA Tech PhD

Barbara Franke 2003 Solar, Price, 619-544-5539, Price_Jeff_R@solarturbines.com UCF SR

David Frankman 2003 Woodward, Benson, 970-498-3921, kbenso@woodward.com BYU SR

Ross Gustafson 2003 GE, Andrew, 864-254-5334 LSU MS

Laura Hansen 2003 Solar, Smith, 619-544-5539, smith_ken_o@solarturbines.com BYU SR

Harika Kahveci 2003 Parker, D.Turko, 440-954-8165, dturko@parker.com Penn State MS

Heidy Laboy 2003 Siemens, Subramanian Texas A&M MS Megan Leggett 2003 Siemens, Chehab Embry-Riddle SR Jonathan Lister 2003 GE, Fossum, 864-254-4459 Tennessee Tech SR Timothy Marbach 2003 Siemens, C. Johnson Univ. Oklahoma MS Christopher Martin 2003 GE, Butterfield, 518-385-8716 VA Tech BS 5/04 start PhD @VA Tech fall/04

Ryan Merrell 2003 Rolls-Royce, Roesler, 316-230-2445, tim.roesler@rolls-royce.com Valparaiso Univ. SR

Angela Morris 2003 Siemens, R. Scott VA Tech SR

Matthew Neidert 2003 GE, Fossum / 864-254-4459 Univ. Dayton

2/04 wkg on Masters p/t-

Purdue 2/04-Goodyear Tire/Rubber Co, Akron, OH

David Paulus 2003 Woodward, Benson, 970-498-3921, kbenso@woodward.com Colorado State PhD asst engrg prof-U of Arkansas-1/04

Mark Shtayerman 2003 Siemens, Lasterman UCSD SR

Elon Terrell 2003 Siemens, Diakunchak, 407-736-5115, ihor.diakunchak@siemens.com Univ. TX, Austin SR

Trent Varvel 2003 Siemens, R. Scott Texas A&M MS

Justin Waldron 2003 Solar, Burnes, 619-544-5428, Burnes_Daniel_W@solarturbines.com Univ. Minnesota MS

W. Scott Walsh 2003 Siemens, Diakunchak, 407-736-5115, ihor.diakunchak@siemens.com VA Tech SR

Lesley Wright 2003 P&W, Blair, 860-557-4407, michael.blair@pw.utc.com Texas A&M MS

- 45 -

Appendix I UTSR FACULTY FELLOWSHIP PROGRAM

Professor Name School Company Research Title

1998 Minking Chyu

Carnegie Mellon University

Solar Turbines, Inc. Contact: Boris Glezer

High Temperature Application of Thermographic Phosphors

Fred Culick California Institute of Technology

Pratt & Whitney, UTRC A Short Course and Research Collaboration for Dynamics and Control of Internal Reacting Flows

Abraham Engeda Michigan State University Allison Engine Company Contacts: J.R. Fagan, Jr, David Sayre

Compressor Volute Design Part I: Theory on Volutes Part II: The Redesign of the Allison Volute

Jay Gore Purdue University Allison Engine Company Contact: Mohan Razdan

Radiation Heat Transfer Studies of Natural Gas Air Flames for Application to Gas Turbine Combustor Design Codes

Ramendra Roy Arizona State University Solar Turbines, Inc. Contact: Michael Fox

Experimental and Computational Study of Disk Cavity Sealing and Cooling

1999 A. K. Agrawal

University of Oklahoma

Solar Turbines, Inc. Contacts: Ken Smith, Mohan Sood

Alternate Fuels for Gas Turbine Combustors

- 46 -

Forrest E. Ames University of North Dakota Solar Turbines, Inc.

Contact: Boris Glezer Characterization of Low NOx Combustion System Turbulence and Associated Heat Transfer to First Stage Nozzles

Cengiz Camci Pennsylvania State University General Electric Company Contact: Ron Bunker

Implementation of the “Invariant h” Method in Liquid Crystal Thermometry Based Heat Transfer Research Including Film Cooling

Phil Ligrani University of Utah General Electric Company Contact: Ron Bunker

Heat Transfer and Flow Characteristics Measured in the Vicinity of Attached Bucket Tip Shrouds

- 47 -

Appendix J UTSR PROFESSOR/STUDENT INVENTORY

University

SRO# Principal

Investigator Co-Principal Investigator

Students PhD M.S. Under-graduates

Other Special Notes

Cal-Berkeley Robert Dibble Jyn-Yuan Chen & Robert F. Sawyer

R. Mongia & Bond

M. Rumminger

L. SmithSRO07/74 Vanderbilt

SRO08 Arthur Mellor T. Prast

Purdue SRO09/19/ 44/64/69/85

Paul Sojka, J.P. Gore, Sanford

Fleeter & Satish Ramadhyani

N.M. Laurendeau, Patrick Lawless, Yudaya

Sivathanu, Jun Ji & Michael W. Plesniak

Andrew Lloyd, Sabrina Zhu & Yuan Zheng

Jun Ji, AaronBrundage & Neal Venters

Lehigh SRO10

Arnold Marder K. Barmak

Texas A&M SRO11/82/94

J.C. Han M.T. Schobeiri, Phil Ligrani & H.C. Chen

L. Wright

Penn State SRO12/32/36/ 50/78/79/90

Sam Y. Zamrick, Robert J.

Santoro, Bud Lakshminarayan & Domenic A.

Santavicca

Donald Koss, Mark L. Renauld, D.A. Santavicca,

V. Yang, P. Brown, C. Camci & R.J. Goldstein

J.G. Lee R. Bandaru, V.Yang & S. Menon

Ravindra Anruigeri,

S.A. Miller, Kwanwoo

Kim & Jose Samperio

Jason Williams, Mark L. Renauld, Ravindra

Annigeri & Arlene Zahiri

1

Virginia Tech

SRO13/65

Vandsburger & William T. Baumann

Seshu B. Desu, Larry A. Roe, William R. Saunders

& U. Vandsburger

C. Ding, R.M. Fuller, S.

Marques, S. LePera, Y. Yuan,

B. McCabe, Ximing Huang,

Christopher Fannin, Vivek

Khanna Prateep Chatterjee, Salahi Basaran, L. Nord & S. Liljenberg

S. Song & K. Lohrman

2

Brigham Young SR014

Paul O. Hedman B. Scott Brewster & Thomas H. Fletcher

- 48 -

LSU

SRO15/89 Sumanta Acharya

Tod A. Myrum, Dimitris Nikitopoulos & Joel

Tohline

Richard Hibbs,Yi Chen, Guy

Pointel, Chirdeep Sharman, Pradipta

Pahigrahi & Vasilis Eliades

Clarkson SRO16

Ronald LaFleur John Reynolds Juan Araujo, Patrick Wing,

Steve Sperling, Susan Jauch &

Brian Scotti

3

MIT SR017

Gerald Guenette

Jack L. Kerrebrock & M.S. Anand

George J.Govatzidakis

Cornell

SRO18/49 Stephen B. Pope Bo Yang & Vivek Saxena

J. Xu, M.

Muradoglu, Q. Tang

P. Jenny, V. Saxena

Jun Xu

Post Doctoral:Bo Yang &

Vivek Saxena

4

Cal-Irvine SRO20/62

Scott Samuelson John LaRue & Vince McDonnell

Darrell Guillaume, Suresh Vilayanur & Ryan

Bullock

Junhua Chen,Matthew

Dudik & Rene Flores

Graham W. Clark

Minnesota SRO21/71

Richard Goldstein

E.R.G. Eckert, S.V. Patankar & T.W. Simon &

C. Camci

M. Berne, S. Burd, P. Jin, R.W.

Kaszeta, A. Leitner, R. Oke, R. Olson, S.J.

Olsen, L. Stone, A. Radmehr &

H.P. Wang

- 49 -

Central Florida

SRO22/39/57/ 67/80

Vimal Desai & Jay Kapat

Alain Kassab Eduardo Divo, Franklin

Rodriguez, F. Zhang, C.P. Rahaim, J.

Pollard, Baker, D.K. Preideman, T.M. Skeen, A. Stefanescu, Ye

Ren, Hadjinicolaou & B. Butler, E. Bass

DnyaneshTamboli & Yakin Patel

Carnegie Mellon

SRO23/70/88

Minking Chyu Tom I-P Shih & Terrence W. Simon

Clemson SRO24/34

James Leylek James Liburdy Jeffery Butkiewicz,

Kevin McGovern, Keith Walters, Daniel Hyams,

Robert Brittingham, John

Farmer, David Seager & Philip

Berger

5

Wyoming SRO25

Paul Dellenback Roger Radomsky

Georgia Tech SRO27/31/66/

75

W.B. Carter & Ben Zinn

J.M. Hampikian, Yedidia Neumeier & Timothy C. Lieuwen

G.W. Book, M.R. Hendrick, E. Enin-Okut,

D.J. Ryan, D.W. Stollberg & Ben Bellows

B. Valek

6

Maryland SRO28

Ashwani Gupta Mark Lewis

Oklahoma SRO29

Ajay Agrawal S.R. Gollahalli, A. Tinneti & Y. Gao

- 50 -

Connecticut SRO30/35/73/

81/91

Maurie Gell, Amir

Faghri, Maurice

Gell, Eric Jordan &

Nitin Padture

Eric Jordan & David R. Clarke

Krishnakumar Valdyanathan, Brent Barber,

Kevin Schlichting & Kathleen McCarron

Jiangtian Cheng

Theresa Roy, K.

Vaidyanathan, L. Xie, J.H.

Kim, S. Sridharan,

M. Madhwal, J. Shen & M.

Wen

JiangtianCheng & Yong Ho

Sohn

7

Arizona State

SRO33

Ramendra Roy V. Agarwal, S. Devasenathipathy,

L. Meler, Y. Zhao,J. He & J.

Feng

Guoping Xu

Syracuse SRO37

Thong Dang Sachin Damle 8

Mass. Institute of Technology SRO38/45

Gerald Guenette & Choon S. Tan

Yang-ShengTzeng & Boris

Sirakov

Michigan State

SRO26/40

Abraham Engeda John R. Lloyd

Cleveland State

SRO42

Kang Lee Surendra N. Tewari C. Ramachandra

Wisconsin SRO43

Karen Thole D.G. Bogard Roger W. Radomsky, Brian Kang, Boris

Bangert, Marcus D. Polanka, Virginia C. Witteveld, Michael

Cutbirth & Marcia I. Etheridge

MichaelSimonich

- 51 -

Pittsburgh SRO46/77

Frederick S. Pettit

Gerald H. Meier Kivilcim Onal Troy Baker

Northwestern SRO47

Katherine Faber Daniel Boss Cyndi Batson & Christopher

Scharff

Jennifer Su & Jennifer

Mawdsley

Cyndi Batson & Christopher

Scharff

Post Doctoral:

Rodney W. Trice

9

Univ. of California,

Davis SRO48

Vincent R. Capece

Ian M. Kennedy Daniel L. Flowers Alberto Ayala, Jeremy Hewton

11

CIT SRO63

Fred Culick Giorgio Isella, Konstantin

Matveev, Steve Palm, Winston

Pun, Claude Stewart & Grant

Swenson

10

Cal. Santa Barbara

SRO68/93

Anthony Evans, Carlos G. Levi & David R. Clarke

C.G. Levi & A.G. Evans Edward A.G. Shillington, Jennifer R.

Litty & Noemi Rebollo

Jennifer B. Pritchard, Will Gans & Dylan

Jones

Mississippi State

SRO76

B.K. Hodge Jeffrey Bons, Rolf Sondergaard & Richard

Rivir

Virginia Comm.

University SRO83

Eric Sandgren Douglas L. Sondak, Paul O. Orkwis, Vipil K. Gupta

& Robert Croft

UCI SRO84

Scott Samuelson Vince McDonnell Junhua Chen

North Dakota SRO86

Forrest E. Ames Pierre Barbot, Chao Wang &

Matthew Argenziano

12

Washington SRO87

Philip C. Malte Ryan Edmonds 13

- 52 -

University of Texas – Austin SRO92

David G. Bogard K.A. Thole Sean Jenkins, Krishnakumar Varadarajan,

Severin Kempf & Daniel Knost

Special Notes

1. Penn State (SRO12/32/36/50/78/79/90) Two Ph.D. candidates have successfully completed their doctorate degrees through this program. Dr. Mark Renauld,

a strong contributor to the success of this research effort has joined United Technologies (Pratt & Whitney Aircraft Co.) in East Hartford, CT, and Dr. Ravi Annigeri has joined General Electric Co. in Schenectady, NY. In addition, through the Penn State CURO minority program.

2. Virginia Tech (SRO13/65/99/100) The ATS project offered an excellent opportunity for education of young engineers in many technically relevant areas of science and technology. The activities involved graduate and undergraduate students alike, university laboratories and industrial locations. Six degrees were awarded. Mr. Liljenberg performed work that was critical to the project, acoustic system ID, and stability analysis of a combustor test rig, and was funded separately by solar turbines, Inc.

3. Clarkson (SRO16) Juan Araujo, John Reynolds Tim Whitten and Michael Halter who as a team supported the hardware and software development and handled the technical details required when optimizing the experiment. These graduate students made the project results possible.

4. Cornell (SRO18/49) Both Saxena and Xu are currently employed in the gas turbine industry, at Pratt & Whitney and GE Power Systems, respectively. 5. Clemson (SRO24/34) Two Clemson students, Dr. Tao Guo and Dr. Xianchang Li, have used the project as a center for their dissertation research and have

been awarded PhD degrees at Clemson. General Electric Power generating currently employs Dr. Guo and Dr. Li is currently available for employment. 6. Georgia Tech (SRO27/31/66/75) Five graduate students worked on the project. Dr. G.W. Brook obtained a PhD in September 1996, Ms. M. Hendricks

obtained an M.S. in June 1996 and Ms. E. Enin-Okut and Mr. D.J. Ryan both received M.S. degrees in June 1998. 7. Connecticut (SRO30/35/73/ 81/91) Theresa Roy, a mechanical engineering graduate student, summarized the results in part of the project. Two graduate

students also participated in the UTSR summer internship program, and one was hired on afterward by GE in Schenectady, NY. 8. Syracuse (SRO37) Sachin Damle received PhD and has been hired by Solar Turbines as a full-time employee. 9. Northwestern (SRO47) Both graduate students Jennifer Su and Jennifer Mawdsley were awarded PhD’s based upon their work on thermal barrier coatings.

Argonne National Lab and General Electric Research and Development now employ them, respectively. 10. Univ. of California, Davis (SRO48) Due to the resignation of Dr. Vince Capece, Clemson University released a Termination Notice on November 26, 1997. 11. CIT (SRO63) Degrees Awarded- Grant Swenson PhD June 2000, Giorgio Isella PhD June 2001, Winston Pun PhD June 2001, Claude Seywert PhD June

2001. 12. North Dakota (SRO86) Pierre is currently working as a C N A to gain medical experience for entry into medical school and is working part time on his

master’s thesis. Chao is being supported ¼ times through the UND’SS school of Engineering and Mines Energy Engineering PhD program and ¼ times by current UTSR contract.

13. Washington (SRO87) The atmospheric pressure testing is conducted by MSME student Ryan Edmonds.

- 53 -

Appendix K

UTSR RESEARCH PROJECTS

Subcontract Number School Principal Investigator Area of Research Project Title

93-01-SR007 University of California – Berkeley 6159 Etcheverry Hall, ME Dept. Berkeley, CA 94720 (510) 642-4901 phone (510) 642-1850 fax

Robert Dibble

dibble@newton.berkeley.edu

C Ultra Low Gas Turbine Emissions Using Catalytic and Non Catalytic Porous Combustors

93-01-SR008 Vanderbilt UniversityBox 1592, Station B, ME Department Nashville, TN 37235-1592 (615) 343-6214 phone (615) 343-6687 fax

Arthur Mellor

stanleyb@vuse.vanderbilt.edu

C NOx and CO Emissions Models for Gas-Fired, Lean Premixed Combustion Turbines

93-01-SR009 Purdue UniversityChaffee Hall, ME Department West Lafayette, IN 47907 (765) 494-1536 phone (765) 494-0530 fax

Paul Sojka

sojka@ecn.purdue.edu

C NOx Abatement in Advanced Gas Turbines

93-01-SR010 Lehigh University117 ATLSS Drive, Whitaker Lab Bethlehem, PA 18017 (610) 758-4197 phone (610) 758-4244 fax

Arnold Marder

arm0@lehigh.edu

M Functionally Graded Material for Thermal Barrier Coatings in Advanced Gas Turbine Systems

93-01-SR011 Texas A&M UniversityDepartment of Mechanical Engineering College Station, TX 77843-3123 (409) 845-3738 phone (409) 862-2418 fax

J. C. Han

JCHan@mengr.tamu.edu

AHT Advanced Turbine Cooling, Heat Transfer, and Aerodynamic Studies

- 54 -

93-01-SR012 Pennsylvania State University

Engineering Science and Mechanics University Park, PA 16802

Sam Y. Zamrick

syzesm@engr.psu.edu

M Life Prediction of Advanced Materials for Gas Turbine Application: The Effects of Thermomechanical Strain/Temperature Cycling on Fatigue Life and Crack Growth of Coated in 738LC Material

93-01-SR013 Virginia Polytechnic InstituteDepartment of Mechanical Engineering 132 Research Building East Blacksburg, VA 24061-0170 (814) 865-1804 phone (814) 865-0497 fax

Uri Vandsburger

Uri@stnick.me.vt.edu

C Advanced CombustionTechnologies for Gas Turbine Power Plants

93-01-SR014 Brigham Young University350 Clyde Building Chemical Engineering Department (801) 378-6238 phone (801) 378-7799 fax

Paul O. Hedman

hedman@BYU.edu

C Combustion Modeling in Advanced Gas Turbine Systems

93-01-SR015 Louisiana State University Mechanical Engineering Baton Rouge, LA 70803 (504) 388-5809 phone (504) 388-5924 fax

Sumanta Acharya

acharya@me.lsu.edu

AHT Vortex-Generator InducedEnhanced Heat Transfer in Gas Turbine Blade Coolant Channels With Rotation

93-01-SR016 Clarkson UniversityBox 5725, Mech/Aero Engineering Potsdam, NY 13699-5725 (315) 268-3823 phone (315) 268-6438 fax

Ronald LaFleur

maddog@sun.soe.clarkson.edu

AHT Reduction of Turbine Endwall Total Pressure Loss And Heat Transfer Using the Ice Formation Design Method

94-01-SR017 Massachusetts Institute of Technology 77 Mass Avenue, Room 31-214 Cambridge, MA 02139 (617) 253-3764 phone (617) 253-6093 fax

Gerald Guenette

jerryg@mit.edu

AHT The Effects of Rotation on the Internal Heat Transfer in Turbine Blades

- 55 -

94-01-SR018 Cornell University

240 Upson Hall Mechanical and Aero Engineering Ithaca, NY 14853-7501 (607) 255-4314 phone (607) 255-1222 fax

Stephen B. Pope

pope@mae.cornell.edu

C Manifold Methods for Methane Combustion

94-01-SR019 Purdue UniversityDepartment of Mechanical Engineering 1288 Mechanical Engineering Building West Lafayette, IN 47907-1288 (765) 494-5622 phone (765) 494-0536 fax

Sanford Fleeter

fleeter@ecn.purdue.edu

AHT Advanced Multistage Turbine Blade Aerodynamics, Performance, Cooling and Heat Transfer

94-01-SR020 University of California – Irvine UCI Combustion Laboratory Irvine, CA 92697-3975 (949) 824-5468 phone (949) 824-7423 fax

Scott Samuelsen

gss@uci.edu

C The Role of Mixedness and Length Scale on Performance and Emissions in a GTE Can Combustor

94-01-SR021 University of MinnesotaDepartment of Mechanical Engineering 125 ME/111 Church Street, S.E. Minneapolis, MN 55455-0111 (612) 625-5552 phone (623) 625-3434 fax

Richard Goldstein

rjgumn@mailbox.mailmumn.edu

AHT Experimental andComputational Studies of Film Cooling with Compound Angle Injection

94-01-SR022 University of Central Florida Department of Mechanical, Materials & Aero Engineering 4000 Central Florida Boulevard Orlando, Florida 32816-0150 (407) 823-5777 phone (407) 823-0208 fax

Vimal Desai

desai@mae.engr.ucf.edu

M Compatibility of Gas Turbine Materials With Steam Cooling

94-01-SR023 Carnegie Melon UniversityDepartment of Mechanical Engineering Pittsburgh, PA 15213-3890 (412) 268-3658 phone (412) 268-3348 fax

Minking Chyu

mc47@andrew.cmu.edu

AHT Development and Application of a Novel Optical Temperature/Heat Cooling Flux Sensor for Advanced Blade Cooling Research and Engine Thermal Diagnostics

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94-01-SR024 Clemson University

Department of Mechanical Engineering 318 Riggs Hall Clemson, SC 29634-0921 (864) 656-5640 phone (864) 656-4435 fax

James Leylek

jim.leylek@ces.clemson.edu

AHT Advanced Design Methodology Using Combined Computational Experimental Techniques for Gas Turbine Film Cooling

94-01-SR025 University of WyomingME Department/PO Box 3295 Laramie, WY 82071-3295 (307) 766-2122 phone (307) 766-2695 fax

Paul Dellenback

pad@uwyo.edu

AHT The Impact of Turbulence on Heat Transfer in Internal Flows

94-01-SR026 Michigan State University ME Department/A231 EB Turbomachine Lab East Lansing, MI 48824-1226 (517) 432-1834 phone (517) 353-1750 fax

Abraham Engeda

engeda@me.msu.edu

AHT Steam Cooled Gas Turbine Blade

94-01-SR027 Georgia Institute of Technology School of MSE 778 Atlantic Drive Atlanta, GA 30332-0245 (404) 894-6762 phone (404) 894-9140 fax

W.B. Carter

brent.carter@mse.gatech.edu

M Combustion Chemical Vapor Deposited Coatings For Thermal Barrier Coating Systems

94-01-SR028 University of MarylandME Department College Park Campus College park, MD 20742 (301) 405-5276 phone (301) 314-9477 fax

Ashwani Gupta

akgupta@eng.umd.edu

C Advanced Concepts for High Efficiency and Low NOx Gas Turbine Combustor Development

94-01-SR029 University of Oklahoma865 Asp Avenue, Room 212 Norman, OK 73019-0501 (405) 325-1754 phone (405) 325-1088 fax

Ajay Agrawal

aagrawal@ou.edu

AHT Improving Aerodynamics of the Intercooler Flow Path for the Development of High Efficiency Gas Turbines

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95-01-SR030 University of Connecticut

Dept. of Metallurgy & Materials Engineering 97 North Eagleville Road, U-136 Storrs, CT 06269 (860) 486-3514 phone (860) 486-4745 fax

Maury Gell

mgell@mail.ims.uconn.edu

M Bond Strength and Stress Measurements in Thermal Barrier Coatings

95-01-SR031 Georgia Institute of Technology 225 North Avenue Atlanta, GA 30332-0150 (404) 894-3032 phone (404) 894-2760 fax

Ben Zinn

Ben.zinn@aerospace.gatech.edu

C Active Control of Combustion Instabilities in Low NOx Gas Turbines

95-01-SR032 Pennsylvania State University Department of Mechanical Engineering 240 Res. Building, East, Bigler Road University Park, PA 16802-2320 (814) 863-1285 phone (814) 865-3389 fax

Robert J. Santoro

rjs2@email.psu.edu

C Combustion Instability Studiesfor Application In Low Emissions, High Performance Land-Based Gas Turbine Combustors

95-01-SR033 Arizona State UniversityMech/Aerospace Eng., Box 876106 Tempe, AZ 85287-6106 (480) 965-1482 phone (480) 965-1384 fax

Ramendra Roy

roy@asu.edu

AHT Flow and Heat Transfer in Gas Turbine Disk Cavities Subject to Non-Uniform External Pressure Field

95-01-SR034 Clemson University Department of Mechanical Engineering 318 Riggs Hall Clemson, SC 29634-0921 (864) 656-3294 phone (864) 656-4435 fax

Joseph (Leo) Gaddis

nasau@clemson.edu

AHT Innovative Schemes for Closed-Loop Air/Stream Cooling of Advanced Gas Turbine Systems

95-01-SR035 University of ConnecticutME Department, 191 Auditorium Road Storrs, CT 06269-3139 (860) 486-2090 phone (860) 486-5088 fax

Amir Faghri

faghri@eng2.uconn.edu

AHT Heat Pipe Turbine Vane Cooling

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95-01-SR036 Pennsylvania State University

Department of Aerospace Engineering 153 Hammond Building University Park, PA 16802-1400 (814) 865-5511 phone (814) 865-7092 fax

Bud Lakshminarayana

B1LAER@ENG.PSU.EDU

AHT Improved Modeling Techniques for Turbomachinery Flow Fields

95-01-SR037 Syracuse University149 Link Hall Department of ME/Aero Engineering Syracuse, NY 13244 (315) 443-4311 phone (315) 443-9099 fax

Thong Dang

tqdang@mame.syr.edu

AHT Development of an Advanced Three-Dimensional And Viscous Aerodynamic Design Method For Turbomachine Components in Utility and Industrial Gas Turbine Applications

95-01-SR038 Massachusetts Institute of Technology 77 Mass Avenue, Room 31-214 Cambridge, MA 02139 (617) 253-3764 phone (617) 253-6093 fax

Gerald Guenette

jerryg@mit.edu

AHT The Effects of Rotation on the Fluid Mechanics Of Internal Turbine Blade Cooling

95-01-SR039 University of Central Florida Department of Mechanical, Materials & Aero Engineering 4000 Central Florida Boulevard Orlando, Florida 32816-0150 (407) 823-5777 phone (407) 823-0208 fax

Vimal Desai

desai@mae.engr.ucf.edu

AHT Compatibility of Gas Turbine Materials With Steam Cooling

95-01-SR040 Michigan State University ME Department/A231 EB Turbomachine Lab East Lansing, MI 48824-1226 (517) 432-1834 phone (517) 353-1750 fax

Abraham Engeda

engeda@me.msu.edu

AHT Steam Cooled Gas Turbine Blade

96-01-SR042 Cleveland State University Chemical Engineering Department, SH464 Cleveland, OH 44115 (216) 433-5634 phone (216) 433-5544 fax

Kang Lee

Kang.N.Lee@lerc.nasangov

M Development of Refractory Oxide and Glass Ceramic-YSZ Dual Layer TBC Top Coats For Advanced Land Based Gas Turbines

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96-01-SR043 University of Wisconsin319 Mechanical Engineering Department 1513 University Aven7ue Madison, WI 53706 (608) 262-0923 phone (608) 265-2316 fax

Karen A. Thole

thole@vt.edu

Currently at Virginia Tech 540-231-7192 phone

540-231-9100 fax

AHT Detailed Flow and Thermal Field Measurements on a Scaled-Up Stator Vane

96-01-SR044

Purdue University School of Mechanical Engineering Thermal Sciences and Propulsion Center West Lafayette, IN 47907-1003 (317) 494-5711 phone (317) 494-0539 fax

Jay Gore

gore@ecn.purdue.edu

C Miniature Infrared EmissionBased Temperature Sensor and Light-Off Detector

96-01-SR045 Massachusetts Institute of Technology Gas Turbine Lab, MS 31-267 Cambridge, MA 02139 (617) 258-7524 phone (617) 258-6093 fax

Choon S. Tan

Choon@mit.edu

AHT Impact of Endwall Flow and Wakes on Multistage Compressor Performance and Design

96-01-SR046 University of PittsburghMaterials Science & Engineering Department 231 Benedum Hall Pittsburgh, PA 15261 (412) 624-9730 phone (412) 624-8096 fax

Frederick S. Pettit

pettit@engrng.pitt.edu

M Chemical and MechanicalInstabilities at Thermal Barrier Coating Interfaces

96-01-SR047 Northwestern UniversityBIRL Industrial Research Laboratory 1801 Maple Avenue Evanston, IL 60208-3108 (847) 491-2444 phone (847) 491-7820 fax

Katherine Faber

k-faber@nwu.edu

M SPPS for Advanced Thermal Barrier Coatings

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96-01-SR048 University of California-Davis

Davis, CA 95616-5294 Vincent Capece AHT An Experimental Investigation of the

Three Dimensional Flow in the Clearance Region of Cantilevered Stator Vanes With and Without Hub Rotation

96-01-SR049 Cornell University240 Upson Hall Mechanical and Aero Engineering Ithaca, NY 14853-7501 (607) 255-4314 phone (607) 255-1222 fax

Stephen B. Pope

pope@mae.cornell.edu

C Development andImplementation of Accurate and Efficient Combustion Chemistry for Gas Turbine Combustor Simulations

96-01-SR050 Pennsylvania State University Department of Mechanical Engineering 132 Research Building East University Park, PA 16802-7000 (814) 863-1863 phone (814) 865-3389 fax

Domenic A. Santavicca

DAS8@PSU.EDU

C Sensors for Measuring Primary Zone Equivalence Ratio In Lean Premixed Combustors

98-01-SR062

University of California – Irvine UCI Combustion Laboratory Irvine, CA 92697-3975 (949) 824-5468 phone (949) 824-7423 fax

Scott Samuelsen

gss@uci.edu

C Mechanistic Study of Critical Technology Issues in Natural-Gas Fired Gas Turbine Combustion

98-01-SR063

California Institute of Technology 207 Guggenheim, MS 205-45 Pasadena, CA 91125 (626) 395-4783 phone (626) 449-2677 fax

Fred Culick

Culick@intruder.caltech.com

C Nonuniformities of Mixture Ratio as a Mechanism of Combustion Instabilities in Lean Pre-Mixed Combustors

98-01-SR064 Purdue UniversityMechanical Engineering Building 1288 Mechanical Engineering Building West Lafayette, IN 47907-1288 (765) 494-5701 phone (765) 494-0539 fax

Satish Ramadhyani

Ramadhya@ecn.purdue.edu

AHT Airfoil Trailing Edge Cooling

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98-01-SR065 Virginia Polytechnic Institute

Department of Mechanical Engineering 132 Research Building East Blacksburg, VA 24061-0170 (814) 865-1804 phone (814) 865-0497 fax

Uri Vandsburger

Uri@stnick.me.vt.edu

C Development of Modular, Reduced -Order Models For Prediction of Combustion Instabilities

98-01-SR066 Georgia Institute of Technology School of Materials Science & Engineering 778 Atlantic Drive Atlanta, GA 30332-0245 (404) 894-2845 phone (404) 894-9140 fax

Janet Hampikian

janet.hampikian@mse.gatech.edu

M Improvements in ThermalBarrier Coating Durability Via Combustion Chemical Vapor Deposition

98-01-SR067 University of Central Florida Department of Mechanical, Materials & Aero Engineering 4000 Central Florida Boulevard Orlando, Florida 32816-0150 (407) 823-5777 phone (407) 823-0208 fax

Vimal Desai

desai@mae.engr.ucf.edu

M Non-Destructive Evaluation andMonitoring of TBC By Electrochemical Impedance Spectroscopy

98-01-SR068

University of California – Santa Barbara Materials Department Santa Barbara, CA 93106 (805) 893-4634 phone (805) 893-8486 fax

Anthony Evans

M A Mechanism-Based Approachto Life Prediction and Non-Destructive Evaluation for Thermal Barrier Coatings

98-02-SR069 Purdue UniversityDepartment of Mechanical Engineering 1288 Mechanical Engineering Building West Lafayette, IN 47907-1288 (765) 494-5622 phone (765) 494-0536 fax

Sanford Fleeter

fleeter@ecn.purdue.edu

AHT Turbine Blade Tip, Endwall and Platform Heat Transfer Including Rotation Effects

98-01-SR071 University of MinnesotaDept. of Mechanical Engrg. 125 ME/111 Church Street, S.E. Minneapolis, MN 55455-0111 (612) 625-5552 phone (623) 625-3434 fax

Richard Goldstein

rjgumn@mailbox.mailmumn.edu

AHT Edge Cooling Heat Transfer on Turbine Blades

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99-01-SR073 University of ConnecticutDepartment of Mechanical Engineering, U-139 191 Auditorium Road Storrs, CT 06269-3139 (860) 486-2371 phone (860) 486-5088 fax

Eric Jordan

jordan@engr.uconn.edu

M Development of Laser Fluorescence as a Non-Destructive Inspection Technique for Thermal Barrier Coatings

99-01-SR074 University of California – Berkeley 6159 Etcheverry Hall, ME Dept. Berkeley, CA 94720 (510) 642-4901 phone (510) 642-1850 fax

Robert Dibble

dibble@newton.berkeley.edu

C Fuel-Air Mixing Explored with Optical Probes, Tomography, and Large Eddy Simulations

99-01-SR075 Georgia Institute of Technology 225 North Avenue Atlanta, GA 30332-0150 (404) 894-3032 phone (404) 894-2760 fax

Ben Zinn

ben.zinn@aerospace.gatech.edu

C Extending the Lean Blowout Limits of Low NOx Gas Turbines by Control of Combustion Instabilities

99-01-SR076 Mississippi State University Department of Mechanical Engineering Mississippi State, MS 39762 (601) 325-7315 phone

Robert P. Taylor

taylor@me.msstate.edu

AHT Real Surface Effects on Turbine Heat Transfer and Aerodynamic Performance

99-01-SR077 University of PittsburghMaterials Science & Engineering Department 231 Benedum Hall Pittsburgh, PA 15261 (412) 624-9720 phone (412) 624-8096 fax

Fred S. Pettit

pettit@engrng.pitt.edu

M Interaction of Steam/AirMixtures with Turbine Airfoil Alloys and Coatings

99-01-SR078 Pennsylvania State University Department of Mechanical Engineering 240 Res. Building, East, Bigler Road University Park, PA 16802-2320 (814) 863-1285 phone (814) 865-3389 fax

Robert J. Santoro

rjs2@email.psu.edu

C Dual Fuel Issues Related to Performance, Emissions and Combustion Instability in Gas Turbine Systems

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99-01-SR079 Pennsylvania State University

Department of Aerospace Engineering 153 Hammond Building University Park, PA 16802-1400 (814) 865-5551 phone (814) 865-7092 fax

Bud Lakshminarayana

B1LAER@ENG.PSU.EDU

AHT Turbine Tip Clearance Region De-Sensitization

99-01-SR080 University of Central Florida Mechanical, Materials and Aerospace Engineering P.O. Box 162450 Orlando, FL 32816-2450 (407) 823-2415 phone (407) 823-2416 fax

Jay Kapat

jkapat@pegasus.cc.ucf.edu

AHT Tip Clearance Heat Transfer and Desensitization in High Pressure Turbines

00-01-SR081

University of Connecticut 97 N. Eagleville Road, U-136 Storrs, CT 06269 (860) 486-4206 phone (860) 486-4745 fax

Nitin Padture

npadture@mail.ims.uconn.edu

M Advanced Thermal Barrier Coatings for Industrial Gas Turbine Engines

00-01-SR082cs Texas Engineering Experiment Station Department of Mechanical Engineering College Station, TX 77843-3123 (409) 845-3738 phone (409) 862-2418 fax

J.C. Han

JCHan@mengr.tamu.edu

AHT Rotating and Stationary Rectangular Cooling Passages Heat Transfer and Friction and Turbulators and Dimples

00-01-SR083 Virginia CommonwealthUniversity Department of Mechanical Engineering 601 West Main Street Richmond, VA 23284-3015 (804) 828-9117 phone (804) 828-4269 fax

Daniel J. Dorney

djdorney@vcu.edu

AHT Improved Performance andDurability in Gas Turbines Through Airfoil Clocking and Hot Streak Management

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00-01-SR084cs University of California- Irvine

UCI Combustion Laboratory Department of Mechanical and Aerospace Engineering Irvine, CA 92697-3550 (949) 824-5468 phone (949) 824-7423 fax

Scott Samuelsen

gss@uce.edu

C Correlation of Ignition Delay with Fuel Composition and State for Application to Gas Turbine Combustion

00-01-SR085cs

Purdue University School of Mechanical Engineering 1003 Chaffee Hall West Lafayette, IN 47907-1003 (765) 494-1452 phone (765) 494-0530 fax

J.P. Gore

gore@ecn.purdue.edu

C Measurements for ImprovedUnderstanding of Combustion Dynamics in Lean Premixed Gas Turbine Combustor Flames

00-01-SR086 University of North Dakota Mechanical Engineering Department POB 8359, ME Department Grand Forks, ND 58202-8359 701-777-2095 phone 701-777-4838 fax

Philip C. Malte

malte@u.washington.edu

AHT Characterization of CatalyticCombustor Turbulence and Its Influence on Vane and Endwall Heat Transfer and Endwall Film Cooling

00-01-SR087 University of WashingtonMechanical Engineering Department Box 352600 Seattle, Washington 98195-2600 (206) 543-5486 phone (206) 685-8047 fax

Sumanta Acharya

acharya@me.LSU.edu

C The Staged Prevaporizing-Premixing Injector: High Pressure Evaluation

98-01-SR088 98-01-SR070 Old Contract # Previously at Carnegie Mellon University

University of Pittsburgh Department of Mechanical Engineering 648 Benedum Hall Pittsburgh, PA 15261 (412) 624-9783 phone (412) 624-4846 fax

Forrest E. Ames

forrest_ames@mail.und.nodak.edu

AHT Experimental andComputational Studies of the Nozzle Endwall Region of Advanced Gas Turbines

01-01-SR089 Louisiana State University 1419B CEBA Building Department of Mechanical Engineering Baton Rouge, LA 70803 (225) 388-5809 phone (225) 388-5924 fax

Domenic A. Santavicca

DAS8@PSU.EDU

AHT Internal Cooling in Leading and Trailing-Edge Passages With Rotational and Buoyancy

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01-01-SR090 Pennsylvania State University

Department of Mechanical Engineering 132 Research Building East University Park, PA 16802-7000 (814) 863-1863 phone (814) 865-3389 fax

Maury Gell

mgell@mail.ims.uconn.edu

C Optimization of the Injector Fuel Distribution for Stable, Low Emissions Combustion in Lean Premixed Gas Turbine Combustors

01-01-SR091 University of ConnecticutDept. of Metallurgy & Materials Engineering 97 North Eagleville Road, U-136 Storrs, CT 06269 (860) 486-3514 phone (860) 486-4745 fax

David G. Bogard

dbogard@mail.utexas.edu

M Thermal Barrier Coatings and Metallic Coatings With Improved Durability

01-01-SR092 University of Texas at Austin Mechanical Engineering Department Austin, TX 78712 (512) 471-3128 phone (512) 471-5727 fax

David R. Clarke

clarke@engineering.ucsb.edu

AHT Attenuation of Hot Streaks and Interaction of Hot Streaks with the Nozzle Guild Vane and Endwall

01-01-SR093 University of California, Santa Barbara Department of Mechanical Engineering Santa Barbara, CA 93106 (805) 893-8275 phone (805) 893-8983 fax

Forrest E. Ames

forrest_ames@mail.und.nodak.edu

M A Science-Based Approach to Enhanced Zirconia-Based Thermal Barrier Coatings for Advanced Gas Turbine Applications

01-01-SR094 Texas Engineering ExperimentStation (Texas A & M University) Department of Mechanical Engineering College Station, TX 77843-3123 (409) 845-3738 phone (409) 862-2418 fax

J. C. Han

JCHan@mengr.tamu.edu

AHT Rotating Heat Transfer in High Aspect Ratio Rectangular Cooling Passages with Shaped Turbulators

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Appendix L UTSR SUCCESS STORIES

MID-INFRARED SENSING CONSORTIUM The ATS subcontract for the development of infrared radiation sensor has contributed to the development of two commercial products already. The first is a fast-scanning infrared linear array spectrometer offered by En’Urga Inc. and the second is a turbine inlet temperature sensor offered by Ametek Inc. and recently advertised in the Gas Turbine World. The fast-scanning spectrometer has been used for measurements on a General Electric combustor rig at GE CRD and on a Siemens Westinghouse combustor facility at NRC in Canada. In each case the resulting spectra could be interpreted in terms of temperatures that matched the trend in changes in operating conditions extremely well. The tests showed that selection of wavelengths for an onboard sensor should be based on multi-wavelength measurements for the actual combustors. This requirement results from the need to correct for the optical depth, wall radiation interference, and the strong effects of pressure on the radiation properties. The development of the mid-infrared spectrometer has spawned activity in other application areas. A consortium of engineers, chemists, biologists, doctors, veterinarians, food scientists in both academia and industry has been formed to explore a variety of applications of the mid-infrared spectral analysis. The early results show applications for measuring fat content in milk, glucose in blood, calcium in interstitial fluid, and thermal properties of live tissue. In addition to pursuing these exciting spin-offs, the Purdue University group is planning additional tests at UTRC, Solar Turbines, Rolls Royce Allison, and Allied Signal for continued gas temperature measurements for turbine applications. TESTS SHOW BETTER HOT CORROSION RESISTANCE FOR MODIFIED TBC Cleveland State University’s research is to improve TBC durability by incorporating a ceramic layer on top of the bond coat or on top of YSZ TBC. In recently completed tests BAS, CaOSiO2 and mullite barriers applied on top of YSZ TBC by APS showed high density, good adherence and crack resistance. Significant improvement in durability with no detrimental chemical reactions was observed after 150 hour hot corrosion test in molten Na2SO4 at 900oC, demonstrating the feasibility of these coatings on a hot corrosion barrier. Thermal cycling tests are now underway.

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As a FYI the nomenclature is:

APS – Air Plasma Spray BAS – Baria – Alumina – Silicate Mullite – 3Al2O3 – 2SiO2TBC – Thermal Barrier Coating YSZ – yttia Stabilizied Zirconia

EIS SHOWS PROMISE FOR NDE OF TBC’S

The University of Central Florida has shown that electrochemical impedance spectroscopy (EIS) has strong potential as a non-destructive evaluation (NDE) technique for determining TBC coating quality and monitoring post service performance. Exposed TBC’s were subjected to high temperature oxidation, hot corrosion and thermal shock tests followed by EIS examination. Characteristic EIS were able to effectively differentiate between post-exposed damaged TBC’s and non-exposed intact TBC’s. More importantly, the type, length and form of exposure were discernible from EIS measurement alone. EIS also allows severity of damage to be evaluated. The development continues; however, EIS shows promise as a non-destructive evaluation procedure for TBC’s for quality assurance, as well as post exposure evaluations. UTSR RESEARCH INTERACTIONS The degree of cooperation is a philosophical change in the manner in which university research is accomplished. Traditional university research is accomplished by a single university researcher working with a single funding agency. This is not the UTSR mode. UTSR funded researchers seek out other researchers for assistance and comment – a positive four-fold increase in interaction has occurred. This adds relevance and timely distribution of results. With 56 research projects reporting to SCIES, 233 interactions have occurred. IRB companies have provided the largest guidance to the research. Within the IRB the contacts have been “relatively” uniform, however, G.E. has the most hits. FETC is the largest government contact, however, a wide range of agencies have been contacted including – NASA Glenn, Argonne, Sandia National Laboratory, NSF, Oak Ridge, Los Alamos, and the Navy, Army and Air Force. These interactions suggest that the use of research facilities and technical experts is being maximized and that the research results are being monitored with rapid exposure to industry.

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ECONOMIC IMPACT STUDY A recently completed Economic Impact study conducted by the UTSR program shows that implementing ATS technology will result in a total net present value fuel saving equal to $3.5 billion over a 20 year time horizon. During the first decade of this period a cumulative reduction of 620,000 short tons of NOx was also estimated. NORTHWESTERN UNIVERSITY ORGANIZES TBC MEETING Professor Katherine T. Faber, Northwestern University, and an UTSR subcontractor, is co-organizing a second Symposium on Thermal Barrier Coatings at the 102nd Annual Meeting at the American Ceramic Society to be held in St. Louis, Missouri in May 2000. More than 35 presentations from industry, academic and national laboratories will be given. NEW COATING TECHNOLOGY TBC durability is a key issue in gas turbine engine performance. Small improvements in TBC lifetimes have significant cost-savings. Georgia Tech in a joint effort with General Electric Power Systems and Pratt & Whitney is developing a new coating technology – combustion CVD. This coating technique is ideally suited for applying interlayer coatings and in particular for depositing graded interfaces such as the alumina/zirconia coating. CCVD provides a ready method for applying CVD quality coatings without the need for high capital investment and the necessity to replace parts within a reaction vessel. Deposition rates very from being comparable to conventional CVD rates (1 micron/hour) up to 1 micron/minute for some materials. DEVELOPMENT OF LASER FLUORESCENCE AS A NON-DESTRUCTIVE INSPECTION TECHNIQUE FOR TBC’S Preliminary evaluation of TBCs has been completed to determine the cyclic lifetime as well as to examine the evolution of laser fluorescence and microstructure. For the electron beam physical vapor deposited (EB-PVD) TBC with MCrAlY bond coat and IN-738 (hereafter denoted as Type B TBCs), lifetime during thermal cycle at 1121oC ranged from 350 to 574 cycles. During the thermal cycle, the structural integrity of TGO and the variation in the TGO (α-Al2O3) stress was observed by laser fluorescence. The TGO stress of as-deposited Type B TBCs was measured to be approximately 2.5 GPa in compression. An increase and then a decrease in the magnitude of compressive TGO stress was observed with thermal cycles. Maximum value of compressive stress was measured to be approximately 5.0 GPa between 200 and 300 cycles. In addition to the photoluminescence from compressively stressed TGO, a stress-free signal was observed. The origin of this stress-free signal and the variation of its intensity as a function of

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thermal cycles are currently being investigated. The photoluminescence signal from θAl2O3 was also observed from Type B TBCs. This research continues with more complete information available in the 2nd semi-annual report. VISUAL INSPECTION OF TURBINE HARDWARE QUESTIONED Initial results at Mississippi State University indicate that the use of turbine blade discoloration is a misleading indicator of roughness. Regions of significant discoloration were just as likely to be smooth as a region without significant coloring. This initial finding puts into question the utility of the common visual inspection technique of using boroscopes in turbine sections. This general funding along with more specifics were developed by MSU by examination of over 70 turbine components – vanes or van sets and turbine blades. The manufacturers supplying MSU with hardware included Solar Turbines, Siemens-Westinghouse and Allied Signal. This MSU study in “real surface effects” continues into its second phase. TBC DURABILITY INVESTIGATED Cleveland State University is pursuing a program to improve TBC durability by incorporating a ceramic layer with low oxygen conductivity and high corrosion resistance on top of a Bond Coat or on top of YSZ TBC. Earlier it was shown that thin barrier coatings (1µ m) applied on top of a Bond Coat using spattering resulted in superior thermal cycling lives when compared to thicker (3µ m) coating. Recent hot corrosion and thermal cycling tests of barrier coatings of mullite, BAS, 1.8CaOSiO2, SmAS#1 and SmAS#2 on top of YSZ have been completed. Although not complete at this time, superior performance in durability of the latest samples have been observed. ADVANCES IN COMBUSION FOR GAS TURBINES Only a small fraction of candidate papers meet the high standards for significance and quality for publication in the quarterly ASME Journal of Engineering for Gas Turbines and Power. The most recent issue (Vol. 122, Apri1 2000) of this journal has two publications describing industry advancements in the ATS Program with acknowledged contributions from the UTSR Project.

The publication "Sub-Scale Demonstration of the Active Feedback Control of Gas Turbine Combustion Instabilities", by representatives from Siemens- Westinghouse and Neumeier, Nabi, and Zinn from Georgia Tech., shows successful demonstration of active feedback control as a means of suppressing damaging combustion oscillations in lean- premix combustors. The four-fold reduction in amplitudes of oscillations represents a major milestone in the implementation of active combustion control.

The publication "Status of Catalytic Combustion R&D for the Department of Energy Advanced Turbine Systems Program", by Fant of SCIES, Jackson of the U. of Maryland,

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Dibble of the U. of California, and industry co-authors describes advanced concepts and R&D results associated with implementing catalytic combustion to achieve ultra-low NOx emissions in next generation gas turbines. The paper indicates that recent advances in reactor design and catalytic coatings have made catalytic combustion a viable technology for advanced gas turbines. NON DESTRUCTIVE EVALUATION OF THERMAL BARRIER COATINGS Use of thermal barrier coatings (TBC) has produced significant improvements in power and efficiency of aircraft, industrial, and utility turbines by reducing the cooling requirements of engine components. However, the implementation of TBCs has been impeded by inconsistent coating lifetimes and inability to predict the life of coatings on individual parts. Consequently, coated parts are often removed from turbine service based on the conservative lower bound life expectancy rather than the much longer typical life. Major turbine maintenance, life and cost benefits would result if a non-destructive evaluation (NDE) method could be developed to determine remaining coating life for TBCs. Coating manufacturing processes could be better optimized, monitored, and controlled, inferior coated parts could be prevented from being installed in turbines, and parts could be removed from service based on actual remaining life.

A previous UTSR project at the University of Connecticut and the University of California-Santa Barbara demonstrated the feasibility of photoluminescense piezo-spectroscopy for non-destructive evaluation of TBCs. The NDE need is so great and the results from this past UTSR project are so promising that several of the U S turbine manufacturers, a coating supplier, and an instrument maker are providing substantial in-kind and direct cost share funding to assist in another UTSR project now in progress with the University of Connecticut and the University of California-Santa Barbara. One planned output from this UTSR project is a prototype of a low cost and portable NDE instrument for TBCs for use by turbine developers, overhaul facilities, and coating suppliers.

ACTIVE CONTROL OF INSTABILITES FOR LOW NOx COMBUSTORS Georgia Tech (GT) Transfers Active Combustion Control Technology to Turbine Companies -Under the UTSR program, GT is developing an active control system to overcome instabilities in low NOx turbine combustors. In the past, such instabilities have produced excessive combustor noise and damaging vibration and fatigue. Tests that demonstrated the success of the GT active control of combustion instabilities have been previously reported. Two patents on this technology have been awarded and a third is in process. GT is now transferring the active control technology to several US turbine manufacturers. GT is developing working arrangements with General Electric, Rolls-Royce, Siemens Westinghouse and United Technologies Research Center to test or evaluate adapting this technology to turbines.

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IMPROVED COMPUTER CODES FOR TURBINE FLOWS

Under the UniversityTurbine Systems Research (UTSR) program, PSU is acquiring data for improving and verifying aerodynamic computer codes used to analyze and design compressor flowpaths of gas turbines. Improved and verified codes are needed for the more complex flows due to fewer stages, increased blade loading, decreased blade aspect ratios, and reduced blade spacings in advanced turbine compressors compared to earlier compressors. Goals of the PSU UTSR project are to measure and understand the steady and unsteady pressure flow field at the exit of an embedded rotor inside a multistage compressor and the effects of the upstream embedded stator. Computer predictions from an advanced computer code (ADPAC) were compared to the data measured by PSU. Pressure values from the ADP AC computer simulation compared reasonably well to measured data in the middle 60% of the flow but poorly in the endwall flow regions. These results show that more work is needed in the ADP AC code development for the viscous endwall regions. The PSU data is available for use in the further development of ADP AC and other computer codes.

ADVANCED ANALYSES CAPABILITIES FOR CONTROLLING COMBUSTION INSTABILITIES Under the University Gas Turbine Systems Research (UTSR) program, VTU has been developing capabilities to analyze gas turbine combustors that utilize multi-port fuel injection to increase low emission combustor stability. Design of low emission turbine combustors has been complicated by problems of dynamic instabilities that have produced damaging vibration and fatigue. Experiments at DOE NETL laboratories have sown that fuel injection at several locations of the combustor (multi-port fuel injection) can enhance combustor stability. Although the benefits of multi-port injection have been demonstrated, capabilities to analyze and design multi-port injected combustors are limited. VTU is developing analytical approaches for explaining and evaluating the benefits of multi-port fuel injection and has conducted a stability analysis of the multi-port injected combustor at NETL. The VTU model has explained the instability frequency jumping and time delay shifts observed in the NETL tests, along with the stabilizing effect of multi-port injection. Observed instability frequencies were also predicted with reasonable accuracy. Although the model development has not been completed, results to date show promise as an approach for analysis and design of future stable low emission gas turbine combustors. MIST/STEAM COOLING TO IMPROVE TURBINE PERFORMANCE

Under the UTSR program, Clemson University (CU) has been evaluating the use of water mist with steam to cool components of advanced turbines. These turbines can operate at such high temperatures that performance penalties are excessive for conventional air-cooling approaches. Consequently, steam cooling is being adapted by the two gas turbine

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manufacturers that use very high turbine inlet temperatures (2600 F) for their Advanced Turbine System (ATS) engines. Since the steam is extracted from the plant bottoming cycle, there is system performance loss for steam cooling, but significantly less than for air cooling. To further reduce performance penalties, CU has conducted experiments in four test configurations to evaluate the benefits of injecting a fine mist of water into steam used for cooling. The experiments showed that cooling performance is substantially improved by adding small amounts of mist. Depending on the test configuration, an addition of 1% by weight of mist to the steam typically enhanced the cooling heat transfer coefficient by 50 to 100%, and in extreme cases, by as much as 700%. These experiments have shown the potential of mist/steam cooling to improve the performance of advanced turbines. The Principal Investigator for this recently completed UTSR project is now seeking new programs to further advance mist/steam cooling towards commercialization.

LIFE PREDICTION AND NON-DESTRUCTIVE EVALUATION FOR THERMAL BARRIER COATINGS Under the UTSR program, University of California, Santa Barbara (UCSB) has been developing both analysis and measurement approaches for life prediction and non-destructive evaluation (NDE) of thermal barrier coatings (TBCs). This research is directed to improving the quality of TBCs for turbine components, since use of TBCs in gas turbines has been hindered by variability in coating lifetimes, limited understanding of TBC failure causes, and inability to predict the lifetime of coatings on individual turbine parts. The project is clarifying the failure processes, identifying changing or degraded materials properties that result in TBC failure, and developing NDE methods for measuring those degraded properties so that remaining life of the TBC can be predicted. Significant advances have been made in understanding the role of TBC bond coat plasticity in failure initiation. The project has shown that Photo-Stimulated Luminescence Spectroscopy (PSLS) can be used to identify different types of internal damage, quantify internal stresses around flaws, and detect the changes with time of internal properties of TBCs. Developments in this project to non-destructively identify degraded properties and quantify remaining life of inferior or degraded TBCs could be used to better monitor, optimize, and control TBC manufacturing processes, to prevent inferior TBCs from being installed in turbines, and to enable parts to be removed from turbines based on measured remaining life. COMPUTER CODE DEVELOPMENT FOR LOW NOx COMBUSTOR DESIGN Cornell University improves capabilities for calculating combustor emissions. Under the Advanced Gas Turbine Systems (UTSR) program, CU has been developing an in situ adaptive tabulation (ISAT) algorithm which can speed computer calculation times for combustion chemistry by a factor up to 40 compared to previous algorithms.

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Earlier work with the ISAT showed greatly improved combustion computation speeds, but with substantial errors in CO emissions. The ISAT algorithm was enhanced in this project and used with a velocity composition PDF (Probability Density Function) model to compare calculations to measurements of a piloted jet flame. Extremely good comparisons were obtained, including results for CO and other minor species. The model also successfully described quantitatively local extinction and reignition. The methodology was further extended to include NO chemistry and radiative heat loss. In general the NO emissions calculations were found satisfactory, and radiative heat losses did not appear to have a large effect on NO in the flames considered. For the first time, a 3-D simulation of an aircraft engine combustor was conducted with the PDF-ISAT method. This recently completed research project has addressed the need for improved computer algorithms, which are computationally efficient and sufficiently accurate for the design of low emission turbine combustors. The successful application of this method for practical gas turbine combustor concepts demonstrated the ability of the method to make detailed emissions predictions and to optimize combustor design to meet stringent emissions and performance requirements of current and future gas turbines. INVESTIGATION OF ENDWALL DESIGN TO IMPROVE GAS TURBINE PERFORMANCE Under the Advanced Gas Turbine Systems (UTSR) program, Carnegie Mellon University (CMU), Michigan State University (MSU), and the University of Minnesota (UM) are investigating endwall transitions between a turbine combustor and first stage vanes. Laboratory experiments and computational analyses have been conducted for an airfoil passage of an existing industrial turbine. Computational analyses of endwall designs have shown that secondary flows (and resulting aerodynamic losses) are markedly decreased when passage endwall contouring starts upstream of the airfoil and continues through the airfoil passage. Film cooling effectiveness for the endwall is also greatly improved for this contoured endwall. The potential for hot gases escaping the flow passage through endwall gaps is also reduced. Consequently, the results of this UTSR project should provide endwall design guidance to gas turbine manufacturers for improved engine power and efficiency. THERMAL BARRIER COATING (TBC) TEST METHOD AND FACTORS THAT CONTROL TBC FAILURES Under the Advanced Gas Turbine Systems (UTSR) program, the University of Pittsburgh (Pitt) has shown for the first time that a simple indentation test can be used to measure the degradation of a turbine grade TBC under isothermal conditions and to clarify the degradation processes that control the spallation failure of the TBC. The indentation test measures apparent toughness of the TBC. Measurements on TBC specimens exposed for

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extended times over a wide range of temperatures showed that the TBC spalled when the toughness decreased to 1.7 Mpa-sqrt(m). Although further work is needed to generalize to other TBC coatings and conditions, the Pitt results show potential that the indentation test might have future use to monitor TBC production processes and degradation of coated turbine parts before failure in the field. Pitt also used the indentation method with controlled tests and analyses to show that all of the loss in apparent toughness of the coating was attributed to two factors, growth of an oxide scale at the TBC/bond coat interface, and to a lesser extent, sintering of the coating. Since spallation was correlated to loss of toughness, these results indicate that future TBC lifetimes could be improved by modifications to inhibit oxygen diffusion to the bond coat and sintering. METHOD FOR COMPRESSOR AERODYNAMIC ANALYSIS Under the Advanced Gas Turbine Systems (UTSR) program, Massachusetts Institute of Technology (MIT) has shown a relatively simple aerodynamic analysis approach can represent the unsteady effects on a compressor rotor blade resulting from its relative motion with respect to the downstream stator vane. Because the unsteady conditions resulting from the changing relative position of the downstream stator with respect to the rotor blade, there has been an issue how to evaluate the rotor blade aerodynamic performance. MT has conducted computational fluid dynamics (CFD) analyses to evaluate this question by comparing results for rotor-stator pairs with different axial spacings. For the analyses conducted, MIT found that the unsteadiness effect is negligible and the primary effect of the downstream stator on rotor performance is the time averaged downstream radial profile of static pressure as seen by the rotor. MIT is now seeking to delineate the general conditions under which this observation holds. For those conditions, the significance of the MIT result is that multiple expensive CFD runs with different relative rotor-stator positions are not needed to determine the rotor performance. Only signal run using the time-averaged downstream radial static pressure profile is needed. AIRFOIL SURFACE ROUGHNESS MEASUREMENTS FOR IMPROVED AERO AND HEAT TRANSFER DESIGN Under the Advanced Gas Turbine Systems (UTSR) program, Mississippi State University (MSU) and Air Force Institute of Technology (AFIT) are obtaining data and developing better characterizations of the effects of turbine flowpath operating environments on the surface roughness and consequently aerodynamics and heat transfer for turbine airfoils. Past analysis of airfoils that had experienced service showed that established methods of characterizing airfoil roughness for aero and heat transfer analyses are not universally appropriate. MSU and AFIT have obtained from three turbine manufacturers over 70 vanes and blades that had experienced service in turbines under a wide range of conditions. Service environments had produced deposition, erosion, corrosion and

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coating spallation, which significantly changed the surface roughness of the parts from their as manufactured condition. Two and three dimensional surface measurements have been completed for the 70 parts and the data is being catalogued into a database for use by the industry participants. One observation was that there is often an abrupt transition from very smooth to very rough surfaces, which can be a significant contributor to the aero and/or thermal penalty for a part. Also, there was observed a significant difference in the surface roughening of a part with time, depending on whether or not it was coated (e.g., with a thermal barrier coating). Uncoated parts subjected to operational erosion or corrosion experienced a monotonic increase in roughness with operational time while coated parts experienced a peak (due to spallation) in roughness followed by a decrease with time. Phase 2 has started to produce scaled models of the “real” rough surfaces and measure their skin friction and heat transfer in a wind tunnel. The data on the roughness experienced by turbine parts in service and measurements of the aero and thermal effects of that roughness will be very useful to the turbine manufacturers for improving their design tools. A summary of the surface roughness data set will be presented by the university researchers at the next AGTI Conference in New Orleans and Westinghouse will present some of the findings this month at the ASM Utilities and Energy Sector Conference. AIRFOIL CLOCKING IMPROVES TURBINE PERFORMANCE Under the Advanced Gas Turbine Systems (UTSR) program, Virginia Commonwealth University (VCU) and the University of Cincinnati (UC) researchers are evaluating the effects of circumferentially positioning (clocking) the airfoils in the fixed rings of vanes in turbines. The goal is to alleviate the two main factors affecting the performance and durability of gas turbine engines, flow unsteadiness and thermal gradient stresses. Computer simulations showed average aerodynamic efficiencies that vary periodically with significant amplitude of 1% for varying clocking positions. The clocking position for maximum efficiency was found. This result provides information to turbine designers for positioning fixed vanes in rows on the two sides of a rotor row to maximize aerodynamic efficiency. EXPERIMENTAL DATA TO DEVELOP TURBINE DESIGN COMPUTER CODES Under the Advanced Gas Turbine Systems (UTSR) program, university researchers at Virginia Tech (VT) and the University of Texas (UT) have conducted extensive detailed experiments on scaled simulated turbine airfoil passages with uncooled and cooled vanes. This recently completed project resulted in detailed flow and thermal field measurements that both give a better physical understanding of the flow and heat transfer in turbine passages and also provide an extensive data base needed to improve and verify turbine design codes for aerodynamics and cooling.

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NEW THERMAL BARRIER COATING (TBC) CANDIDATES Under the Advanced Gas Turbine Systems (UTSR) program, the University of Connecticut (Uconn) is screening oxides that have the potential to provide greater insulation for turbine components than current TBCs and thereby enable higher operating temperatures and increased turbine performance. Materials data for over 130 candidate ceramics were defined and compared to the properties for the conventional TBC material, yttria stabilized zirconia (YSZ). The screening criteria were related to eight properties significant for operation in a gas turbine. To identify the most promising candidates, ceramics were sought with the potential for 25% lower thermal conductivity, a maximum use temperature 360 F higher (above 2900 F), and thermal expansion coefficient equal to, or greater relative to YSZ. Seven promising candidates (5 zirconates and 2 phosphates) for advanced TBCs were down-selected from the oxides. Detailed assessment of properties has begun on samples of two ceramics (Gd2Zr2O7, and La PO4) of the seven candidates. BLADE TIP PLATFORM EXTENSIONS IMPROVE AERODYNAMIC PERFORMANCE Experiments at Penn State University (PSU) measured pressure losses for tip platform extensions on the pressure side of rotors. The data showed that this approach is capable of reducing a significant portion of the aerodynamic losses associated with the tip vortex. Use of this passive design approach for reduction of the aerodynamic loss of each blade would be expected to significantly improve the efficiency of turbine stages. ALLOYS AND COATINGS FOR WATER AND STEAM INJECTED TURBINES Steam is introduced into turbine flow paths in plants where water or steam injection is used for NOx control or power augmentation. Although field experience has shown that the introduction of steam causes increased hot section distress, little is understood about the interaction of the steam with turbine materials to enable remedies. Under the Advanced Gas Turbine Systems (UTSR) Program, experiments at the University of Pittsburgh (Pitt) have been used to evaluate degradation processes and measure degradation rates of turbine alloys and coatings in steam/air environments. The experiments have shown how the presence of steam results in less protective and less adherent oxide scales and increased oxidation degradation rates for turbine materials. Degradation rates for several turbine materials have been measured. Results from this project should enable selection and development of better alloys and coatings for turbines that operate with steam or water injection.

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SENSOR FOR LOW EMISSION, MULTI-NOZZLE COMBUSTORS Under the Advanced Gas Turbine Systems (UTSR) program, Pennsylvania State University (PSU) researchers have shown that a chemiluminescence sensor can be used to finely resolve changes in combustion equivalence ratios corresponding to NOx emissions variations as small as 1 to 2 ppm. They have also identified a measurement strategy to operate this sensor as a part of a fuel trimming system for multi-nozzle low NOx gas turbine combustors so as to maintain a uniform primary zone equivalence ratio. This might be used to minimize the problem of nozzle-to-nozzle equivalence ratio variations, which reduce the operating range over which stable, low emissions combustion can be achieved. Although this project has recently ended, additional work is expected to explore this promising approach for low emission turbines. Further tests are planned in UTSR gas turbine company facilities to assess factors affecting the implementation of the chemiluminescence sensor for low NOx turbine combustors. DEVELOPMENT OF EXPERIMENTAL METHODS FOR COMBUSTOR INSTABILITIES Under the Advanced Gas Turbine Systems (UTSR) program, California Institute of Technology (CIT) has produced the first ever experimental measurements using a pulsed laser induced fluorescence (PLIF) sensor of combustion dynamics in an acoustically forced combustion facility. This sensor is designed to obtain the superior spacial resolution needed to measure the role of local fluctions in combustion products on combustion instabilities, to determine effects of combustor geometry on local production of NOx, and to validate low NOx combustor design codes. The development of the PLIF sensor is a part of the overall effort that uses analyses and supporting basic experiments to develop design rules for control of instabilities in low emission turbine combustors. PROMISE FOR NON-DESTRUCTIVE TECHNIQUE FOR THERMAL BARRIER COATINGS (TBCs) Under the Advanced Gas Turbine Systems (UTSR) program, University of Central Florida (UCF) has recently completed a project which conducted laboratory tests to evaluate the use of electrochemical impedance spectroscopy (EIS) for non-destructive evaluations of TBCs. The data indicates that EIS shows great promise as an effective evaluation technique not only for quality assurance for the manufacture of TBCs, but also for the evaluation of coatings on turbine parts that have experienced service. UCF also claims advantages for EIS over other techniques being developed in providing data on TBC characteristics such as topcoat thickness, porosity, defects, and type of degradation (corrosion, cyclic oxidation damage, etc.). Based on the success of the laboratory tests, a probe configuration for evaluating turbine parts in the field has been identified for future assessment and development.

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CONDITIONS THAT CAUSE INSTABILITIES IN LOW EMISSION TURBINE COMBUSTORS Under the Advanced Gas Turbine Systems (UTSR) program, Pennsylvania State University (PSU) is conducting experiments in a model combustor designed to operate at pressures and air inlet temperatures of gas turbine combustors. The goal is to explore factors that initiate and sustain combustion oscillations (and resulting noise and structural damage) in low emission combustors, especially for dual fuel operation. The PSU data indicates that, under the lean premixed and prevaporized conditions of low emission combustors, instability behavior is similar for liquid fuels tested as for natural gas. This implies that solutions to combustion instabilities for natural gas fired turbines might be extended to dual fuel use. The PSU experiments are also providing a data base for the gas turbine companies to validate their combustion models. GE is currently using the PSU data for that purpose. PROGRESS FOR NON-DESTRUCTIVE EVALUATION (NDE) OF THERMAL BARRIER COATINGS (TBC) Under the Advanced Gas Turbine Systems (UTSR) program, University of Connecticut (UCONN) researchers are developing laser fluorescent (LF) techniques for non destructive evaluation (NDE) of thermal barrier coatings. NDE approaches are needed to improve TBC processing quality, assess the quality of coated parts before putting them into service in turbines, and to determine the remaining life of coated parts during periodic turbine inspections. UCONN has collected LF data for specimens with both EB-PVD and plasma sprayed TBC coatings exposed to thermal cyclic tests of varying cycle frequencies and duration. Each coating system was found to have a unique stress versus cycle response. The data is being processed to obtain statistics for life prediction. The data shows that specimens exposed to 24 hr thermal cycles experience the same stress life behavior as specimens exposed to 1 hr thermal cycles. This suggests that number of cycles (and not a precise representation of the cycle time history in turbines) is probably sufficient for laboratory tests. The observed insensitivity to cycle duration also indicates that adequate data can be obtained in accelerated laboratory tests of short thermal cycle times. The data and evaluations to date indicate that LF continues to look promising for non destructive evaluations, quality control monitoring, and assessment of remaining life of TBC. CAPABILITIES FOR EVALUATING AIRFOIL COOLING Under the Advanced Gas Turbine Systems (UTSR) program, Purdue University (PU) researchers have redesigned and modified an existing experimental facility and instrumentation and have improved computational capabilities for the purpose of evaluating airfoil cooling in turbines. These improved capabilities can be used to develop an understanding of the fundamental physical processes that determine the heat transfer

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cooling rates at the trailing edges of gas turbine vanes. This knowledge enables insights into the optimal balance between airfoil cooling and aerodynamic performance. TBC THAT ENABLE SUBSTANTIALLY REDUCED FUEL COSTS AND CO2 EMISSIONS Under the Advanced Gas Turbine Systems (UTSR) program, University of Connecticut (UCONN) researchers are developing TBC’s with the goal of more than 300 F higher temperature capability and much lower thermal conductivity than current coatings. Resulting benefits include: - $ 4.7 Billion fuel cost savings over a ten-year time frame (for $3.00/MMBtu gas ) - 156 million metric tons in reduced CO2 emissions - Achievement of about one-third of the near-term efficiency improvement and CO2

emission reduction goals of the NGT program

DEVELOPMENT OF TEMPERATURE SENSOR Under the Advanced Gas Turbine Systems (UTSR) program, Purdue University (PU) has developed a miniature infrared temperature sensor. Because of the high sensitivity of NOx emissions to combustion temperatures, accurate temperature measurements are needed for turbine combustor development, combustor model validation, and sensing and control of lean premixed low emission turbine combustors. Laboratory tests in this recently completed project showed excellent performance of the PU temperature sensor. Sensor capabilities were also demonstrated in combustor tests at General Electric, Siemens Westinghouse, Solar Turbines, and the United Technologies Research Center. AIRFOIL CLOCKING TO ALLEVIATE EFFECTS OF COMBUSTOR HOT STREAKS Under the Advanced Gas Turbine Systems (UTSR) program, Virginia Commonwealth University (VCU) researchers have numerically calculated effects of circumferential positioning (or clocking) the stator airfoils in an upstream turbine row on surface temperatures of airfoils in downstream rows. The evaluations showed that judicious clocking of the upstream stator vanes diffuses simulated combustor hot streaks to reduce the time-averaged temperatures of airfoils in the downstream rotor row and following vane row. Reduced surface temperatures for airfoils results in lower cooling requirements with corresponding higher turbine performance (greater power and efficiency).

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FACTORS FOR IMPROVED STABILITY OF LOW NOx TURBINE COMBUSTORS Under the Advanced Gas Turbine Systems (UTSR) program, Penn State University (PSU) is evaluating effects on combustion stability of improving fuel and air premixing to decrease NOx emissions. Low NOx combustors rely on premixing to reduce emissions but have experienced excessive noise and damaging instabilities in commercial gas turbines. Experiments at PSU with a model gas turbine combustor showed that high levels of premixing decreased the combustor stable operating range by a factor of two (i.e., halved the range of premixed fuel/air ratios that enabled stable operation). However, lengthening (by 50%) of the combustion zone downstream of the premixed region eliminated the unstable operating range for high levels of premixing. The PSU results indicate that turbine combustor designs that simultaneously reduce NOx emissions and instabilities appear possible. CONTROL OF INSTABILITIES IN LOW EMISSION TURBINE COMBUSTORS Under the Advanced Gas Turbine Systems (UTSR) program, Georgia Tech (GT) is conducting experiments in a test combustor and computer analyses to develop approaches for active control of instabilities in low emissions combustors. Low emissions turbine combustors have experienced damaging and noisy pressure oscillations in the field. GT has observed in their most recent semi-annual report (for the period ending in January, 2001) that, although pressure oscillations are reduced by active control, white noise in the combustor pressure variations and the time delay in the control loop inherently limit the active controller’s effectiveness. These results suggest that the most effective instability control for low emissions turbine combustors may require a combination of both active control and passive design approaches. DATA ON TURBINE PART SURFACE CHARACTERISTICS Under the Advanced Gas Turbine Systems (UTSR) program, Mississippi State University (MSU) and Air Force Institute of Technology (AFIT) researchers have taken measurements at GE’s turbine repair facility in Cincinnati of surface roughness on turbine parts that had been removed from service. This data and discussions with personnel responsible for servicing the parts provided valuable insights on the effects of turbine operation on precisely designed and manufactured turbine airfoil surfaces. Service environments produced deposition, erosion, corrosion and surface coating spallation, which were seen to change the surface roughness of the turbine airfoils from their as manufactured condition. These surface changes significantly affect airfoil aerodynamic and cooling characteristics. The surface roughness measurements and data from following wind tunnel tests representing the observed roughness will be provided to turbine manufacturers to improve their tools for design and analyses of airfoils.

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APPROACH FOR NON-DESTRUCTIVE EVALUATION (NDE) OF THERMAL BARRIER COATINGS (TBC) Under the Advanced Gas Turbine Systems (UTSR) program, University of Connecticut (UCONN) researchers are developing laser fluorescent (LF) techniques for non destructive evaluation (NDE) of thermal barrier coatings. NDE approaches are needed to improve TBC processing quality, assess the quality of coated parts before putting them into service in turbines, and to determine the remaining life of coated parts during periodic turbine inspections. UCONN has collected LF data for specimens with EB-PVD TBC coatings and two different bond coat/superalloy substrates exposed to tests with thermal cycles of one hour frequency. Past evaluations in the project indicated qualitative trends of remaining coating life with LF measured coating stresses. Tests and analyses described in the August 1, 2000 to February 28, 2001 semi-annual report determined quantitative correlations for predicting remaining life using LF measurements of the two coating types. These results indicate that LF measurements continue to look very promising for non destructive evaluations, quality control monitoring, and assessment of remaining life of TBC coatings. REDUCTION OF INTERNAL OXIDATION DEGRADATION OF THERMAL BARRIER COATINGS (TBC) Under the Advanced Gas Turbine Systems (UTSR) program, Northwestern University (NU) researchers are developing advanced small particle (down to 40 nano meter) plasma spray (SPPS) techniques to produce superior TBC’s. Spallation due to oxidation of TBC bond coatings has been a primary cause of TBC failures in turbines. NU is using SPPS to produce a yttrium aluminum garnet (YAG) oxygen diffusion barrier between the yttria-stabilized zirconia (YSZ) thermal barrier layer and the bond coat layer of TBC’s. The YAG material has 10 orders of magnitude lower oxygen diffusivity than the YSZ material. Tests described in the NU semi-annual report for the period ending on January 1, 2001 showed approximately 60% reduction in oxidation weight gains for TBC specimens with the YAG oxygen diffusion barrier compared to TBC specimens without the diffusion barrier. These and other results from the NU UTSR project show significant promise for SPPS techniques to produce multi-layered TBC’s with superior properties such as longer lifetimes in turbines. EFFECTS OF SERVICE ON TURBINE SURFACE AERODYNAMICS AND HEAT TRANSFER CHARACTERISTICS Under the Advanced Gas Turbine Systems (UTSR) program, Mississippi State University (MSU) and Air Force Institute of Technology (AFIT) researchers had previously taken measurements of surface roughness on nearly 100 turbine parts that had been removed from service. The most recent semi-annual report from this project (for the period ending

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2/2001) described tests that determined turbine design parameters associated with the measured surface roughness contours. Five scaled surface models corresponding to different turbine service conditions were constructed for wind tunnel tests that measured aerodynamic and heat transfer parameters (skin friction and heat transfer coefficient) needed for design of turbine airfoils. These tests showed that skin friction augmentation ratios (referenced to smooth surfaces) varied from 1.44 to 2.68. Heat transfer augmentation ratios (referenced to smooth surfaces) varied from 1.16 to 1.45. The data show that one set of heat transfer and skin friction parameters is not sufficient to represent all turbine service conditions and gives representative values for these parameters as a function of service condition. The surface roughness measurements and data from the wind tunnel tests representing the observed roughness will be provided to turbine manufacturers to improve their tools for design and analyses of airfoils. DIAGNOSTIC MEASUREMENT METHOD FOR LOW EMISSION TURBINE COMBUSTORS Under the Advanced Gas Turbine Systems (UTSR) program, University of California at Berkeley (UCB) is conducting laboratory experiments of new diagnostic approaches for measuring fuel-air mixing in premixers for gas turbine combustors. Thorough premixing of fuel in air is critical for low emission performance of turbine combustors. Without thorough premixing, NOx emissions from turbine combustors are unacceptable. Measurement of fuel-air mixedness is important for the development testing of advanced low emission turbine combustors and might be used for monitoring and tuning emissions performance of operating turbines. An UTSR project report (for the period ending 12/31/2000) from UCB described experimental evaluations of infrared light emitting diodes (IR LED) for measuring fuel-air mixedness. Light emitting diodes have only recently become available in the infrared light bands. They offer the advantage of less than one-third of the cost of HeNe lasers for measuring mixedness and are more compact and rugged. Based on the laboratory experiments, UCB has demonstrated that fuel concentration is measurable with an IR LED device at fuel-air ratios of lean premixed gas turbine combustors. The ultimate goal is to propose a reduced cost, compact and rugged diagnostic instrument for measuring fuel-air fluctuations in gas turbine premixers. REDUCTION OF AERODYNAMIC LOSSES FOR ROTOR BLADES Under the Advanced Gas Turbine Systems (UTSR) program, Penn State University (PSU) is evaluating methods to reduce aerodynamic inefficiencies associated with the gap between the tips of rotating turbine blades and adjacent stationary surfaces. Leakage through these gaps and associated tip vortices cause pressure losses and the aerodynamic inefficiencies.

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Designs using side extensions at the tips of both the concave and convex side of rotor blades have also been evaluated in the project. Experiments have shown that convex side extensions are not effective but concave side tip extensions weaken the tip vortex and reduce tip pressure losses. The measurements showed that local efficiency gains from pressure side tip extensions can be as high as 5%. This results in a significant improvement in the overall performance of a turbine stage. INTERNSHIP TO SUPPORT NEW UNIVERSITY TEST FACILITY The Advanced Gas Turbine Systems (UTSR) program has supported 78 student internships at companies that produce gas turbines engines and components. Twelve interns were placed for periods of 10 to 12 weeks during the summer of this year. Michael Durham, an M.S. student at the University of Central Florida (UCF), assessed the feasibility of a turbine cooling test rig and designed the test rig during his UTSR intern assignment this year at the Siemens Westinghouse Power Corporation (SWPC). This work initiated a five-year UCF/SWPC project to evaluate advanced cooling methods for turbine airfoils and endwalls. FACULTY FELLOWSHIP DEVELOPS SHORT COURSE ON COMBUSTION DYNAMICS A major reliability issue for low emissions gas turbine combustors has been instabilities. Operation of these lean premixed combustors near their lean blowout limits to limit NOx emissions has resulted in instabilities, excessive combustor noise, structural damage, and removal of commercial turbines from service for repair. Because lean premixed, low emissions turbine combustors are a relatively recent development, understanding is limited concerning their dynamics and the sources and control of their instabilities. Under a Faculty Fellowship to Professor F. E. C. Culick of the California Institute of Technology, the Advanced Gas Turbine Systems (UTSR) program has supported the development of a short course of lectures to equip combustor specialists with a comprehensive understanding of combustion dynamics and control. This course is providing a foundation for engineers at gas turbine companies to design improved stable low emissions combustors. A host gas turbine company (Pratt&Whitney/UTRC) participated in the development of the short course with technical staff providing information on problems encountered in the development of low emissions combustors. Professor Culick presented the short course on periodic visits to UTRC over the six months of the course development. The course is comprehensive (Power Point files with size about 57 MB) in depth and thoroughness with extensive figures and illustrations. It is available to the US gas turbine industry on the Internet.

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EFFECTS OF WATER VAPOR ON TURBINE MATERIALS Under the Advanced Gas Turbine Systems (UTSR), the University of Pittsburgh (Pitt) has conducted experiments to evaluate how water vapor affects oxidation performance of turbine alloys and coatings. Turbine materials are protected from high temperature combustion products by formation of protective oxide scales that are barriers to further penetration of oxygen to the underlying metal. Without protective scales, turbine materials oxidize at excessive rates, resulting in spallation and excessive material loss. Turbine materials can be classified according to whether they tend to form one or the other of the two most protective scales, alumina or chromia oxides. Commercial experience has shown that use of water or steam injection to control emissions or augment power has produced accelerated oxidation of turbine airfoils. Oxidation experiments at Pitt have shown that turbine materials that form chromia scales are more protective to steam enhanced oxidation than those that form alumina scales in the 700 C temperature range of downstream turbine airfoils. Conversely, turbine materials that form alumina scales were found to be more protective in steam environments than those that form chromia scales in the 900 C temperature range of upsteam turbine airfoils. The experiments at Pitt also revealed relative oxidation performance of a number of turbine materials in the 700 C and 900 C temperature ranges. The experiments at Pitt provide data to turbine designers for the selection of airfoil materials for engines that operate with water or steam injection to reduce emissions or increase power. MECHANISM-BASED STRATEGIES FOR EVALUATING TBC FAILURES Under the UTSR program, the University of California, Santa Barbara (UCSB) has been developing a mechanism-based strategy to assess the damage evolution and failure of thermal barrier coatings (TBC) in addition to a life-prediction methodology and non-destructive evaluation (NDE) testing protocol using the mechanism-based strategy. Elements of the mechanism-based strategy for life prediction have been put into place. A finite element framework has been developed to integrate several of the various mechanisms that contribute to coating spallation and failure. UCSB has also advanced the use of Photo-Stimulated Luminescence Spectroscopy (PSLS) as a practical NDE tool for TBCs. The project has demonstrated that PSLS can identify different types of coating internal damage, quantify the thermally grown oxide (TGO) stresses around flaws and other coating internal features, identify transient phases in the TGO, and explore the kinetics of TGO transformations. Since PSLS can identify and quantify sources of TGO transformations which produce the stresses that result in TBC spallation and failures, PSLS has been shown to be a promising tool for determining the quality and reproducibility of coatings as they emerge from the manufacturing process.

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NEW COMPOSITIONS FOR IMPROVED TBC COATINGS Under the UTSR program, the University of Connecticut (UCONN) has been exploring new materials for thermal barrier coatings (TBCs). A new composition with decreased thermal conductivity compared to conventional TBC materials would better insulate turbine alloy surfaces and enable higher turbine operating temperatures, with resulting improvements in engine power and efficiency. UCONN has screened candidate materials with respect to nine physical and chemical properties pertinent to TBC performance and life. The most promising candidates were determined to be a variety of rare-earth zirconates and lanthanum phosphate. Measurements for hot-pressed compacts of gadolium zirconate have shown a 33% lower thermal conductivity compared to the conventional TBC material used in turbines. Compositional modifications of the zirconates are being evaluated to reduce susceptibility to hot corrosion and reactivity with the thermally grown alumina layer that forms under TBCs in turbine operating environments. LASER FLUORESCENCE FOR NON-DESTRUCTIVE EVALUATION OF TBC There is no accurate measurement technique to predict the expected remaining coating life on turbine parts. Consequently, the great variability of TBC coating lifetimes has resulted in turbine coating failures in the field or parts prematurely taken out of service if removed based on a conservative lower bound of expected coating lifetime. Under the UTSR program, the University of Connecticut (UCONN) has been evaluating the use of laser fluorescence (LF) to measure average internal stresses for non-destructive evaluation (NDE) of thermal barrier coatings (TBCs). Experiments in the project subjected TBC coated specimens to thermal cycles up to a temperature of 1121 C (2050 F). The LF technique was able to predict remaining life of coatings to within 5% for specimens that had been exposed to 1 hour thermal cycles and to within 7% for specimens that had been exposed to 24 hour thermal cycles. Useful engineering predictions of remaining TBC lifetimes were consequently shown for 1 hour and 24 hour thermal cycles. However, except for LF measurements taken near the end of coating life, the correlation of LF data with remaining TBC life differed for the two different cycle times. Additional work using LF measurements at times closer to end of life will evaluate whether the prediction method can be used without requiring knowledge of cycle times. AIRFOIL SURFACE ROUGHNESS EFFECTS ON TURBINE PERFORMANCE Roughness characteristics of turbine vane and blade airfoil surfaces change with operation time due to erosion, corrosion, deposition, and spallation of coatings from the parts. These surface changes can degrade the airfoil aerodynamics and cooling from their initial finely tuned, as manufactured, levels.

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Under the UTSR program, the Air Force Institute of Technology (AFIT) and Mississippi State University (MSU) are characterizing the effects of service conditions on turbine vane and blade heat transfer and aerodynamic performance. Over 100 turbine parts have been obtained from Allied-Signal, GE, Siemens-Westinghouse, and Solar Turbines. These components had experienced service in turbines under a wide range of conditions. Scaled models of measured surfaces from turbine parts were produced for wind tunnel experiments in which heat transfer and aerodynamic data were obtained for those surfaces. Comparison of data representing real turbine surfaces and data representing ordered arrays (cones or hemispheres) and equivalent sand grain roughness, which are traditionally used to simulate real surfaces, showed limitations in the traditional methods to characterize roughness of turbine surfaces. A more accurate method was identified to represent turbine surfaces for turbine aerodynamic and heat transfer analyses and design. The surface roughness measurement database from turbine parts and data from the wind tunnel tests representing the observed roughness are being provided to turbine manufacturers to improve their tools for design and analyses of airfoils. NEW SPPS PROCESS FOR IMPROVED TBC An important cause of failure for thermal barrier coatings (TBC) in turbines has been the growth of internal aluminum oxide scales within the TBC at the bond coat. This produces internal stresses and ultimate cracking because of the volumetric growth of the internal oxide layer. The detrimental growth of the alumina scales results from oxygen penetration through the porous outer layer of the TBC to the underlying bond coat. Under the UTSR program, Northwestern University (NU) has evaluated a new Small Particle Plasma Spray (SPPS) process to apply a thin YAG (yttrium aluminum garnet) layer on TBC bond coats to block oxygen penetration and thereby alleviate TBC failures. This process also offers the potential for applying graded layers of coating materials to facilitate engineered TBC coatings with other specialized properties. Research in this recently completed project showed that SPPS is a viable process for applying the YAG layer on a bond coat. Experiments on specimens of coated turbine materials indicated that a TBC with the YAG layer on the bond coat experienced internal oxidation rates nearly a factor of two lower than rates for specimens with conventional TBCs. The project has also shown the SPPS process can produce TBC coatings that experience lower fatigue damage (through graded porosity). Lower fatigue damage in addition to lower internal oxidation rates demonstrated in this project indicates that the SPPS process offers the potential for enabling longer TBC lifetimes in turbines. Two patents (#5,744,777 and 5,858,470) were issued concerning the SPPS process during the course of this UTSR project.

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LESSER COOLING REQUIREMENTS FOR COMPONENTS DOWNSTREAM OF CATALYTIC COMBUSTORS Conventional low NOx combustors currently used in gas turbines sustain combustion in regions of large-scale flow re-circulation. This causes large-scale turbulence that propagates into the first stage turbine vanes. The large-scale turbulence produces high rates of heat transfer to the vanes, which consequently must be highly cooled. Under the UTSR program, the University of North Dakota (UND) has used experiments and computer analyses to evaluate the effects of flow characteristics representative of catalytic combustors on first stage vane cooling requirements. The research has verified that the relatively small scale and low level turbulence representative of catalytic combustors can reduce heat transfer to vanes by a factor of two compared to turbulence representative of conventional low emission combustors. Consequently, catalytic combustors are capable of not only reducing turbine emissions compared to current low NOx combustors, but UND has also shown they might provide advantages to turbine designers in reducing cooling requirements and the complexity of first stage vanes. DEVELOPMENT OF SCIENTIFIC BASIS FOR IMPROVED TBC Under a continuing UTSR project, the University of California at Santa Barbara is developing a scientific basis for improving thermal barrier coatings (TBCs) used in gas turbines. One effort is determining how TBCs fail under cyclic conditions and how impending failures might be detected. Determining how TBCs fail will aid in the development of better coatings. Detection before failure will enable turbine parts to be taken out of service before loss of the protective coating. The project has shown that an early warning of TBC internal damage leading to eventual failure is wrinkling or rumpling at the surface of the TBC that increases with time and the number of thermal cycles. These surface undulations are evidence of separation of the outer ceramic coating layer from an internal thermally grown oxide layer and can be detected using low level magnification and oblique illumination. The project has also shown that use of laser techniques to monitor the change in internal stresses within the TBC combined with monitoring surface rumpling enhances the ability to detect TBC degradation before failures that limit the protection of the underlying metal surface. METHODS TO IMPROVE INTERNAL COOLING OF TURBINE AIRFOILS Under the UTSR program, Texas A&M is evaluating methods to improve cooling for gas turbine airfoils. The project experimentally and computationally evaluates parameters and design aspects associated with airfoil internal cooling passages with rectangular cross sections and various internal features such as dimples to enhance cooling effectiveness. Evaluations in the program have shown that dimples on interior surfaces of cooling

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channels can improve cooling effectiveness by as much as a factor of two compared to smooth cooling channels. The stationary and rotating experimental and computational results from this project will provide turbine engineers with new data for design of airfoil internal rectangular cooling passages and thereby potentially improve the cooling efficiency and thermal efficiency of gas turbines. NEW MATERIAL WITH IMPROVED TBC PROPERTIES Under the UTSR program, a University of Connecticut (UCONN) project has the goal of identifying a new thermal barrier coating (TBC) material with improved properties over those for the conventional TBC now used in turbines. Two of those properties are lower thermal conductivity (to better insulate underlying metal surfaces) and no reactivity with the aluminum oxide scale that forms on the interface between the insulation layer and the bond coat layer on the metal turbine part. Experiments at UCONN have previously shown that compositions of gadolinium zirconates (Gd-Zr) have over 30 % lower thermal conductivity than the conventional TBC material. Recently reported experiments have shown that Gd-Zr compositions do not react with aluminum oxides even at 500 F higher than turbine temperatures. Consequently, UCONN has identified a material with two important superior properties over those for current TBCs used in turbines. LASER FLUORESCENVE TO MEASURE STRESSES WITHIN TBC Under the UTSR program, a recently completed University of Connecticut (UCONN) project had a goal of advancing a laser fluorescence (LF) technique as a non-destructive evaluation (NDE) technique for anticipating and predicting thermal barrier coating (TBC) failures. TBC life variability is high and NDE approaches are needed to remove turbine parts from service before failure and resulting forced turbine shut down. The LF technique was used to measure internal stresses within three types of TBC coatings on specimens cycled to three high temperatures. The tests showed that TBC failure occurred only over narrow range of measured stresses and it is possible for LF to predict the time of failure to within 7 % of expected life from measurements made prior to half of the coating life. LF was also used to measure stresses in 20 turbine vanes and blades before and after operation in engines. The LF measurements were readily obtained and the measured stresses in the turbine parts decreased in a way consistent with those observed in the laboratory experiments. Significance: The project has shown that LF can provide predictions of remaining TBC life that are sufficiently reliable for engineering use.

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EFFECTS OF OPERATING CONDITIONS AND FUEL PROPERTIES ON COMBUSTION INSTABILITIES The analysis techniques to design natural gas fired, low emissions turbine combustors have been insufficient to predict and completely eliminate instabilities that cause unacceptable noise, structural damage, and removal of turbines from service. Available analysis techniques in this area are even less capable for liquid turbine fuels. Under the UTSR program, a recently completed Pennsylvania State University (PSU) project conducted experiments with a variety of liquid fuels in a low emissions combustor to evaluate effects of operating conditions and fuel characteristics on stability and emissions performance. Significance: The experiments have provided a database obtained under well-defined and controlled conditions to aid in the development of computational models for predicting instabilities and designing gas turbine combustors. General Electric and CFD Research Corporation are currently using this database to validate new combustor design computational models. EFFECTS OF PREMIXER FLOW FIELD CHARACTERISTICS AND OPERATING CONDITIONS ON COMBUSTION INSTABILITIES The premixer of gas turbine combustors is a critical component. Thorough mixing must be accomplished in very short time intervals under fuel lean conditions to achieve low emissions without damaging flashback into the premixer. Combustion instability oscillations resulting from operation near lean blowout limits must be controlled since such pressure oscillation can cause unacceptable noise and fatigue induced structural damage and failure of the turbine combustor. Under the UTSR program, a Purdue University (PU) project is conducting experiments to measure the flow fields and pressure oscillations in a Solar Turbines premixer and a General Electric turbine premixer for a range of operating conditions. Significance: The experiments have provided insights on the effects of operating conditions and flow field characteristics on instabilities for low emissions turbine premixers. Such insights can enable turbine designers to improve stability performance of turbine combustors. NEW METHOD TO DETERMINE STABILITY MARGIN OF COMBUSTORS Low emission turbine combustors operate near their lean blowout limits where combustion temperatures and resulting NOx emissions are low. However, this has caused combustion pressure oscillations and instabilities with accompanying noise and

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vibrations. In a number of cases, such pressure oscillations have resulted in unacceptable noise, vibration induced fatigue structural failures in engines, and removal of commercial turbines from service for repair. Under the UTSR program, a Georgia Tech (GT) project has developed a new experimental technique for determining the stability margin of combustors, which is a measure of how close they are to becoming unstable. Significance: Turbine operators have little warning of how close the combustor is to becoming unstable, unless an actual instability occurs. Since the GT approach can determine combustor stability margins, operators could avoid combustor instabilities and resulting excessive noise, structural failures, and forced shutdowns. EVALUATION OF TURBINE PARTS FOR IMPROVED DESIGN PARAMETERS REPRESENTING SERVICE LIFE EFFECTS Turbine vane and blade airfoil surfaces experience surface roughening during service due to deposition, erosion, corrosion, and coating spallation. Surface roughening significantly increases aerodynamic losses and heat loading of the airfoils. Consequently, engineers must represent the roughening effects of turbine service in the aerodynamic and cooling design of vanes and blades. However, past methods of representing turbine surface roughening due to service have not been adequate for turbine design. Under the UTSR program, an Air Force Institute of Technology (AFIT) and Mississippi State University (MSU) project has analyzed over 100 parts that had experienced turbine service and has developed new methods to analytically represent roughening for aerodynamic and cooling design of airfoils. Significance: The new MSU model for turbine surface roughness was shown to represent laboratory measured aerodynamic roughness effects to within 7% and heat transfer roughness effects to within 16%. This accuracy was demonstrated for surfaces representing both deposit buildup and erosive removal and is significantly improved over that of previous models used by turbine manufacturers for vane and blade design. The MSU student that developed the model has received his Ph.D. degree, accepted an Assistant Professorship at the University of Alabama, and is now pursuing research to develop even more accurate representations of service roughening of airfoil surfaces for turbine design.

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POSITIONING AIRFOILS FOR IMPROVED AERODYNAMIC PERFORMANCE Hot streaks in turbine expander flow paths substantially affect vane and blade lifetimes and stage aerodynamic performance. These hot streaks are located in circumferential positions related to the location of the upstream combustor fuel injectors. Under the UTSR program, a Virginia Commonwealth University (VCU) project has conducted computational analyses to improve airfoil temperatures and stage aerodynamic performance by selecting the circumferential positions of first and second stage vanes with respect to the hot streaks (i.e., fuel nozzles). The analyses previously showed that locating the circumferential position of the second stage vanes with respect to the first stage vanes could affect stage efficiency by as much as 0.5%. The analyses have recently indicated that selective circumferential positioning the first stage vanes with respect to the hot streaks can significantly reduce the time average surface temperature of the downstream first rotor blades and second stator vanes. Significance: A 55 degree centigrade increase in time average surface temperature can reduce the lifetime of turbine rotor blades by a factor of ten. The VCU project showed the potential of significantly increasing turbine component lifetimes or reducing cooling (and associated performance penalties) by selective circumferential positioning of first stage vanes. SOURCES OF WATER VAPOR INDUCED DEGRADATION OF AIRFOILS AND SELECTION OF MATERIALS Oxide scales that are slow growing and relatively impermeable to further oxygen penetration are the primary line of defense of turbine materials and coatings from accelerated oxidation and corrosion. High levels of water vapor from steam and water injection into turbines to reduce emissions or augment power have adversely affected part life. One cause has been the effect of steam in the hot gas stream on protective oxide formation on the turbine components. Effects of water vapor on oxidation and corrosion of components is also important for turbines operating with coal syngas, for which turbine expansion gases contain high water vapor levels. Under the UTSR program, a recently completed University of Pittsburgh (UPT) project has conducted experiments and analyses to evaluate sources of water vapor induced degradation and to identify turbine alloys and coatings resistant to water vapor effects. The project has determined that turbine alloys that form chromium oxide scales should not be used for surface temperatures above 700 C (1290 F) in high water vapor environments. Of the alloys and coatings tested that form aluminum oxide scales, those that contain low levels of hafnium performed better in high water vapor environments. Two superior alloys and one coating that form aluminum oxide scales were identified for

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operation at surface temperatures above 700 C (1290 F). The thermal barrier coating that was tested did not experience significant degradation associated with water vapor effects. Significance: The UPT project has determined alloy and coating properties and specific materials for turbine components that operate in high water vapor environments, such as produced by water or steam injection for emissions control. Project results should also be beneficial for identifying turbine materials for operation with syngas. COMBUSTION INSTABILITY RESEARCH BENEFITS DISSEMINATED TO GT INDUSTRY Instabilities in low emission combustors have forced removal of industrial and utility turbines from service because of excessive noise and structural failure. Under the UTSR program, a Georgia Tech (GT) project has conducted experiments and analyses to determine the processes that drive combustor instabilities and to determine active and passive methods to suppress the instabilities. GT identified critical factors that affect the interactions between the flow and combustion process oscillations, which produce the instabilities. A method was found to determine the stability margin of combustors before experiencing problems in the field. Promising techniques were further advanced to actively control instabilities by modulating combustor fuel flow. Success in the UTSR project has resulted in three other separate GT projects with major gas turbine manufacturers, two in active control and one in modeling. Using UTSR project results, a semester long course in combustion instabilities was developed and offered to GT students and employees of a major gas turbine manufacturer through a live communication link. A combustion instabilities short course was also developed and offered at two gas turbine company sites. Significance: The GT project has developed important knowledge about the causes and control of instabilities in gas turbine combustors and is disseminating that information to the gas turbine industry. DESIGN OF INTERNAL CHANNELS FOR IMPROVED AIRFOIL COOLING The thin trailing edges of turbine airfoils are difficult to cool and consequently operate at higher temperatures than most other regions of the airfoils. As a result, risk of thermal failure is a significant issue for turbine vanes and blades, so small features (such as ribs and pins) are used within airfoil internal cooling channels to increase turbulence and thereby increase the effectiveness of cooling flows. In progressing towards the trailing edges, the aspect ratios of internal rectangular cooling channels increase as the airfoil thickness decreases.

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Under an UTSR program recently completed in 2003, Texas A&M (TAM) and the University of Utah (UTH) have conducted experiments and computer analyses to investigate the benefits of internal features such as ribs, pins, and dimples on cooling, especially for trailing edge regions and rotating blades. The project has provided data to guide turbine engineers for improving the cooling design of turbine airfoils. Significance: The TAM/UTH project has developed an airfoil cooling data base that did not previously exist for certain high aspect ratios and various turbulence enhancing features associated with rectangular cooling channels of rotating blades. GAS TURBINE WORLD PUBLICATION RECOGNIZES BENEFITS OF UNIVERSITY PROGRAM TBC RESEARCH Under the UTSR and University Turbine Systems Research (UTSR) programs, the University of Connecticut, the University of California at Santa Barbara, the University of Pittsburgh, and the University of Central Florida have performed research for thermal barrier (TBC) coating research and development. An article in the January-February 2003 issue of the gas turbine trade magazine, Gas Turbine World, described this research and the resulting “…significant progress to improve the performance and reliability of thermal barrier coatings for gas turbine components--and to accurately predict remaining TBC life once in service.” This four-page article focused mainly on the results of projects at the University of Connecticut and the University of Pittsburgh. Quoting the summary heading the article, “DOE-university research has already paid off in the form of more durable bonding, ability to predict service lifetime of installed coatings, and portable TBC evaluation probe for use by gas turbine builders, repair service suppliers and operators.” Significance: The Gas Turbine World article not only describes DOE funded university research programs but also recognizes their significance and benefits for the gas turbine industry. SCHEMES FOR IMPROVED COOLING OF VANES AND ENDWALLS First turbine vane end walls are typically protected from burnout by injecting coolant flows through holes in the end walls and/or through circumferential slots between the combustor and vane platforms. Determination of appropriate cooling flow rates and placement of cooling holes is a difficult challenge for turbine designers because of the complicated flow and heat transfer interactions between slot and end wall cooling flows, combustor hot spots, and the secondary flows that develop through the vane passages. Under an UTSR project, the University of Texas (UT) and Virginia Tech (VT) are using experiments and computer analyses to evaluate the cooling effectiveness of slot cooling alone, end wall film cooling alone, and combined slot and end wall cooling. The evaluations showed that slot cooling alone is not adequate because passage secondary

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flows prevent full coolant flow coverage of the end walls. End wall film cooling alone was found deficient in protecting the end wall regions near the interface between adjacent vanes. The combination of slot cooling with end wall cooling provides the best protection of end walls from burnout but a certain minimum level of end wall film cooling flow is needed to prevent a higher temperature ring that extends along the entire vane convex surface. The experiments also showed that the cooling flows interacted with the passage secondary flows to produce an environment that would not be predicted by superposition of the separate benefits of the two cooling approaches so that use of superposition would under predict end wall life. Significance: The UT and VT UTSR project will provide guidance to turbine engineers that could enable more efficient cooling of first vane end walls, thereby increasing component life and decreasing turbine power and efficiency performance losses due to cooling. PROCESSING BENEFITS FOR TBC WITH LONGER LIFETIMES Under UTSR projects, the University of Connecticut has been evaluating approaches to improve durability of thermal barrier coatings (TBC). Ridges are produced at TBC bond coat grain boundaries by oxidation. A previous UTSR project, started in 1995, showed that removal of the ridges before applying the zirconia insulation layer can increase TBC lifetimes by a factor of three times. This finding for the 1995 project provided an incentive for another UCONN UTSR project that started in 2001 to improve durability of TBCs through manufacturing process modifications. The UCONN research in the latter project has shown that polishing to remove bond coat surface defects (e.g., roughness and embedded oxides) increases coating spallation lifetimes by a factor of four times. A gas turbine manufacturer has implemented and refined the UCONN findings and has achieved even greater improvements in TBC lifetimes. Significance: TBCs, originally developed for aircraft turbines with short maintenance intervals, had inadequate lifetimes and an unacceptable wide range of lifetime variability for land based turbines. This has impeded the full realization of the power and efficiency benefits of TBCs in industrial and utility turbines. The research at UCONN has identified TBC processing improvements that will increase the coating lifetimes and more fully realize the turbine performance benefits of TBCs.

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Appendix M

UTSR PRESENTATIONS & PUBLICATIONS LIBRARY

SR007

Principal Investigator: Robert Dibble Project Title: Ultra Low Gas Turbine Emissions Using Catalytic and Non Catalytic

Porous Combustors, October 1993- March 1997 Publications: Catalytic Oxidation of Gas over Supported Platinum: Flow Reactor

Experiments and Detailed Numerical Modeling, Conference Presentation-26th International Symposium on Combustion, Naples, Italy, 1996 “A Comparison of the Influence of Fuel/Air Unmixed ness on NOx Emissions in Lean Premixed, Non- Catalytic and Catalytically Stabilized Combustion” Journal Publication-The American Society of Mechanical Engineers “Gas Temperature above a Porous Radiant Burner: Comparison of Measurements and Model Predictions” Conference Presentation-26th International Symposium on Combustion, Naples, Italy 1996 “An Experimental and Numerical Comparison of Extractive and In-Situ Laser Measurements of Non Equilibrium Carbon monoxide in Lean-Premixed Natural Gas Combustion” Journal Publication- Combustion and Flame

SR008

Principal Investigator: Arthur Mellor Project Title: NOx and CO Emissions Models for Gas-Fired, Lean-Premixed

Combustion Turbines, March 1996-December 1996 Publications: “ Effects of Unmixedness in Piloted-Lean Premixed Gas Turbine

Combustors” Abstract- for publication and presentation at the 1997 International Gas Turbine Institute Meeting, Orlando, FL “Quantifying Unmixedness in Lean Premixed Combustors Operating at High Pressure, Fired Conditions” Abstract-for publications and presentation at the 1997 International Gas Turbine Institute Meeting, Orlando, FL “Characteristic Time Modeling of NOx Emissions and Lean Blow off for Piloted-Lean Combustors” Abstract-for publication and presentation at the 1997 International Gas Turbine Institute Meeting, Orlando, FL “Design of Inlet Conditions for High Pressure NOx Measurements in Lean Premixed Combustors” Conference Presentation- 1995 IGTI Turbo Expo, Houston, TX “Engineering Analysis for Lean Premixed Combustor Design” Technical Paper/Journal Publications-AIAA joint Propulsion and Power/Conference Paper-1995 AIAA Joint Propulsion Conference, San Diego, CA “NOx, CO, and Lean Blow off in a Piloted-Lean Premixed Combustor” Abstract “Preliminary Study of NOx, CO, and Lean Blow off in a Polited-Lean Premixed Combustor Part I: Experimental” Technical Paper/Conference Presentation

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“Preliminary Study of NOx, CO, and Lean Blow off in a Polited- Lean Premixed Combustor Part II: Modeling” Journal Publication, Combustion Science and Technology Journal “Behavior on NOx in Lean Premixed Pre mixed Prevaporized Combustion: Effects of Fuel Composition and Inlet Jet Size” Journal Publications-Transaction of ASME, Conference Presentation-June 1997, ASME Gas Turbine and Aero engine Congress, Orlando, FL “Chemical Reactor Modeling Applied to the Prediction of Pollutant Emissions an LP Combustor” Conference Presentation-33rd AIAA/ASME/SAE/ASEE/Joint Propulsion Conference, July 1997, Seattle WA “Effects of Incomplete Premixing or NOx Formation at Gas Turbine Engine Conditions” Journal Publication, and Conference Presentation-42nd ASME Gas Turbine and Aero engine Congress June 1997 Orlando, FL “Characterization of NOx, N20, and CO for Lean Premixed Combustion in High-Pressure Jet-Stirred Reactor” Journal Publication-ASME Journal of Engineering for Gas Turbine and Power Conference Presentation-1996 “NoxEI Sensitivity to Inlet Conditions for Lean Premixed Turbine Combustors” International Gas Turbine and Aero Engine Congress, Central States Combustion Institute Meeting, June 1994 (Abstract) “Simplified Models for NOx Production Rates in Lean-Premixed Combustion” Conference Presentation “NOx and N2O In Lean Premixed Jet Stirred Flames” Conference Presentation “Measurements of Turbulent Premixed Methane Flames by Raman Scattering And Fluorescence: Plans and Progress Conference Presentation “NOx Kinetics and Mechanism for Lean Premixed Combustion: Part I- One Atmosphere Experimental Results” Conference Presentation “NOx Kinetics and Mechanism for Lean Premixed Combustion: Part II-Engineering Modeling Considerations” Conference Presentation “LP NOx Characteristic Time Model Validation Tests at METC” Conference Presentation “NOx Emissions for Lean-Premixed Combustion” Conference Presentation-Pacific Rim International Conference on Environmental Control of Combustion Processes “Raman Measurements of Mixing and Finite-Rate Chemistry in a Supersonic Hydrogen/Air Diffusion Flame” Journal Publication-Submitted to Combustion Flame, 1993

SR009

Principal Investigator: Paul E. Sojka Project Title: “ NOx Abatement in Advanced Gas Turbines” Publications: “ Background Corrections of LIF Measurements of NO in Lean, High-

Pressure, Premixed Methane Flames” Journal Publication “Laser-Induced Fluorescence Measurements of Nitric Oxide Formation in High-Pressure Premixed Methane Flames” Journal Publication “Discreet Probability Function Method for a Turbulence Mixing Layer” Journal Publication

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SR010

Principal Investigator: Arnold Marder Project Title: “Functional Graded Material for Thermal Barrier Coatings in

Advanced Gas Turbine Systems” Publications: “Processing of Layered Metal Matrix Composite and Ceramic

Coatings by Electrochemical Methods” Journal Publication, Conference Presentation “Structure of Electrodeposited Graded Composite Coatings of Ni-A1-A1203” Journal of Microscopy, Vol. 185,Pt. 2, February 1997 “Electrodeposited functionally graded Composite Coatings” Microscopy of Composite Materials III Conference, St. Johns College, Oxford, England, April 1-3, 1996 (abstract) “Characterization of Single and Discretely-Stepped Electro-Composite Coatings of Nickel-Alumna” Conference Presentation

“Microstructural Characterization and Hardness of Electrodeposited Nickel Coatings from a Sulfate Bate” Conference Presentation

SR011

Principal Investigator: J.C. Han Project Title: “Advanced Turbine Cooling, Heat Transfer and Aerodynamic Studies” Publications: “Effect of Channel Orientation in a Rotating two-pass coolant Passage

heat transfer” ASME Journal of Heat Transfer, Vol. 118, No.3 Pp. 578-584, August 1996 “Detailed Heat Transfer Measurements in a Non-rotating two-pass channel with and without bleed holes using transient liquid Crystal Technique” International Journal of Heat Mass Transfer, Vol. 40, No. 11, Pp. 2525-2537, 1997 Conference Proceedings; HTD-Vol. 330, National Heat Transfer Conference, Vol. 8, ASME 1996, Pp. 133-140 Heat Transfer Inside and Downstream of Cavities Using Transient Liquid Crystal Method” Journal of Thermophysics and Heat Transfer, Vol. 10, No. 3 July-September 1996 “Detailed Heat Transfer Distributions on a Cylindrical Model with Simulated TBC Spallation” AIAA 97-0595 35th Aerospace Meeting & Exhibit January 6-10 1997 Reno, NV

SR012 Principal Investigator: Sam Zamrick Project Title: “Life Prediction of Advanced Materials for Gas Turbine Application: Effects of Thermomechanical Strain/Temperature Cycling on Fatigue Life Crack Growth of Coated in 738LC Material”

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Publications: “The use of Viscoplastic Model for Time-Dependent Stress-Strain Life Cycle” Inelasticity and Damage in Solids Conference, St. John’s, Newfoundland, Canada, September, 1996 “Thermomechanical Fatigue life Prediction Model for Advanced Gas Turbine Materials” Poster Presentation

SR013

Principal Investigator: Uri Vandsburger Project Title: “Advanced Combustion Technologies for Gas Turbines Power Plants”,

July 1997 Publications: “Flow Actuation, Controller, and Materials Development for Gas

Turbine Systems,” DOE Advanced Gas Turbine Systems Research- Combustion Technology Workshop IV, Atlanta, GA, March 5-7,1997 “Coupled Multiple Jet Excitation,” AIAA-97-0075, paper presented at the 35th Aerospace Sciences Meeting and Exhibit, Reno, NV, 1997 “Neural Network Estimation of the Flow field Structure of Spatially Excited Jets”, AIAA-97-0073, paper presented at the 35th Aerospace Sciences Meeting and Exhibit, Reno, NV 1997 “Actuation Methodologies and Actuator Materials for Combustion Control,”DOE Advanced Turbine Systems- Annual Program Review, Washington, DC, November 7-8, 1996 “Flow and Combustion Control: Actuation Methodologies and High Temperature Actuator Materials,” DOE Advanced Gas Turbines Systems Research- Combustion Technology Workshop III, Lake Arrowhead, CA, March 19-22, 1996 “Actuation Methodologies and Actuator Materials for Combustion Control,” DOE Advanced Turbine Systems- Annual Program Review, Morgantown, WV October 17-18,1995 “Active Combustion Devices,” DOE Advanced Turbine Systems Research-Combustion Technology Workshop II, Indianapolis, IN, March 26-29, 1995 “Actuators for Combustion Control- New Approaches and Materials,” DOE Advanced Turbine Systems- Annul Program Review, Arlington, VA, November 9-11, 994 “Advanced Combustion Technologies for Gas Turbine Power Plants,” DOE Advanced Turbine Systems- Combustion Technology Workshop, Nashville, TN February 23-25,1994 “Advanced Combustion Technologies for Gas Turbine Power Plants,” .S. Dept. of Energy Joint Contractors Meeting-Advanced Turbine Systems Conference, Morgantown, WV, August 3-5,1993

SR014

Principal Investigator: Paul O. Hedman Project Title: “Combustion Modeling in Advanced Gas Turbine Systems”, February

28, 1998

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Publications: “Simultaneous Measurements of Temperature and Species Concentration on Premixed Natural Gas Flames Using a Dual Dye, Single- Strokes CARS System” Paper Presented at the 1996 Fall Meeting of Western States Section/Combustion Institute Meeting at the University of Southern California, Los Angeles October 28-29,1996 “CARS Temperature and LDA Velocity Measurements in a Turbulent, Swirling, Premixed Propane/Air Fueled Model Gas Turbine Combustor” Paper Presented at the 1995 Annual Meeting of ASME International Gas Turbine And Aeroengine Congress and Exposition Houston, TX, June 5-8,1995 “Evaluation of CH4/NOx Reduced Mechanisms Used for Modeling Lean Premixed Turbulent Combustion of Natural Gas” Submitted to ASME Journal Of Engineering for Gas Turbines and Power October, 1997 “Numerical Method for Predicting Fluid Flow in Practical, Industrial Geometries” International Journal for Numerical Methods in Fluid In Review, 1998 “Modeling of Lean Premixed Combustion in Stationary Gas Turbines ”Progress in Energy and Combustion Science, In Press, 1998 “Stochastic Modeling of CO and NO in Premixed Methane Combustion”, Combustion and Flame 113, 135-146,1998 “Comprehensive Model for Lean Premixed Combustion in Industrial Gas Turbines- Part I Validation” Paper No. 97S041 Paper Presented at the 1997 Spring Meeting of the Western States Section/Combustion Institute Meeting at the University of Southern California, Los Angeles April 1997 “Chemical Kinetic Modeling of Bluff-Body Lean Premixed Combustor” Submitted Full Length article to Combustion and Flame January 1998 “Comprehensive Model for Lean, Premixed Combustion in Industrial Gas Turbines: Part II-Application” Paper Presented at the 1997 Spring Meeting Of the Western States Section/Combustion Institute Meeting at the South Coast Air Quality Management District Headquarters, Diamond Bar, CA April, 1997

SR015

Principal Investigator: Sumanta Acharya Project Title: “ Vortex Generator Induced Enhanced Heat Transfer in Gas Turbine

Blade Coolant Channels with Rotation” Publications: “Mass Heat Transfer in a Ribbed Blade Coolant Passage with

Cylindrical Vortex Generators: The Effect of Generator-Rib Spacing Journal Publication and Conference-ASME Conference “An Efficient 3D Poison Solver in Cylindrical Coordinates for SIMD Architectures” Journal Publication-Computer Physics Communications A Parallel Direct D3 Poisson Solver in Cylindrical Coordinates” Conference Presentation-Proceedings of Supercombustion ’95 “Detailed Heat Mass Transfer Distribution in a Ribbed Coolant Passage” Journal Publication and Conference Presentation- 1996 Turbo Expo ASME/IGTI Meeting, Birmingham, England

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“Heat Transfer in a Two Pass Internally Ribbed Turbine Blade Coolant Channel with Cylindrical Vortex Generators” Conference Presentation-1996 Turbo Expo ASME/IGTI Meeting, Birmingham, England “Heat/Mass Transfer in a Two Pass Rotating Smooth and Ribbed Channel” Conference Presentation-ASME National Heat Transfer Conference, Houston, August 1996 “Heat Transfer Enhancements in Internally Ribbed Coolant Channels of Gas Turbine Blades” Conference Presentation-ASME National Heat Transfer Conference, Houston, August 1996 “Detailed Mass Transfer Distribution in Rotating Two Pass Coolant Channel with Profiled Ribs” Conference Presentation, IGTI 2000 (Sub) “Detailed Measurements of Enhanced Heat Transfer in a Two Pass Coolant Channel for Two Profiled Rib Configurations” Conference Presentation, IGTI 2000 (Sub) “Heat Mass Transfer in an Internally Ribbed Turbine Blade Coolant with Vortex Generators” Conference Presentation

SR016

Principal Investigator: Ronald LaFleur Project Title: “Reduction of Turbine Endwall Total Pressure Loss and Heat Transfer

Using the Ice Formation Design Method” Publications: “Review and Theory of four and five hole Pressure Probes

Calibrations” Conference Presentation-ASME/AIAA Journal Publications

SR017

Principal Investigator: Gerald Guenette Project Title: “The Effects of Rotation on the Internal Heat Transfer in Turbine

Blades” Publications: NA

SR018

Principal Investigator: Stephen B. Pope Project Title: “Manifold Method for Methane Combustion” Publications: ”Treating chemistry in combustion with detailed mechanisms-In situ

adaptive tabulation in principal direction,” Combustion Flame 1996 “An Investigation of the accuracy of manifold methods and splitting schemes In the computational implementation of combustion chemistry” Combustion Flame 1996 B. Yang & S..B. Pope"Treating chemistry in combustion with detailed mechanisms- In situ adaptive tabulation in principal direction," Combustion & Flame, 112, 85-112 (1998)

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B. Yang & S..B. Pope "An Investigation of the accuracy of manifold methods and splitting schemes In the computational implementation of combustion chemistry" Combustion & Flame, 112, 16-32 (1998) V. Saxena & S.B. “PDF simulations of turbulent combustion incorporating detailed chemistry” Combustion & Flame, 117, 340-350 (1999) J. Xu and S.B.Pope “PDF calculations of turbulent nonpremixed flames with local extinction” Combustion & Flame, 123, 281-307 (2000) S. James, M.S. Anand, M.K. Razdan and S.B. Pope “In situ detailed chemistry calculations in combustor flow analyses” J. of Engng. for Gas Turbines and Power, 123, 747-756 (2001)

SR019

Principal Investigator: Sanford Fleeter Project Title: “Advanced Multistage Turbine Blade Aerodynamics, Performance,

Cooling and Heat Transfer” Publications: “Advanced Multistage Turbine Blade Aerodynamics, Performance,

Cooling and Heat Transfer” Poster Session

SR020

Principal Investigator: Scott Samuelson Project Title: “The Role of Mixed ness and Length scale on Performance and

Emissions In a GTE can combustor” June 1994-March 1998 Publications: “ The Role of Reactant Unmixedness, Strain Rate, and Length Scale on

Premixed Combustor Performance” Poster Presentation

SR021

Principal Investigator: Richard Goldstein Project Title: “Experimental and Computational Studies of Film Cooling with

Compound Angle Injection” Publications: “ Computations of Inverse Phase Change Using a New Enthalpy

Method” Numerical Methods in Thermal Problems, Vol. IX, Part 2 “A Numerical Study of Discrete Hole film Cooling” ASME Paper, 96-WA/HT/-8, Atlanta, GA “Computation of discrete hole Film Cooling: Hydrodynamic Study” ASME Paper, 97-GT-80, -Orlando, FL. “A Numerical Study of Discrete-Hole Film Cooling” Submitted to Numerical Heat Transfer, February 1998 “Curvature Effects on Discrete-Hole Film Cooling” Presented at the 1998 ASME Turbo Expo in Stockholm, Sweden, June 1998

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“Investigation of discrete-Hole Film Cooling Parameters using Curved-Plate Models” Presented at the 1998 ASME Turbo Expo in Stockholm, Sweden, June 1998 “Measurements in film Cooling Flows: Hole L/D and Turbulence Intensity effects” ASME Paper 96-WA/HT/7, To Be Published in Trans ASME Journal of Turbomachinery “Measurements of Aerodynamics Penalties Associated with Film Cooling” Submitted to 1998 ASME IMECE, Anaheim, CA “Influence of Coolant Supply Plenum Geometry on Film Coolant Surface Adiabatic Effectiveness” ASME Paper 97-GT-25 “Measurements of Discharge Coefficients in Film Cooling” Accepted to 1998 ASME IGTC/ Turbo Expo, Stockholm, Sweden, and Recommended for Publication in ASME Transactions J. Turbomachinery. ASME Paper 98-GT-009 “Turbulence Spectra and Length scales Measured in Film Coolant Flows Emerging from Discrete Holes” Accepted to 1998 ASME IGTC/Turbo Expo, Stockholm, Sweden, and Recommended for Publication in ASME Transactions J. Turbomachinery “Total-Coverage Discrete Hole wall Cooling” Journal of Turbomachinery, Vol. 119, No. 2, Pp. 329-338, 1997 “Experimental Mass (Heat) Transfer in and Near a Circular Hole in a Flat Plate” International Journal of Heat and Mass Transfer, Vol. 40, Pp. 2431-2441, 1997 “Exploration of the Influence of Heat Conduction on Temperature Distribution in Turbine Blades” HTD-Vol. 350, National Heat Transfer Conference, Vol. 12 “Heat (Mass) Transfer and Film Cooling Effectiveness with Injection Through Discrete Holes, Part I: Within Holes and on the back Surface” Journal of Turbomachinery, Vol. 117, Pp.440-450, 1995 “Heat (Mass) Transfer and Film Cooling Effectiveness with Injection Through Discrete Holes, Part II: On Exposed Surface” Journal of Turbomachinery, Vol. 117,Pp. 451-460, 1995 ‘The Influence of Secondary Flows Near the Endwall and Boundary Layer Disturbance on Convective Transport from a Turbine Blade” Journal of Turbomachinery, Vol. 117, Pp. 675-665, 1995 ‘Effect of Plenum Cross-Flow on Heat (Mass) Transfer Near and Within the Entrance of Film Cooling Holes” Journal of Turbomachinery, Vol. 119, No. 4 Pp. 761-769, 1997 “Row-of-Holes Film Cooling of a Convex and a Concave Wall at Low Injection Angles” Journal of Turbomachinery Vol. 119 No.3, Pp. 574-579, 1997 “Film Cooling Effectiveness and Mass/Heat Transfer Coefficient Downstream of one Row of Discrete Holes” Presented at the 43rd ASME Gas Turbine and Aeroengine Congress, Stockholm, Sweden, June 2-5, 1998. Recommended for Publication in the Journal of Turbomachinery. ASME Paper 98-GT-174 “Effects of Blade Profile on Turbine Blade Heat (Mass) Transfer” Symposium on Process, Enhanced and Multiphase Heat Transfer in Honor of Professor Author E. Bergles, Georgia Institute of Technology, Atlanta, Georgia, November 16, 1996 “Influence of High Free stream Turbulence on Mass/Heat Transfer in a Simulated High Performance Turbine Blade Cascade” Accepted for Presentation at the XVI UIT National Heat Transfer Conference, Siena, Italy, June 17-19, 1998

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“Film Cooling of Gas Turbine Endwall with Discrete-Hole Injection” Journal of Turbomachinery, Vol. 118, Pp. 278-284, 1996 “Flow Measurements in Film Cooling Flows with Lateral Injection” Presented at the 1998 ASME Turbo Expo in Stockholm, Sweden, June 1998. ASME Paper 98-GT-054 “Film Cooling of Gas Turbine Endwall with Discrete-Hole Injection” Journal of Turbomachinery, Vol. 118, Pp. 278-284, 1996 “Measurements in Film Cooling with Lateral Injection: Adiabatic Effectiveness Values and Temperature Fields” Submitted to the 1998 ASME IMECE Conference, Anaheim, CA, November 1998. “A Study of Film Cooling Injection Geometry’s: Measured Flow and Thermal Fields with lateral, Compound, and In-Line Injection” Submitted to the 1998 ASME IMECE Conference, Anaheim, CA, November 1998. “Flow and Heat Transfer Measurements in Gas Turbine Film Cooling” Presented at The Energy Sources Technology Conference and Exhibition, 1998 In Search of a Blowing Parameter for Correlating Film Cooling Effectiveness Data” 2nd European Thermal Sciences and 14th UIT National Heat Transfer Conference, Rome, Italy, Pp. 647-653, 29-31 May, 1996. “Effect Endwall Boundary Conditions on Turbine Blade Mass Transfer in Presence of High Freestream Turbulence” Accepted for Presentation at the 11th International Heat Transfer Conference, Seoul, Korea, August 23-28, 1998 “Effect of High Free Stream Turbulence with Large Length Scale on Blade Heat/Mass Transfer” Presented at the 43rd ASME Gas Turbine and Aeroengine Congress, Stockholm, Sweden, June 2-5 1998, Recommended for Publication in the Journal of Turbomachinery, ASME Paper 98-GT-107 “Secondary Flows in the Blade/Endwall Region of a Turbine Cascade”Symposium on Thermal Science and Engineering in Honor of Chancellor Chang-Lin Tie, University of California, Berkeley, California, November 14, 1995 “Flow Visualization in a Linear Cascade of High Performance Turbine Blades” Journal of Turbomachinery, Vol. 119, No. 1 Pp. 1-8, 1997 “Measurements of Mean Flow and Eddy Transport over a Film Cooling Surface” HTD-Vol. 327, National Heat Transfer Conference, Vol. 5. “Film Cooling Effectivness and Mass/Heat Transfer Coefficient Downstream of a Row of Holes with Compound Angle Injection” Submitted to the 44th ASME Gas Turbine and Aeroengine Congress, Indianapolis, Indiana, June 1999. “Effect of Wake-Distributed Flow on Heat (Mass) Transfer to a Turbine Blade” Submitted to the 44th ASME Gas Turbine and Aeroengine Congress, Indianapolis, Indiana, June 1999. “Effect of Edge Roughness on the Development of Taylor-Gortler Vortices on Pressure Surface of A Turbine Blade” Submitted to Experiments of Fluids. “Mass Transfer from a Simulated Gas Turbine Blade in the Presence of Taylor- Gortler Vortices” Submitted to International Journal of Heat and Mass Transfer. “A Numerical Study of Discrete-Hole Film Cooling” Thesis, University of Minnesota, MN. “Experiments in Film with Various Coolant Delivery Geometries” Master of Science Thesis in Mechanical Engineering, University of Minnesota, Minneapolis, Minnesota, December 1996

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“Film Cooling Effectiveness and Mass/Heat Transfer Coefficients Downstream of one Row of Discrete Holes with 45 degree Compound Angle” Master of Science Thesis in Mechanical Engineering, University of Minnesota, Minneapolis, Minnesota, March 1998. “Measurements in Film Cooling Flows with Lateral Injection” Master of Science Thesis in Mechanical Engineering, University of Minnesota, Minneapolis, Minnesota, January 1998. “Prediction of three-dimensional Film cooling Situations” Ph.D. Dissertation University of Minnesota, Minneapolis, Minnesota, June 1997 “Film Cooling Effectiveness and Heat (Mass) Transfer Coefficient for a single Row of Discrete Film Cooling Holes” Master of Science Thesis in Mechanical Engineering, University of Minnesota, Minneapolis, Minnesota, May 1996 “Effects of High Turbulence and Wakes on Heat (Mass) Transfer from Gas Turbine Blades” Ph.D. Dissertation, University of Minnesota, Minneapolis, Minnesota, June 1998. “Local Mass Transfer Measurement from a Turbine Blade: Influence of High Turbulence with Large Length Scale on Heat/Mass Transfer” Ph.D. Dissertation University of Minnesota, Minneapolis, Minnesota, October 1997.

SR022

Principal Investigator: Vimal Desai Project Title: “Compatibility of Gas Turbine Materials with Steam Cooling” Publications: “Influence of Steam Cooling on Hot Corrosion” Poster Session

SR023

Principal Investigator: Minking Chyu Project Title: “Development and Application of Novel Optical Temperature/Heat

Cooling Flux Sensor for Advanced Blade Cooling Research and Engine Thermal Diagnostics”

Publications: “Film Cooling Studies with Thermographic Phosphor Imaging” Technical Paper for the 1996 International Gas Turbine Conference in Birmingham, UK

SR024

Principal Investigator: James Leylek Project Title: “ Advanced Design Methodology using Combined Computational

Experimental Techniques for Gas Turbine Film Cooling” Publications: “Effect of Geometry on Slot-Jet Film-Cooling Performance”

Conference Presentation- 1996 Turbo Expo ASME/IGTI, Birmingham, England, June 10-13, 1996

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“Computational Methodology for Gas Turbine Film Cooling design-Part 1,2 and 3” Conference Presentation-, 1995 ASME Turbo Expo, Houston, TX, June 1995 “A Systematic Computational Methodology applied to a three-dimensional film cooling flowfield” Conference Publication- 1996 Turbo-Expo ASME/IGTI, Birmingham, England, June 10-13, 1996 “A Detailed Analysis of Film Cooling Flow Physics-Part 1,2,3 and 4” ASME/IGTI Turbo Expo, 97, Orlando, FL, June 1997 (4 Abstracts) “Film Cooling Heat Transfer: Shaped and Compound Angle Hole Injection” Conference Presentation-ASME IGTI Turbo Expo, June 1998

SR025

Principal Investigator: Paul Dellenback Project Title: “The Impact of Turbulence on Heat Transfer in Internal Flows” Publications: NA

SR026/040

Principal Investigator: Abraham Engeda Project Title: “Steam Cooled Gas Turbine Blade” Publications: NA

SR027

Principal Investigator: W.B. Carter & Janet Hampikian Project Title: “Combustion Chemical vapor Deposited Coatings for Thermal Barrier

Coating Systems” Publications: “ Aerosol size Effects in Combustion CVD” Conference Presentation

“Combustion CVD- Deposited Oxidation Resistant Coatings” International Symposium on Chemical Vapor Deposition: CVD XIV and EUROCVD Paris, France August 1997 “Combustion CVD of Magnesium Spinel and Nickel Spinel” Conference Presentation “Silica thin Films applied to Ni-20Cr Alloy via Combustion Chemical Vapor Deposition” Conference San Diego, CA April 21-25 1999 “Aerosol Size Effects in Combustion CVD” Conference Presentation “High Temperature Oxidation of an Alumina-Coated Ni-Based Alloy” Conference Presentation “The Effects of Alumina Coatings on the Oxidation of Ni-20Cr” Conference-1996 Electrochemical Society (ECS) Conference “Mechanical Properties of YSZ-Alumina thin Films Deposited via Combustion CVD” Conference-1996 Electrochemical Society (ECS) Conference “Combustion Chemical Vapor Deposition of CeO2 Films” Conference-1996 Electrochemical Society (ECS) Conference

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“Hot corrosion and Thermal Fatigue Behavior of Modified Thermal barrier Coatings” Conference Presentation/Research Presentation-CIMTEC ’98, Florence, Italy, June 1998 “The Combustion Chemical Vapor Deposition of High Temperature Materials” Journal Publication “Combustion Chemical Vapor Deposited Coatings for Thermal Barrier Coating Systems” Poster Session

SR028 Principal Investigator: Ashwani Gupta Project Title: “ Advanced Concepts for High Efficiency and Low NOx Gas Turbines

Combustor Development” Publications: “Premixed Burner Experiments: Burner Geometry, Mixing And flames

Structure Issues” Abstract-Conference Presentation “Analysis of Gaseous Fuel and Air Mixing” Journal Publication-Combustion Science and Technology, Vol.141, 1999 “Effects of Swirl on Combustion Characteristics in Premixed Flames” Journal Publication- Journal of Engineering for Gas Turbine and Power,Trans ASME, Vol. 120, July 1998 and Conference Presentation-IGTI Conference, Orlando, FL, June 1997 “Analysis of Gaseous Fuel and Air Mixing in Flames and Flame Quenching” Journal Publication- Journal of Propulsion and Power, Vol. 15, No.6 January/February 2000 “Effects of Swirl on Temperature Distribution in Premixed Flames” Conference Presentation-33rd AIAA Aerospace Sciences Meeting, Reno, NV, January 1997 “Maximum Mixing Times of Methane and Air under Non-Reacting and Reacting Conditions” Accepted for Journal Publication- Propulsion and Power, 2000 “Analysis of Propane- Air Mixing under Reacting and Non-Reacting Conditions” Conference Presentation-35th AIAA/ASME/SAE/ASEE joint Propulsion Conference, Los Angeles, CA, June 1999 “Effects of Swirl and Momentum Distribution on Thermal Non-uniformities and Emissions in Premixed Flames” Poster Presentation

SR029

Principal Investigator: Ajay Agrawal Project Title: “Improving Aerodynamics of the Intercooler Flow Path for the

Development of high Efficiency Gas Turbines” Publications: “Flow Development in an Annular Contraction” Conference

Presentation at 1998 ASME IGTI Turbo Expo, Stockholm Sweden and Journal ASME Paper 98-GT-306

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“Flow Characteristics of an Annular Intercooler Diffuser for Gas Turbines” Conference Presentation at 1998 ASME IGTI Turbo Expo, Stockholm, Sweden ASME Paper 98-GT-283. “Flow Measurements in a Curved wall Annular Contraction” Published in Journal of Gas Turbines For Engineering and Power, Vol. 121 444-450

SR030

Principal Investigator: Maurie Gell Project Title: “Bond Strength and Stress Measurements in Thermal Barrier

Coatings” Publications: “Mechanism of Spallation in Platinum Aluminide/Electron Beam

Vapor Deposited Thermal Barrier Coatings” Journal Publication- Metallurgical Transactions “Assessment of damage Accumulation in Thermal Barrier Coatings Using Florescent Dye Infiltration Technique” Journal Publication - Journal of Thermal Spray, Vol. 8, No. 1, March 1999 “Thermal/Residual Stress in a Thermal Barrier Coating System” Journal Publication-ACTA Materialia, Vol. 46, No. 16, October 1998 “Measurement of Interfacial Fracture Toughness of thermal Barrier Coatings” Journal Publication-Script Met, Vol. 39, No. 10, 1998 “Bond Strength, Bond Stress and Spallation Mechanisms of Thermal Barrier Coatings” Journal Publication- Surface and Coatings Technology-In press “Bond Strength and Stress Measurements in Thermal Barrier Coatings-1997 Status” Poster Session

SR031 Principal Investigator: Ben Zinn Project Title: “Active Control of Combustion Instabilities in Low Nox Gas Turbines” Publications: ”Application of Boundary Element Methods in Modeling

Multidimensional Flame-Acoustic” Conference Presentation:20th World Conference on the Boundary Element Method, Orlando, FL , August 1998. “The Role of Unmixedness in Driving Combustion Instabilities in Low Nox Gas Turbines” Journal Publications: Combustion Science and Technology 1998, Vol. 135, pp.193-211. Presentation /Proceedings: 27th Symposium (International) on Combustion, Boulder, CO, August 1998. “Combustion Instabilities in Low NOx Gas Turbines and Their Active Control” Conference Presentation and Proceedings Publication: AGARD-AVT Gas Turbine Engine Combustion Symposium in Lisbon, Portugal, October 1998 “Theoretical Investigation of Combustion Instability Mechanisms in Lean Premised Gas Turbines” Conference Presentation/ Publication-AIAA 98-0641,36th Aerospace Sciences Meeting, Reno, NV, January 1998

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“Theoretical Investigation of Unsteady Flow” Conference Presentation/Publication-AIAA 98-0641,36th Aerospace Sciences Meeting, Reno, NV, January 1998 “Interactions with a Planar Flame” Conference Presentation/Publication-AIAA 99-0324,37th AIAA Aerospace Sciences Meeting and Exhibit, Reno NV, January 11-14,1999 “Experimental Investigation of Combustion Instabilities in a Gas Turbine Combustor Simulator” Conference Presentation/Publication- AIAA 99-0324,37th AIAA Aerospace Sciences Meeting and Exhibit, Reno NV, January 11-14,1999 “The Application of Multiple Expansions to Unsteady Combustion” Conference Presentation/Publication- AIAA 99-0324,37th AIAA Aerospace Sciences Meeting and Exhibit, Reno NV, January 11-14,1999 “A Mechanism of Combustion Instability in Lean Premixed Gas Turbines Combustors” Conference Presentation: ASME Turbo Expo’ 99, Indianapolis, IN, June 1999 “Online Identification Approach for Adaptive Control of Combustion Instabilities” Conference Presentation: AIAA 99-2125,35th AIAA/ASME/SAE/ASEE/ Joint Propulsion Conference, Los Angeles, CA June 1999 “Determination of Unsteady Heat Release Distribution in Unstable Combustor From Acoustic Pressure Measurements” Journal Publications: Technical Note-J. Propulsion and Power, Vol. 15, No. 4, July-August 1999 “The Role of Equivalence Ratio Oscillations in Driving Combustion Instabilities In Low NOx Gas Turbines” Conference Presentation- 27th Symposium (International) On Combustion, Boulder, CO “Active Control of Combustion Instabilities of Low Nox Gas Turbines” Poster Presentation

SR032

Principal Investigator: Robert J. Santoro Project Title: “ Combustion Instability Studies for Application In Low Emissions,

High Performance Land-Based Gas Turbine Combustor” Publications: “ An Experimental Study Of Combustion Dynamics of Premixed

Swirl Injector” Conference Presentation-27th International Symposium on Combustion, August 1998 “Combustion Instability Studies for Application to Land-Based Gas Turbine Combustors” Poster Presentation

SR033

Principal Investigator: Ramendra Roy Project Title: “Flow and Heat Transfer in Gas Turbine disk Cavities subject to Non-

Uniform External Pressure Field” Publications: R.P. Roy, S. Devasenathipathy, G. Xu, and Y. Zhao, "A Study of the

Flow Field in a Model Rotor-Stator Cavity," Paper 99-GT-246, Indianapolis, IN.

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R.P. Roy, G. Xu, and J. Feng, "Study of Mainstream Gas Ingestion in a Rotor-Stator Disk Cavity," Paper AIAA-2000-3372, Huntsville, AL. R.P. Roy, G. Xu, and J. Feng, "A Study of Convective Heat Transfer in a Rotor-Stator Cavity,"ASME Journal of Turbomachinery, Vol. 123, pp. 621-632. R.P. Roy, G. Xu, J. Feng, and S. Kang, "Pressure Field and Mainstream Gas Ingestion in a Rotor-Stator Disk Cavity," Paper 2001-GT-0564, New Orleans, LA.

SR034

Principal Investigator: Joseph Gaddis Project Title: “Innovative Schemes for Closed-Loop Air/Stream Cooling of Advanced

Gas Turbine Systems” Publications: “Mist/Steam Cooling in a Heated Horizontal Tube, Part

1:Development of the Experimental Program” Accepted for Publication on the ASME Journal of Turbomachinery, 2000 “Mist/Steam Cooling in a Heated Horizontal Tube, Part 2: Results Modeling” Accepted for Publication on the ASME Journal of Turbomachinery, 2000. Mist/Steam Cooling in 180 degree Tube Bend” Accepted for Publication in the ASME Journal of Heat Transfer, 2000. “Modeling of Heat Transfer in a Mist/Steam Impingement Jet” ASME Paper NHTC2000-12044, to be presented at the National Heat Transfer Conference, 2000 “Mist/Steam Heat Transfer of Confined Slot Jet Impingement” ASME Paper 2000-GT-221, Presented at the ASME Turbo 2000, 1999. “Mist/Steam Cooling in 180 degree Bend” ASME Paper NHTC 99-196, Presented at the 1999 National Heat Transfer Conference, Albuquerque, August, 1999 “Mist/Steam Cooling in a Heated Horizontal Tube, Part 1: Development of the Experimental Program” ASME Paper 99-GT-144, Presented at the ASME Turbo Expo 99, Indianapolis, IN, June 1999. “Mist/Steam Cooling in a Heated Horizontal Tube, Part 2: Results and Modeling” ASME Paper 99-GT-145 Presented at the ASME Turbo Expo 99, Indianapolis, IN, June 1999. "Modeling of Heat Transfer in a Mist/Steam Impinging Jet" X. Li, J. L. Gaddis, and T. Wang. ASME Journal of Heat Transfer, Vol 123, 6, pp 1086-1092, 2001. Mist/Steam Heat Transfer of Confined Slot Jet Impingement” ASME Paper 2000-GT-221, Presented at the ASME Turbo 2000, 1999. "Mist/Steam Heat Transfer in Confined Slot Jet Impingement" X. Li, J. L. Gaddis, T. Wang. J. Turbomachin. 123,1,pp161-167.(2001)

SR035

Principal Investigator: Amir Faghri Project Title: “Heat Pipe Turbine Vane Cooling” Publications: NA

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SR036

Principal Investigator: Bud Lakshminarayana Project Title: “Improved Modeling Techniques for Turbomachinery Flow Fields” Publications: “Steady and Unsteady three-dimensional Flow Field Downstream of

an Embedded Stator in a Multistage Axial Flow Compressor, Part 1: Unsteady Velocity Field” Conference Presentation-ASME International Gas Turbine and Aeroengine Congress an Exhibition, Stockholm, Sweden, June 1998 “Steady and unsteady three-dimensional Flow Field Downstream of an Embedded Stator in a Multistage Axial Flow Compressor, Part 2: Composite Flow Field” Conference Presentation-ASME International Gas Turbine and Aeroengine Congress an Exhibition, Stockholm, Sweden, June 1998 “Steady and unsteady three-dimensional Flow Field Downstream of an Embedded Stator in a Multistage Axial Flow Compressor, Part 3: Deterministic Stress and Heat-Flux Distribution and Average Passage Equation System” Conference Presentation-ASME International Gas Turbine and Aeroengine Congress an Exhibition, Stockholm, Sweden, June 1998 “Aerodynamic Modeling of Multistage Compressor Flowfields- Part 1: Analysis of Rotor/Stator/Rotor Aerodynamic Interaction” Published Proceedings of Institute of Mechanical Engineering, Vol. 212 Part G. “Aerodynamic Modeling of Multistage Compressor Flowfields- Part 2: Modeling Deterministic Stresses” Published Proceedings of Institute of Mechanical Engineering, Vol. 212 Part G. “Improving Modeling Techniques for Turbomachinery Flow Fields” Poster Session

SR037

Principal Investigator: Thong Dang Project Title: “Development of Advanced three-dimensional and Viscous

Aerodynamic design method for Turbomachine Components in Utility and Industral Gas Turbine Applications”

Publications: “Practical use 3D Inverse Viscous Method for Design of Compressor Balding” Conference Presentation-- 1998 ASME IGTI Gas Turbine Conference (Abstract) Journal of Turbomachinery, Vol. 121 April 1999

SR038

Principal Investigator: Gerald Guenette Project Title: “The Effects of Rotation on the Fluid Mechanics of Turbine Blade

Cooling” Publications: NA

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SR039

Principal Investigator: Vimal Desai Project Title: “ Compatibility of Gas Turbine Materials with Steam Cooling” Publications: NA

SR042

Principal Investigator: Kang Lee Project Title: “Development of Refractory Oxide and Glass Ceramic-YSZ Dual

Layer TBC Top Coats for Advanced Land Based Gas Turbines” Publications: C. Ramachandra, K. N. Lee and S. N. Tewari, “Durability of TBCs

with a Surface Environmental Barrier Layer under Thermal Cycling in Air and in Molten Salt, (to be published in Surface and Coatings Technology, 2003). Y. He, K. N. Lee, R. A. Miller and S. Tewari, "Development of Refractory Silicate-YSZ Dual Layer TBC's," NASA/TM-1999-209079 (1999); J. Thermal Spray technology, 9 [1] 59-67 (2000). “Development of Refractory Oxide and Glass Ceramic-YSZ Duel Layer TBC’s”Oral Presentation, TMS Conference (Fall, 1999)

SR043

Principal Investigator: Karen Thole & D. Bogard Project Title: “Detailed Flow and Thermal Field Measurements on a Scaled-Up

Stator Vane” Publications: “High Freestream Turbulence Simulation in a Scaled-Up Turbine

Vane Passage” 97-GT-51 “Heat Transfer and Flowfield Measurements in the Leading Edge Region of a Stator Vane Endwall” Journal of Turbomachinery, Vol. 121 No. 3, Pp. 558-568 “Effects of High Freestream Turbulence Levels and Length Scales on Stator Vane Heat Transfer” 98-GT-236 “Flowfield Measurements for a Highly Turbulent Flow in a Stator Vane Passage” Journal of Turbomachinery, Vol. 122 pp. 255-262 (also presented as ASME Paper 99-GT-253) “Flowfield Measurements in the Endwall Region of a Stator Vane” Journal of Turbomachinerey, Vol. 122, pp. 458-466 (98-GT-188) “High Freestream Turbulence Effects in the Endwall Leading Edge Region” Journal of Turbomachinery, Vol. 122, pp. 699-708 (2000-GT-201) “Measurements and Predictions of a Highly Turbulent Flowfield in a Turbine Vane Passage” Journal of Fluids Engineering, Vol. 122. Pp.666-676 “High Freestream Turbulent Effects on Turbine Vane Boundary Layer Development” ASME Paper 2001-GT-0404 (Recommended by reveiwers for the Journal of Turbomachinery)

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“Film Cooling Effectiveness in the Showerhead Region of a Gas Turbine Vane Part 1: Stagnation Region and Near Pressure Side” 99-GT-048 “Film Cooling Effectiveness in the Showerhead Region of a Gas Turbine Vane Part2: Stagnation Region and Near Suction Side” 99-GT-049 “Effects of Showerhead Injection on Film Cooling Effectiveness for a Downstream row of Holes”, 2000-GT-240 Scaling of Performance for Varying Density Ratio Coolants on an Airfoil with Strong Curvature and Pressure Gradients”, Accepted to the Journal of Turbomachinery (2000-GT-239) “Effects of Showerhead Cooling on Turbine Vane Suction Side Film Cooling Effectiveness” Accepted for Presentation at the ASME 2000 IMECE, 2000. “Three component Velocity field measurements in the stagnation region ofa film cooled turbine vane” Submitted to ASME Gas Turbine and Aeroengine Congress, 2001. “Thermal Field and Flow Visualization within the stagnation region of a film cooled turbine vane” Submitted to ASME Gas Turbine and Aeroengine Congress, 2001. Thesis & Dissertations: “The SUDI Turbulence Generator-A Method to Generate High Freestream Turbulence levels and a range of Length Scales” Dimplomarbeit, Mechanical Engineering Department, University of Wisconsin. “Development and Testing of a Scaled up Turbine Vane Cascade” M.S. Thesis, Mechanical Engineering Department, University of Wisconsin. “Detailed Measurements in the endwall region of a Gas Turbine Stator Vane” M.S. Thesis, Mechanical Engineering Department, University of Wisconsin. “High Freesttream Turbulence Studies on a Scaled-Up Stator Vane” Ph.D. Dissertation, Mechanical Engineering Department, University of Wisconsin.

“Detailed Film Cooing Effectiveness and Three Component Velocity Field Measurements in a First Stage Turbine Vane Subject to High Mainstream Turbulence” Ph.D. Dissertation, The University of Texas at Austin

“Film Cooling Effectiveness in the Showerhead Region of a Gas Turbine Stator Vane under High Mainstream Turbulence” MS Thesis, The University of Texas at Austin

“Suction Side Film Cooling of a First Stage Gas Turbine Vane” MS Thesis The University of Texas at Austin

“Turbulence and three-dimensional Effects on a Film Cooled Turbine Vane” Ph.D. Dissertation, The University of Texas at Austin

SR044

Principal Investigator: Jay Gore Project Title: “ Miniature Infrared Emission Based Temperature Sensor and Light-

Off Detector” Publications: “Laminar Flamelet Calculations of Piloted Jet Diffusion Flame”

Conference Presentation “Miniature Infrared Emission Based Temperature Sensor and Light-Off Detector” Poster Presentation

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SR045

Principal Investigator: Choos S. Tan Project Title: “Impact of Endwall Flow and Wakes on Multistage Compressor

Performance and Design” Publications: “Effect of Upstream Unsteady Flow Conditions on Rotor Tip Leakage

Flow” (Abstract)-MIT Gas Turbine Laboratory, Cambridge Massachusetts.

SR046

Principal Investigator: Fredrick Pettit & Gerald Meier Project Title: “Chemical and Mechanical Instabilities at Thermal Barrier Coating

Interfaces” Publications: “Mechanisms for Failure of Electron beam Physical Vapor Deposited

Coatings Induced by High Temperature Oxidation”, in Elevated Temperature Coatings” TMS, 1999, p.51. “Thermal Barrier Coatings for 21st Century” Metallkunde, 90,1069 (1999). “The Effects of High Temperature Exposure on Durability of Thermal Barrier Coatings” Key Engineering Material, 197,145 (2001) “Measurement of Interfacial Toughness in Thermal Barrier Coating Systems By Indention” Accepted to Engineering Fracture Mechanics “Mechanisms for Interfacial Toughness Loss in Thermal Barrier Coating Systems” Key Engineering Materials, 197,165 (2001). “The Effects of Oxidation on Thermal Barrier Coating Failures” Proc. International Metallurgy and Materials Congress, May 2001, Istanbul, Turkey, Vol. II, p.711. “Processing Effects on the Failure of EBPVD TBC’s on McrA1Y and Platinum Aluminide bond Coats”, in Super alloys 2000, TMS, 2000. P.621. “Accelerated Durability Testing of Coatings For Gas Turbines” Elevated Temperature Coatings: Science and Technology IV”, TMS, 2001, P.1

SR047

Principal Investigator: Katherine Faber Project Title: “SPPS for Advanced Thermal Barrier Coatings” June1997-June 2001 Publications: “Small Particle Plasma Spray Apparatus, Method and Coated Article”

Patents Issued Patent # 5,744,777(1998) and 5,858,470 (1999) “Microstructural Characterization of Small Particle Plasma Spray Coatings” J. Am. Ceramic Society, 82 [8] 2204-208-1999 The Role of NZP Additions in Plasma-Sprayed YSZ: Microstructure, Thermal Conductivity and Phase Stability Effects” Material Science Engineering A, A272, 284-91, 1999

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The Dissociation of NZP during Plasma Spraying” Scripta Materialia, 42, 855-60, 2000 Deformation Mechanism in Compression Loaded stand-alone Plasma-Sprayed Coatings” J. Am. Ceramic Society, 83 [12] 3057-64, 2000 “Comparative Study of TEM Sample Preparation Techniques for Plasma Sprayed Ceramic Coatings” Bol. Soc. Esp.Ceramic Vidrio, 39 [6] 735-40, 2000 “Thermal Conductivity and Phase Evolution of Plasma-Sprayed Multilayer Coatings” Journal Material Science,36 3511-18, 2001 “The Role of Starting Powder size on the Compressive Response of stand-alone Plasma-Sprayed Coatings” Journal Material Science, 37 [3] 629-36, 2002 “In-Situ Characterization of Small Particle Plasma-Sprayed Powders” Journal of Thermal Spray Technology, In Press “Effects of Heat-Treatment on Phase Stability, Microstructure, and Thermal Conductivity of Plasma-Sprayed YSZ” Journal Material Science, In Press ‘Yttrium-Aluminum-Garnet Oxygen Barriers in Zirconia-Based Thermal Barrier Systems” J. American Ceramic Society “The Effects of Spraying Parameters on the Sub-micron pores and Microcracks in Plasma-Sprayed YSZ Coatings as Revealed by Small-Angle X-ray Scattering” In Preparation

Presentations: “The Effect of Processing Parameters on Properties of Zirconia

Thermal Barrier Coatings Fabricated using Small Particle Plasma Technology,” 100th Annual Meeting of American Ceramic Society, Cincinnati, OH, May 5,1998

“Processing and Characterization of A12O3/YSZ Multi-Layer Coatings made by small Particle Plasma Spray” 100th Annual Meeting of American Ceramic Society, Cincinnati, OH, May 5,1998

“The Effect of Processing Parameters on Properties of Zirconia Coatings Fabricated using Small Particle Plasma Spray” ASM International Materials Solutions Conference, Rosemont, IL October 12, 1998

“Statistical Design on Experiments of A12O3/YSZ Multilayer Coating made by small Particle Plasma Spray” ASM International Materials Solutions Conference, Rosemont, IL October 14, 1998

“The Role of Particle Substrate Interaction on the Roughness of Small particle Plasma-spray Coatings” Fall Meeting of Basic Science Division of the American Ceramic Society” Irvine, CA, October 23, 1998

“Small Particle Plasma-Sprayed Coatings for Corrosion on Thermal Protection” Material Science and Engineering Colloquium, Lehigh University, Bethlehem, PA, April 6, 1999

“Small Particle Plasma Sprayed Yttria-Stabilized Coatings with Zirconium Phosphate Additions” 101st Annual Meeting of the American Ceramic Society, Indianapolis, IN April 26,1999

“Thermal Conductivity and Microstructural Stability of Microlaminate Plasma Spayed Coatings” 101st Annual Meeting of the American Ceramic Society, Indianapolis, IN April 26, 1999

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“The Relationship between Spray Parameters, Splat Geometry, and Properties of Zirconia Thermal Barrier Coatings” 101st Annual Meeting of the American Ceramic Society, Indianapolis, IN April 26,1999 “Mechanical Properties of Small Particle Plasma Spray Coatings” ASM International Thermal Spray Symposium, Cincinnati, OH, November 1, 1999 “Thermal and Microstructural Characterization of YSZ-Based Microlaminate Thermal Barrier Coatings” ASM International Thermal Spray Symposium, Cincinnati, OH, November 3, 1999 “The Effects of Spray Parameters on the Splat Morphology, Porosity and Properties of Zirconia Thermal Barrier Coatings” ASM International Thermal Spray Symposium, Cincinnati, OH, November 3, 1999 “Small-Particle Plasma Spray Coatings for Thermal Barriers and Corrosion Protection and Damage Mechanism in Plasma Sprayed Alumina Coatings” Undergraduate and Graduate Seminars, Alfred University, March 16, 2000 “Oxidation and Thermal Resistance of Plasma-Sprayed YAG-YSZ Coatings” Annual Meeting of American Ceramic Society, St. Louis, MO, May 2, 2000 ‘Compressive Loading of stand-alone Plasma Sprayed Alumina Coatings: Deformation Mechanisms and Lamella side Effects” Annual Meeting of the American Ceramic Society, St. Louis MO, May 2, 2000 “The Effects of Spraying Conditions on the Porosity in Zirconia Thermal Barrier Coatings” Annual Meeting of the American Ceramic Society, St. Louis MO, May 3, 2000 “Microscopy Investigation of Plasma Sprayed NZP( Ca0.5Sr0.5Zr4P6O24)” Annual meeting of the American Ceramic Society, St. Louis MO, May 3, 2000 “Damage Mechanism in Plasma-Sprayed Alumina Coatings” ASME Annual Meeting, Orlando, FL, November 8, 2000 “Damage Mechanism in Plasma-Sprayed Alumina Coatings” Materials Science and Engineering Colloquium, The Ohio State University, February 9,2001 “The Role of Starting Powder Size on the Compressive Response of Stand- Alone Plasma Sprayed Alumina Coatings” Annual Meeting of the American Ceramic Society, Indianapolis, IN, April 23, 20001 “In-Situ Characterization of Small-Particle Plasma Sprayed Powders” Annual Meeting of the American Ceramic Society, Indianapolis, IN, April 23, 2001 ‘Oxidation Behavior of Plasma-Sprayed YAG/YSZ Coatings” Annual Meeting of the American Ceramic Society, Indianapolis IN, April 23, 2001 “Effects of Heat Treatment on Phase Stability, Lamella and Grain Morphology and Thermal Conductivity on Plasma Sprayed YSZ” Annual Meeting of American Ceramic Society, Indianapolis, IN, April 24, 2001 “Multilayer Thermal Barrier Coatings for Enhanced Oxidation Resistance” Fall Meeting of the Canadian Ceramic Society, Toronto, Canada, September 24,2001 “Plasma-Sprayed YAG/YSZ Coatings” ASM International Materials Solutions Conference, Indianapolis, IN, November 7, 2001 “Small Particle Plasma Spray Coatings for Thermal Barriers” Section of ASM International, Skokie, IL, January 8, 2002

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SR048

Principal Investigator: Vincent Capece Project Title: “An Experimental Investigation of the Three Dimensional Flow in the

Clearance Region of Cantilevered Stator Vanes with and Without Hub Rotation” Publications: NA

SR049 Principal Investigator: Stephen B. Pope Project Title: “Development and Implementation of Accurate and Efficient

Combustion for Gas Turbine Combustor Simulations” Publications: “ In Situ Detailed Chemistry Calculations Combustor Flow Analysis”

Conference Presentation-1999 ASME/IGTO Turbo Expo Indianapolis, IN. “An Investigation of the Accuracy of Manifold Methods and Splitting Schemes in the Computational Implementation of Combustion Chemistry” Journal Publication-Combustion and Flame “PDF Calculations of Piloted-Jet Turbulent Flames of Methane/Air Flames” Conference Presentation-28th Combustion Symposium “PDF Calculations of Turbulent Non premixed Flames with Local Extinction” Journal Publication- Combustion and Flame, December 2000

SR050

Principal Investigator: Domenic Santavicca Project Title: “Sensors For Measuring Primary Zone Equivalence Ratio In Lean

Premixed Combustors” November 2000 Publications: N/A

SR062

Principal Investigator: Scott Samuelsen Project Title: “Mechanistic Study of Fuel State and Composition Effects

In Natural-Gas Fired Gas Turbine Combustion” Publications: “Impact of Ethane and Propane Variation in Natural Gas on

The performance of a Model Gas Turbine Combustor”2001 Turbo Expo 2002 Response of a Model Gas Turbine Combustor to Variation in Gaseous Fuel Composition 2001 Vol. 123, No. 4,ASME J. Eng. Gas Turbines and Power, Pp.824-831, Paper 00-GT-0141, Presented at Turbo Expo 2000 “Rapid Liquid Fuel Mixing for Lean Burning Combustors: Low Power Performance 2001. ASME Gas Turbines and Power, Vol.123 Pp. 574-579 Paper 00-GT-0116, Presented at Turbo Expo 2000

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“Active Optimization of the Performance of Gas Turbine Combustor” 2000 RTO Symposium on Active Control Technology for Enhanced Performance Operational Capabilities of Military Aircraft, Land Vehicles and Sea Vehicles Braunschweig, Germany, May8-11 “Active Optimization of Model Gas Turbine Combustor”2000 Presented at the Spring 2000 Meeting of the Western States Section, The Combustion Institute, WSS/CI OOS-41 “Effect of Fuel Composition on the Performance of a Model Gas Turbine Combustor” 1999 Presented at the Fall 1999 Meeting of Western States Section, The Combustion Institute, WSS/CI 99F-69

SR063 Principal Investigator: Fred Culick Project Title: “Nonuniformities of Mixture Ratio as a Mechanism of Combustion

Instabilities in Lean Pre-mixed Combustors” March 1998-June 2001 Publications: Dynamics of Combustion Systems: Fundamentals, Acoustics, and

Control- 1st Version of Course was completed on June 1999, In Revised form the course was given in September 2001 at the NASA Glenn Research Center. Access to the viewgraphs posted on the web can be had upon request: fecfly@caltech.edu.

SR064

Principal Investigator: Satish Raymadhyani Project Title: “Airfoil Trailing Edge Cooling” Publications: NA

SR065 Principal Investigator: Uri Vandsburger Project Title: “Development of Modular Reduced Order Models for Prediction of

Combustion Instabilities” Publications: “Experimental Validation of one-dimensional Acoustic Modeling

Techniques for Gas Turbine Combustors,” submitted to Journal of the Acoustic Society of America (JASA), July 2001. “Measurement of Dynamic Flame Response in a Lean Premixed Single Can Combustor,” Paper 2001-GT-38 of the International Gas Turbine & Aeroengine Congress, New Orleans, LA, June 4-7 “Control of Combustor Instabilities using an Artificial Neural Network,” Paper No. 2000-GT-0529, Proceedings the ASME Turbo Expo, Munich, Germany May, 2000

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“An Examination of the Relationship Between Chemiluminescent light Emissions and Heat Release Rate under Non-Adiabatic Conditions,” Proceedings of ASME Turbo Expo, Paper No. 2000-GT-0121, Munich, Germany, May, 2000 Part I: Laminar Premixed Flame,” Proceedings of the American Flame Research Committee International Symposium, Newport Beach, CA September 2000: Presentation Part II: Effects of Fuel Composition,” 2nd Joint US sections of Combustion Institute Meeting, Oakland, CA, March 2001:Presentation “An Experimental Examination of the Relationship between Chemiluminescent Light Emission and Heat Release rate Under Non-Adiabatic Conditions,” Proceedings of the RTO/AVT Symposium, Braunschweig, Germany, May 2000. “Diagnostics and Modeling of Acoustic Signatures in a Tube Combustor,” accepted for publication in the Proceedings of the 6th Int. Cong. Of Sound and Vibration, Copenhagen, Denmark, July, 1999

SR066

Principal Investigator: Janet Hampikian Project Title: “Improvements in Thermal Barrier Coating Durability Via Combustion

Chemical Vapor Deposition” Publications: “The Combustion Chemical Vapor Deposition of High Temperature

Materials” Materials Science and Engineering A, A267,7-18, (1999). “Mechanical Properties of YSZ-Alumina Thin Films Deposited via Combustion CVD” In Elevated Temperature Coatings: Science and Technology III, Feb. 28-March 4, 1999 Pp. 161-172, TMS (1999) “The Effect of Alumina Coatings on Oxidation Behavior of Nickel-base Alloys” M.S. Thesis in Materials Science and Engineering, Georgia Institute of Technology, May 1998 “Nannoindentation of YSZ-Alumina Ceramic thin Film grown by Combustion Chemical Vapor Deposition” Ph.D. thesis in Materials Science and Engineering, Georgia Institute of Technology, May 2000. Combustion Chemical Vapor Deposition of Alumina, YSZ, and Multilayer Alumina/YSZ Films” M.S. Thesis in Materials Science and Engineering, Georgia Institute of Technology, May 2001. “Flame Structure Effects on the Deposition of Alumina Via Combustion CVD” M.S. Thesis in Materials Science and Engineering, Georgia Institute of Technology, December, 2002

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SR067

Principal Investigator: Vimal Desai Project Title: “Non-Destructive Evaluation and Monitoring of TBC by

Electrochemical Impedance Spectroscopy” Publications: NA

SR068

Principal Investigator: Anthony Evans Project Title: “A Mechanism-Based Approach to life Prediction and Non-Destructive

Evaluation for Thermal Barrier Coatings” Publications: “The influence of imperfections on the Nucleation and Propagation of

buckling driven Delaminations” Journal of the Mechanics and Physics of Solids 48 (2000) 709-734 “Micromechanics Model for the Detachment of Residually Compressed Brittle Films and Coatings” Acta Mater, Vol. 47, No. 5, Pp. 1513-1522, 1999 “The Ratcheting of Compressed Thermally Grown Thin Films on Ductile Substrates” Acta mater, 48 (2000) 2593-2601 “Mechanics-based scaling laws for the durability of thermal barrier coatings” Progress in Materials Science 46 (2001) 249-271 “Mechanisms Controlling the Durability of Thermal Barrier Coatings” Progress in Materials Science 46 (2001) 505-553 “Precursor to TBC Failure Caused by Constrained Phase Transformation in the Thermally Grown Oxide” Journal Publication-The Minerals and Materials Society, 1999 Microstructural study of the theta-alpha transformation in Alumina scales formed on Nickel-aluminides” Materials at High Temperatures 17 (1) 59-70 “Spalling Failure of a Thermal Barrier Coating Associated with Aluminum Depletion in the Bond-Coat” Acta Mater, Vol. 47 No.4, Pp. 1297-1305, 1999 “Surfacing Rumping of a (Ni, Pt) A1 Bond Coat induced by Cycle Oxidation” Acta Mater, 48 (2000) Pp. 3283-3293 “Piezospectroscopic Analysis of Interface Debonding in Thermal Barrier Coatings” Journal Publication- J. Am. Ceramic Society 83 (5) Pp. 1165-70 (2000) “Evolution of Porosity and Texture in Thermal Barrier Coatings Grown by EB-PVD” Journal Publication- The Minerals, Metals and Materials Society, 1999, Pp. 13-26.

SR069

Principal Investigator: Sanford Fleeter Project Title: “Turbine Blade Tip, Endwall and Platform Heat Transfer Including

Rotation Effects” Publications: NA

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SR70/088

Principal Investigator: Minking Chyu Project Title: “ Experimental and Computational Studies of the Nozzle Endwall

Region of Advanced Gas Turbines” Publications: “Film Cooling Experiments with Flow Introduced Upstream of a First

Stage Nozzle Guide Vane through Slots of Various Geometries” Submitted for Presentation at the 2002 ASME IGTI Conference. “Measurements Over a Film-Cooled, Contoured Endwall with Various Coolant Injection Rates” Submitted for Presentation at the 2001 ASME IGTI Conference.

SR071

Principal Investigator: Richard Goldstein Project Title: “ Edge Cooling Heat Transfer on Turbine Blades” Publications: “Effects of Tip Geometry and Tip Clearance on the Mass/Heat

Transfer From a Large Scale Gas Turbine Blade” Presentation at the 2002 ASME IGTI Conference “Local Mass/Heat Transfer on Turbine Blade Near-Tip Surfaces” Presentation at the 2002 ASME IGTI Conference

SR073

Principal Investigator: Eric Jordan Project Title: “Development of Laser Fluorescence as a Non-Destructive Inspection

Technique for Thermal Barrier Coatings” Publications: “Surface Geometry and Strain Energy Effects in the Failure of Ni

(Pt,A1)/EB-PVD Thermal Barrier Coatings” To be Published in ACTA Materialia “Failure Mechanisms of Dense Vertically Cracked Thermal Barrier Coatings” and Damaged Evolution in an Electron Beam Physical Vapor Deposited Thermal Barrier Coatings as a Function of Cycle Temperature and Time” Journal Publication “Photoluminescence Piezospectroscopy: A Multi-Purpose Quality Control And NDI Technique For Thermal Barrier Coatings” Journal Publication

SR074 Principal Investigator: Robert Dibble Project Title: “Fuel-Air Mixing Explored with optical Probes, Tomography and

Large Eddy Simulations” Publications: NA

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SR075 Principal Investigator: Ben Zinn Project Title: “Extending the Lean Blowout Limits of Low Nox Gas Turbines by

Control of Combustion Instabilities” Publications: NA

SR076

Principal Investigator: B.K. Hodge Project Title: “Real Surface Effects on Turbine Heat Transfer Publications: “Predicting Skin Friction and Heat Transfer for Turbulent Flow over

Real Gas -Turbine Surface Roughness using the Discrete-Element Method” Submitted for Presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003 and possible journal publication. “Real Surfaces Effects on Turbine Heat Transfer and Aerodynamic Performance” Submitted for presentation at the 6th ASME-JSME Thermal Engineering Joint Conference and possible journal publication. “St and cf Augmentation for Real Turbine Roughness with Elevated Freestream Turbulence” Submitted for presentation at 2002 ASME IGTI Conference and possible journal publication. “The many Faces of Turbine Surface Roughness” Submitted for presentation at the June 2001 IGTI Conference and also for Publication in the ASME journals. “Predicting Skin friction for Turbulent Flow Over Random Rough Surfaces using the discrete-element Method: Part I-Surface Characterization” Submitted for publication and conference presentation. “Predicting Skin Friction for Turbulent Flow over Randomly-Rough surfaces using discrete-element Method: Part II-Skin friction Validation” Paper GT-2003-45411, Proceedings of FEDSM’03, 4th ASME-JSME Joint Fluids Engineering Conference, 6-11 July, Honolulu, HI.

SR077

Principal Investigator: Fred S. Pettit Project Title: “Interaction of Stream/Air Mixtures with Turbine Airfoil Alloys and

Coatings” Publications: “Water Vapor Effects on the Cyclic Oxidation Resistance of Alumina-

Forming Alloy’s, Proceeding of Microcoscopy of Oxidation V, In Press.

SR078

Principal Investigator: Robert J. Santoro Project Title: “Dual Fuel Issues Related to Performance, Emissions and Combustion

Instability in Gas Turbine Systems”

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Publications: “Combustion Instability studies in a high-pressure lean Premixed Model Combustor Under Liquid Fuel Operation” Conference Presentation -JPGC ’01 June 4-7, 2001-New Orleans, LO.

SR079

Principal Investigator: Bud Lakshminarayana Project Title: “Turbine Tip Clearance Region Desensitization” Publications: “Aerodynamics Character of Partial Squealer Tip Arrangements in an

Axial Flow Turbine , Part 1, Part 2, and Part 3” Submitted for Presentation at the 2002 ASME IGTI Conference and possible journal publication. “Methods for Desensitizing Tip Clearance Effects in Turbines” Presentation at the 2001 ASME IGTI Conference. “Variable Property and Temperature Ratio Effects on Nusselt Numbers in a Rectangular Channel with 45 degrees Angled Rib Turbulators” Submitted for possible journal publication. “Tips Leakage Flows Near Partial Squealer Rims in an Axial Flow Turbine Stage” Submitted for Conference Presentation “Flow and Heat Transfer in Internally Ribbed Ducts with Rotation: An Assessment of LES and URANS” Submitted for Publication “Heat/Mass Transfer in 1:4 Rectangular Passages with Rotation” Submitted for Publication

SR080

Principal Investigator: Jay Kapat Project Title: “Tip Clearance Heat Transfer and Desensitization in high pressure

Turbines” Publications: NA

SR081

Principal Investigator: Nitin Padture Project Title: “Advanced Thermal Barrier Coating for Industrial Gas Turbine

Engines” Publications: "Low Thermal Conductivity Rare-Earth Zirconates for Potential

Thermal-Barrier-Coatings Applications" J. Wu, X. Wei, N.P. Padture , P.G. Klemens, M. Gell, E. Garcia, P. Miranzo and M.I. Osendi Journal of the American Ceramic Society , 85 [12] 3031-3035 (2002). "Thermal Conductivity of Ceramics in the ZrO2 -GdO 1.5 System" J. Wu, N.P. Padture , P.G. Klemens, M. Gell, E. Garcia, P. Miranzo and M.I. Osendi, Journal of Materials Research, 17 [12] 3193-3200 (2002).

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"Thermal Barrier Coatings for Gas-Turbnie Engine Applications" N.P. Padture, M. Gell and E.H. Jordan Science, 296 [5566] 280-284 (2002). “High Temperature Chemical Stability of Low Thermal Conductivity ZrO2-GdO1.5 Thermal-Barrier Beramics in Contact with cx-Al2O3” Journal Publication “Photoluminescence Piezospectroscopy: A Multi-Purpose Quality Control And NDI Technique For Thermal Barrier Coatings” Journal Publication

SR082

Principal Investigator: J.C Han Project Title: “Rotating and Stationary Rectangular cooling Passages Heat Transfer

and Friction and Turbulators and Dimples” Publications: “Nusselt Number Behavior on deep Dimpled Surfaces within a

Channel” Presented at 2002 IMECE, November 17-22, 2002, New Orleans, LO. “Effect of Rotation on Heat Transfer in Narrow rectangular Cooling Channels (AR=8:1 and 4:1) with Pin-Fins” Submitted for Presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003. “Variable Property Nusselt Numbers in a Channel with Pin-Fins” Submitted for Possible journal publication. “Variable Property and Temperature Ratio Effects on Nusselt Numbers in a Rectangular Channel with 45 degree angled Rib Turbulators” Submitted for Possible Journal Publication “Flow Structure and Local Nusselt Number Variations in a Channel with Angled Rib Turbulators” Submitted for Possible Journal Publication “Heat Transfer in Rotating Rectangular Cooling Channels (AR=4) WITH Dimples” “A Numerical Study of Flow and Heat Transfer in Rotating Rectangular Channels (AR=4) with Rib Turbulators by Reynolds Stress Turbulence Model” ASME Turbo Expo 2002 June 3-6, 2002, Amsterdam, The Netherlands “Spatially-Resolved Heat Transfer and Flow Structure in a Rectangular Channel with 45 degree Angled Rib Turbulators” Presented at 2002 ASME IGTI Conference and possible journal publication. “Spatially-Resolved Heat Transfer and Flow Structure in a Rectangular Channel with Pin Fins” Submitted for presentation at the 2003 ASME Turbo Conference in Atlanta, GA. And possible journal publication. “Spatially-Resolved Surface Heat Transfer for Parallel Rib Turbulators with 45 degree Orientations Including Test Surface Conduction Analysis” Submitted for journal publication

SR083

Principal Investigator: Eric Sandgren Project Title: “Improved Performance and Durability in Gas Turbines through

Airfoil clocking and Hot streak Management” Publications: NA

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SR084

Principal Investigator: Scott Samuelsen Project Title: “Correlation of Ignition delay with Fuel Composition and State for

Application to Gas Turbine Combustion” Publications: NA

SR085 Principal Investigator: Jay Gore Project Title: “Measurements for Improved Understanding of Combustion Dynamics

in Lean Premixed Gas Turbine Combustor Flames” Publications: “Combustion Instabilities in an Advanced Turbine System Premixer”

AIAA 2001

SR086

Principal Investigator: Forrest Ames Project Title: “Characterization of Catalytic Combustor Turbulence and its influence

on Vane and Endwall Heat Transfer and Endwall Film Cooling” Publications: “Effects of Catalytic and Dry Low Nox Combustor Turbulence on

Endwall Heat Transfer Distributions” Submitted for Presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003 Possible journal publication “Measurements and Prediction of the Influence of Catalytic and Dry Low Nox Combustor Turbulence on Vane Surface Heat Transfer” “Effects of Aeroderivative Combustor Turbulence on Endwall Heat Transfer Distributions Acquired in a linear vane Cascade” Submitted for Presentation at the 2002 ASME IGTI Conference and Possible journal publication. “Measurement and Prediction of Heat Transfer Distributions on an Aft Loaded Vane subjected to the Influence of Catalytic and Dry Low Nox Combustor Turbulence” Submitted for presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003 and possible journal publication.

SR087

Principal Investigator: Philip Malte Project Title: “The Staged Prevaporizing Premixing Injector: High Pressure

Evaluation” Publications: NA

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SR089

Principal Investigator: Sumanta Acharya Project Title: “ Internal Cooling in leading and trailing edge passages with

Rotational and Buoyancy” Publications: “Large Eddy Simulations of Flow and Heat Transfer in a Ribbed

Coolant passage with Rotation and Buoyancy effects” In preparation. “LES of Flow and Heat transfer in a rotating ribbed Duct: Flow Physics” In preparation. “Aspects Ratio Effects in Rotating Ribbed Ducts” In preparation.

SR090

Principal Investigator: Domenic Santavicca Project Title: “ Optimization of the Injector Fuel Distribution for Stable, Low

Emissions Combustion in Lean Premixed Gas Turbine Combustors” Publications: NA

SR091

Principal Investigator: Maurie Gell Project Title: “Thermal Barrier Coatings and Metallic Coatings with Improved

Durability” Publications:” Failure Mechanisms of Dense Vertically Cracked Thermal Barrier

Coatings” and Damaged Evolution in an Electron Beam Physical Vapor Deposited Thermal Barrier Coatings as a Function of Cycle Temperature and Time” Journal Publication

“Photoluminescence Piezospectroscopy: A Multi-Purpose Quality Control and NDI Technique For Thermal Barrier Coatings” Journal Publication

SR092

Principal Investigator: David Bogard Project Title: “Attenuation of Hot Streaks with the Nozzle Guide Vane and Endwall” Publications: “Effects of Coolant Density ratio on Film Cooling Performance on a

Vane” Submitted for presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003. “The Effects of High Turbulence and Turbine Vane Film Cooling on the Dispersion of a Simulated Hot Streak” Submitted for Presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003. “Computational predictions of Endwall Film-Cooling for a First Stage Vane” Submitted for Presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003.

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“Effects of Hot Streaks on Adiabatic Effectiveness for a Film Cooled Turbine Vane” Submitted for approval fro conference presentation at IGTI 2004, Vienna. “The Effects of the Vane and Mainstream Turbulence Level on Hot Streak Attenuation” Submitted for approval fro Conference presentation at IGTI 2004, Vienna.

SR093

Principal Investigator: David R. Clarke Project Title: “A Science Based Approach to Enhanced Zirconia Based Coatings for

Advanced Gas Turbine Application” Publications: NA

SR094

Principal Investigator: J.C. Han Project Title: “Rotating Heat Transfer in High Aspect ratio Rectangular Cooling

Passages with Shaped Turbulators” Publications: “Computation of flow and Heat Transfer in Rotating Rectangular

Channels (AR=4) with V-Shaped Ribs by Reynolds Stress Turbulence Model” Submitted for presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003. “Heat Transfer and Pressure drop in Two-Pass Rotation of Rectangular Channel (AR=2) with Discrete angled Rib Turbulators” Submitted for presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003. “Heat Transfer in Rotating Rectangular Channels (AR=4:1) with V-shaped and angled Rib Turbulators with and without Gaps” Submitted for presentation at the 2003 ASME Turbo Conference in Atlanta, June 2003. “Thermal Performance of Angled, V-Shaped, and W-Shaped Rib Turbulators in Rotating, Rectangular (AR=4:1) Cooling Channels” Submitted for approval for presentation at the ASME Turbo Expo Conference, June 14-17, 2004, Vienna “Computation of Flow and Heat Transfer in Two-Pass Rotating Rectangular Channels (AR=1:1), (AR=1:2), (AR=1:4) with 45-Deg Angled Ribs by Reynolds Stress Turbulence Model” Submitted for approval for presentation at the ASME Turbo Expo Conference, June 14-17, 2004, Vienna “Heat Transfer in Two-Pass Rotating Rectangular Channels (AR=1:2 and AR= 1:4) with 45 degree Angled Rib Turbulators” Submitted for approval for presentation at the ASME Turbo Expo Conference, June 14-17, 2004, Vienna.

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Appendix N

BY-LAWS University Turbine Systems Research

Administered by

South Carolina Institute for Energy Studies at Clemson University

INITIAL ISSUE: March 23, 1993 (AGTSR) REVISED: September 18, 1996

July 1, 1998 (SCIES name change) June 15, 2000 October 30, 2002 (UTSR) October 28, 2003

1 .0 ORGANIZATION

The U.S. Department of Energy has established the Turbine Program aimed at developing gas turbine power generation systems with significantly improved thermodynamic and environmental performance. The Turbine Program includes university research into technology barrier issues facing the industry and an outreach activity to promote program growth, education and technology transfer. A consortium, University Turbine Systems Research (UTSR), has been established to administer the University research and outreach portion of the Turbine Program. The consortium is headquartered at the South Carolina Institute for Energy Studies (SCIES) at Clemson University. UTSR is "without walls," i.e.; it represents all university participants in the consortium. .0 PURPOSE 2

The UTSR consortium is charged with support of the DOE/NETL Turbine Program by conducting research on longer range technology development issues defined by industrial participants and to promote the Turbine Program via outreach. The goal is to remove the echnical barriers that may exist in areas such as (but not limited to): t

• Combustion and emissions; • Advanced cooling and heat transfer; • Aerodynamic designs and analysis; • High temperature materials and coatings;

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• System performance and evaluation; • Use of coal, coal derived and biomass fuels; • Manufacturing and technology; • Concurrent engineering; • Sensors and controls

3.0 MEMBERSHIP Membership and participation in the consortium will be in accordance with the following criteria: 3.1 GAS TURBINE MANUFACTURERS: Open to manufacturers of gas turbine turbomachinery supplied to the utility and/or industrial markets. The companies must perform at least 50% (determined on a dollar basis) of their gas turbine related R&D engineering in the U.S. and also must manufacture its products in the U.S. Gas turbine manufacturers are eligible for membership on the Industrial Review Board and may have voting privileges (see 4.0). 3.2 UNIVERSITIES: Open to all American colleges and universities with an accredited Engineering curriculum. Expertise and experience in the turbomachinery, high temperature materials, environmental compliance, or power generation field is required, as the program is geared to enhancing current capabilities, rather than developing new ones. Participating universities that have a statement of interest and qualifications on file with the UTSR will be referred to as the Performing Members, and will be eligible to receive RFP's issued by UTSR. Performing Members are not eligible for membership on the Industrial Review Board (see 4.0). 3.3 OTHER ORGANIZATIONS: These will be accommodated along the general guidelines listed below:

3.3.1 Architect Engineers: Can participate as a non-voting member of the IRB (see 4.1.2 below), as subcontractor to a Performing Member, or as member of Advisory Board (see 4.2 below).

3.3.2 Research Institutes: (see 3.3.1) 3.3.3 National and DOE Laboratories: (see 3.3.1) 3.3.4 Utility and Industrial Customers: (see 3.3.1) 3.3.5 Component suppliers and packagers: (see 3.3.1)

3.4 ELECTION TO MEMBERSHIP: Performing Member Universities are elected to UTSR membership by the UTSR Research Manager. All other memberships must be approved by the Industrial Review Board voting members (see 4.0).

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4.0 BOARDS

4.1 INDUSTRIAL REVIEW BOARD: The Industrial Review Board (IRB) guides the technical activities of the UTSR. Membership consists of the following:

Gas Turbine Manufacturers (electing voting membership) (note a.)

Associate Members (non-voting) (no membership limit) (note b.) EPRI and GRI Representatives (non-voting) 2 UTSR Principal Investigator (non-voting) 3 (may vary) and Program Managers

note a. Number of members may vary. note b. Includes architect engineers and utility and industrial customers.

The IRB will elect a Chairman of the Board (by majority vote of the IRB) to voice IRB opinion to the UTSR Principal Investigator and the DOE. 4.1.1 The EPRI and GTI representatives are ex-officio, do not pay a fee and do not have voting privileges. EPRI and GTI may elect Associate Member privileges.

4.1.2 An organization requesting Associate Membership must be nominated by the UTSR Principal Investigator, be approved by majority vote of the IRB, and receive DOE approval. Performing Members are not eligible for Associate Membership.

4.1.3. A quorum for the IRB to conduct business will consist of at least two-thirds of the voting members. IRB voting members may be represented at business meetings by phone or proxy vote. Board decisions will be based on two-thirds vote of IRB voting members. Tie votes, unless resolved by further discussion, will be deemed "No" votes.

4.2 ADVISORY BOARD: An Advisory Board of industry experts may be appointed by the IRB Chair as the need arises, to review progress, and obtain input on university research. Performing members and university subcontractors are not eligible for this Board. All Advisory Board members are non-voting.

4.3 MEETINGS: The IRB will meet at least annually, and more frequently as requested by the IRB Chair and UTSR Principal Investigator, to review proposals, conduct contract performance reviews, and review the overall UTSR program. Performing Members will not attend IRB meetings unless specifically requested.

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5.0 FUNDING

5.1 RESEARCH CONTRACTS: Funds for university research contracts are derived from the Cooperative Research and Development Agreement (CRADA) awarded to SCIES for UTSR, and from membership fees assessed the IRB members.

5.2 FELLOWSHIPS: The UTSR may award student Industrial Fellowships and Faculty Fellowships at the discretion of the IRB and NETL. The number of Fellowships to be awarded (in both categories) will be established at the annual IRB meeting as will the source of funding. 5.3 ADMINISTRATION: Administration costs for the Director's office are paid for under the CRADA.

5.4 FEES:

5.4.1 Voting Members: Voting IRB members are assessed $25,000 per year, to be paid prior to March 31.

5.4.2 Non-voting Associate Members: IRB members electing non-voting status will be assessed an annual fee of $7,500 to be paid prior to March 31. Non-voting members will receive the following: complimentary copies of all research progress and final reports, attendance for up to 5 staff members at voting member rates to all UTSR workshops, input to research ideas included in the RFP, non-voting voice on proposal review and IRB business meetings, and participation in the UTSR Gas Turbine Industrial Fellowship and Faculty Fellowship programs.

5.4.3 Performing Members: No fees will be assessed to the university participants.

5.4.4 Advisory Board: A nominal administration fee may be assessed at the discretion of the Chairman of the IRB with approval by the DOE.

5.4.5 Non-member UTSR companies may attend UTSR functions at a fee decided by UTSR.

5.5 USE OF RESEARCH FUNDS: It is the intent of the consortium to fund analysis and testing, but not to create new facilities. Performing Members will be made aware of each other's capabilities, and also of other available facilities. Costs of modifying and using existing facilities will be acceptable.

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6.0 STAFFING AND ADMINISTRATION

The UTSR will have minimal staff as required to effectively administer the UTSR cooperative agreement. Current SCIES personnel and Clemson students will supplement full-time UTSR staff. Total UTSR support staff will be approved by DOE.

6.1 Principal Investigator: The SCIES Director is UTSR Principal Investigator (PI) and responsible for all program functions including all interactions with the DOE. The PI may, at his discretion, delegate select program duties to the UTSR managers. The UTSR PI will attend IRB meetings but is a non-voting member of the Board.

6.2 MANAGER(S): The UTSR Research and Outreach Manager(s) will be selected from a nationwide search among experienced leaders in the gas turbine industry. Input from the IRB and DOE will be sought, with final approval by Clemson University. The UTSR Managers may attend IRB meetings, but are non-voting members.

6.3 ASSOCIATE MANAGER(S): Depending on the future size of the program and availability of funds, one or more Associate Managers may be added to help administer the UTSR. Associate Managers will also be recognized industry leaders. The Associate Managers may attend IRB meetings, but are non-voting members.

6.4 PUBLICATIONS: The UTSR will publish all research results presented at UTSR held workshops. The UTSR may also issue periodic newsletters and other DOE correspondence to members of the consortium to report on items of interest. Trade journal articles will be published as UTSR accomplishments are developed.

6.4 BUSINESS PRACTICES: All transactions among the members of the consortium will be conducted in accordance with the applicable statutes of Clemson University, the State of South Carolina, the Federal Acquisition Regulations, and other U.S. Government regulations.

7.0 RESEARCH CONTRACTS

7.1 REQUEST FOR PROPOSALS: The UTSR will issue broad-based RFP's to which the Performing Members will respond with specific proposals that address the areas of needed technology advancement. These areas will be identified by the IRB and be approved by DOE/NETL.

7.2 PROPOSALS: The Performing Members will be the lead organization for all proposals. Teams are strongly encouraged, and may include any of the parties identified in Membership, Paragraph 3.0.

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7.2.1 The parties must agree to abide by the contract terms and conditions that are passed through from DOE to UTSR, and hence to the Performing Members and their subcontractors.

7.3 AWARDS: Performing Member proposals will be reviewed and ranked by the IRB. Awards will be made within the available funding. It is the intent of the review process that an IRB consensus will be obtained on which proposals are recommended for award; however, if a vote is necessary, the voting members present will decide (see Paragraph 4.1.3). DOE must approve the awards prior to notification of the Performing Members.

7.4 REPORTS: Progress and topical reports, and conference paper presentations related to the work performed, will be in accordance with contract specifications.

7.5 INTELLECTUAL PROPERTY: It is the general intent of this program to have these rights remain with the Performing Members. Specifics will be defined in the contract language.

8.0 WORKSHOPS

The UTSR will schedule workshops based on the recommendations of the DOE and the IRB. It is anticipated that the Workshops will at least be held annually for program review, to review reporting, to develop program guidance, to develop topics for future investigation, and to provide a formal means of interacting with other land-based power system programs.

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Appendix O UTSR SUBCONTRACT FUNDING BY STATE

STATE

AMOUNT OF FUNDING

Arizona $328,645.00

California $2,755,767.97

Connecticut $1,037,144.75

Florida $690,663.00

Georgia $1,894,994.00

Illinois $495,011.00

Indiana $2,274,266.00

Louisiana $478,180.36

Massachusetts $585,236.66

Maryland $573,135.57

Michigan $318,421.57

Minnesota $1,270,270.00

Mississippi $311,000.00

New York $1,453,694.00

Ohio $313,680.00

Oklahoma $297,712.00

Pennsylvania $5,697,949.00

South Carolina $1,139,223.00

Tennessee $862,591.71

Texas $585,873.13

Utah $1,040,985.00

Virginia $1,074,894.01

Wisconsin $370,570.00

Wyoming $69,259.00

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