SWAGºÏ¼¯

To address the goals set for tackling international climate change, the power sector needs to decrease emissions, which account for ≈40% CO2 production. Gas turbines (GT) are expected to remain key asset for dispatchable power, and will need to decrease their emission, by using alternative fuels, and/or increase in efficiency. Additive manufacturing (AM) could help increase the efficiency of the GTs by enabling complex designs. AM has been used for static GT components, however the use for high pressure (HP) turbine blades and HP vanes is still immature. There is a need to understand the effect of AM processing conditions to the properties of the final materials, especially in non-conventional combustion environments.

Alternative fuels have a different chemical composition from natural gas, which would change depending on the production method used. These unique compositions would translate into different exhaust streams compositions and issues in managing high temperature corrosion. As such, understanding the impact of changes on materials could help increase the life of the components, the potential to reduce mining for critical minerals needed in component manufacturing, and cut pollution (linked to both the corrosion product and also the less efficient waste combustion with component uses related deformation).

This work aims to analyse the effects of different fuels’ chemical compositions (with particular attention to S, Cl, Na, K, Ca levels) on the degradation of novel AM alloys, with respect to AM printing parameters. The project will also be able to generate suggestions for the design of new alloys to be produced via additive manufacturing as well as advise on protective coatings. By the end of the project, the student will be able to estimate whether AM materials will be able to withstand these different environments better than or as well as components made by traditional materials.

SWAGºÏ¼¯ is a unique learning environment with world-class programmes, and close links with business, industry and governments, all combining to attract the best students and teaching staff from around the world. In the last Research Excellence Framework (REF) assessment, 81% of research at Cranfield was rated as world-leading or internationally excellent. ETN Global is a leading global organisation in the field of turbomachinery, with experience in managing and delivering EU/international projects, and lobbying to the EU commission. This PhD project will be part of a larger project on development and validation of AM materials for the use in rotating parts of GTs. The consortium brings together 12 turbomachinery stakeholders worldwide, including end-users, OEMs, service providers, and research centres.

It is anticipated that the new materials’ understanding and the model generated within the project will enable a faster uptake of AM materials for rotating components and help the development of new alloys. The implementation of AM materials for HP blades and vanes would increase the efficiency of GT, with a resulting decrease of CO2 released of 9,000 tons a year of (compared to medium size GT (55MW) running on natural gas). Currently there are thousands of GT installed, which means a CO2 decrease of the order of Mt a year. The participation to the Consortium will fast-track the impact of the goal, since it is composed by the different players in the GTs supply chain with a keen interest in using AM materials in GTs. Furthermore, the participation to ETN meetings and initiatives, will also help advocate towards achieving the final goal.

The PhD student will participate in meetings within the Consortium and present their findings to the partners. This will inform the development of the student’s project and allow them to network. The partners will also be able to offer the PhD student the opportunity of placements, during which the student can gain major insights. This would help them to understand the needs of the different players. ETN will also provide to the student opportunities to interact with companies within the network during the Annual General Meetings and the conferences organised by the organisation (International Gas Turbine Conference).

The placements will give them the chance to understand the importance of GTs in the generation of electricity but also start to have hands-on experience on GTs. ETN also provides the opportunity to network with several young engineers, through the Young Engineering Committee (YEC). In the last few years, the YEC has published report, delivered presentation to conference and drafted white papers for the EU, as such they would present their work to senior management of different companies (e.g., Uniper, Siemens-Energy, Baker Huges, Engie).