GE公司燃气涡轮发动机碳封严测试方法介绍
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– 13,500 rpm – 7,000 rpm 5512 ft/min (63 mph) 2858 ft/min
• • • • •
Loads 2 to 5 lbs (5.4 to 13.6 psi) Coating surface finish 4 & 8 µ-in Ra Carbon seal finish ~2 µ-in Ra Ambient oil temp 225 F Mil-L-7808 oil at about 0.025 gph per jet
Carbon Seal Team
• • • •
Aircraft Engine
GEAE – OEM Lead, Test Plan, Matls Engineering Diversitech – Mechanical Engineering Rexnord – Carbon Seal Mfg, Test Rig Design, Testing Others
2 Oil jets
wk.baidu.com
Aircraft Engine
High speed spindle
4 Carbon face seals
Housing
Four carbon seal cartridges 2 Oil drains
Rexnord Carbon Seal Test Rig
Aircraft Engine
Test Matrix (cont.)
Aircraft Engine
Test # X456- Set-up # Position # 33 9 1 34 9 2 35 9 3 36 9 4 37 10 1 38 10 2 39 10 3 40 10 4 41 11 1 42 11 2 43 11 3 44 11 4 45 12 1 46 12 2 47 12 3 48 12 4 49 13 1 50 13 2 51 13 3 52 13 4 53 14 1 54 14 2 55 14 3 56 14 4 57 15 1 58 15 2 59 15 3 60 15 4 61 16 1 62 16 2 63 16 3 64 16 4 Shaft Coating Finish Carbon USGPS WC-17Co 4 67 PS WC-17Co 4 67 EHC 8 39 EHC 8 67 HVOF WC-17Co 8 39 HVOF WC-17Co 8 67 HVOF Tribaloy 400 8 67 HVOF Tribaloy 400 8 39 HVOF Tribaloy 800 4 67 HVOF Tribaloy 800 4 39 HVOF Tribaloy 400 8 67 HVOF Tribaloy 400 8 39 HVOF Cr3C2-20NiCr 4 67 HVOF Cr3C2-20NiCr 4 67 HVOF Tribaloy 800 4 39 HVOF Tribaloy 800 4 67 HVOF WC-17Co 8 39 HVOF WC-17Co 8 67 PS WC-17Co 8 39 PS WC-17Co 8 39 PS Tribaloy 400 8 67 PS Tribaloy 400 8 67 HVOF Cr3C2-20NiCr 8 39 HVOF Cr3C2-20NiCr 8 39 PS Tribaloy 400 4 39 PS Tribaloy 400 4 39 EHC 8 39 EHC 8 67 PS Tribaloy 400 8 67 PS Tribaloy 400 8 67 HVOF WC-17Co 4 39 HVOF WC-17Co 4 67 Speed Seal Housing # 13,500 1 13,500 4 13,500 3 13,500 2 7,000 4 7,000 2 7,000 3 7,000 1 13,500 4 13,500 2 13,500 3 13,500 1 7,000 2 7,000 4 7,000 3 7,000 1 7,000 1 7,000 3 7,000 2 7,000 4 13,500 1 13,500 4 13,500 2 13,500 3 13,500 4 13,500 1 13,500 2 13,500 3 7,000 3 7,000 2 7,000 4 7,000 1
Test Materials
1.0
Aircraft Engine
VARY EHC ALTERNATIVE MATERIALS AND PROCESSES
HVOF Process
Composition, Wgt % WC-17 Co Cr3C2-20 (Ni,Cr) Co-28 Mo-17 Cr-3 Si* Co-28 Mo-8 Cr-2 Si** * Tribaloy 800 ** Tribaloy 400 Powder Diamaloy 2005 Amdry 5260/Diam 3007 Diamaloy 3001 Diamaloy 3002
Aircraft Engine
Face Seal
Shaft
Rotor
• Gearboxes • Sumps • Shafts
• Type depends on component design and assembly methods • Air and Oil Seals
3D Model of Carbon Seal Rig
Aircraft Engine
Speed Seal Housing # 13,500 3 13,500 1 13,500 4 13,500 2 7,000 2 7,000 1 7,000 3 7,000 4 7,000 3 7,000 1 7,000 4 7,000 2 13,500 1 13,500 3 13,500 4 13,500 2 13,500 1 13,500 2 13,500 3 13,500 4 7,000 3 7,000 2 7,000 4 7,000 1 13,500 2 13,500 4 13,500 3 13,500 1 7,000 2 7,000 4 7,000 1 7,000 3
Aircraft Engine
Test Hardware Photos
Carbon Seal
Aircraft Engine
Unworn reference datum surface
Wear area
Rotor Contact Area
Aircraft Engine
Rotor - coated carbon seal contact area (seal runner coating)
Stator carbon seals, 4 locations
2 rotors, runner coated fwd & aft sides
Aircraft Engine
TEST APPROACH
Test Conditions
Aircraft Engine
• Each test is 4 time segments of 12 hrs each • 2 Spindle Speeds
Aircraft Engine
Gas Turbine Engine Carbon Seal Tests
J.D.Schell – GE Aircraft Engine G.Holloway – Diversitech,Inc. R.Engelmann – Rexnord Corp.
KSC/11-19-2003
PS Process
Composition, Wgt % WC-17 Co Co-28 Mo-8 Cr-2 Si** Powder Metco 73F-NS-1 Metco 66F-NS
2.0 COVERED RANGE OF CARBON MATERIALS CARBON MATERIAL US GRAPHITE GRADE 39 US GRAPHITE GRADE 67 SCLEROSCOPE HARDNESS 100 75
• Rotor Material, 9310 steel RC 36-40
Test Matrix
Test # X456- Set-up # Position # 1 1 1 2 1 2 3 1 3 4 1 4 5 2 1 6 2 2 7 2 3 8 2 4 9 3 1 10 3 2 11 3 3 12 3 4 13 4 1 14 4 2 15 4 3 16 4 4 17 5 1 18 5 2 19 5 3 20 5 4 21 6 1 22 6 2 23 6 3 24 6 4 25 7 1 26 7 2 27 7 3 28 7 4 29 8 1 30 8 2 31 8 3 32 8 4 Shaft Coating Finish Carbon USGHVOF Tribaloy 400 8 39 HVOF Tribaloy 400 8 67 HVOF Tribaloy 800 4 39 HVOF Tribaloy 800 4 67 HVOF Cr3C2-20NiCr 8 39 HVOF Cr3C2-20NiCr 8 39 PS WC-17Co 4 67 PS WC-17Co 4 67 PS Tribaloy 400 4 39 PS Tribaloy 400 4 39 HVOF WC-17Co 4 39 HVOF WC-17Co 4 67 HVOF WC-17Co 8 39 HVOF WC-17Co 8 67 PS WC-17Co 8 39 PS WC-17Co 8 39 HVOF WC-17Co 4 39 HVOF WC-17Co 4 67 HVOF Cr3C2-20NiCr 4 67 HVOF Cr3C2-20NiCr 4 67 HVOF Tribaloy 800 4 67 HVOF Tribaloy 800 4 39 EHC 8 39 EHC 8 67 PS Tribaloy 400 8 67 PS Tribaloy 400 8 67 HVOF WC-17Co 8 67 HVOF WC-17Co 8 39 EHC 8 39 EHC 8 67 HVOF Tribaloy 400 8 67 HVOF Tribaloy 400 8 39
– Peppers Machine Shop: Seal Runner Mfg – Hitemco: Seal Runner Coatings – Westfield Gage: EHC and Coatings Grind & Lapping
Carbon Seals in GTEs
Radial Seal
Aircraft Engine
CARBON TEMPERATURE(CLOSE TO RUBBING SURFACE INTERFACE) SURFACE FINISHES OF RUBBING FACES(CARBON AND RUBBING RING) HARDNESS OF CARBON AND COATING MATERIALS SPINDLE SPEED CARBON SPRING LOAD (INTERFACE PRESSURE) OIL INLET AND EXIT TEMPERATURES COLLECTED OIL SAMPLES FOR ANALYSIS
Unworn reference datum surface
Rotor & Seal Runner Coating
Aircraft Engine
Coating
Aircraft Engine
Test Data
Measured Data
PARAMETERS MEASURED • • • • • • • • • CARBON WEAR COATING WEAR ON RUNNERS
Aircraft Engine
• Seal Runner Coatings (DPH)
EHC (hard chrome) ---HVOF WC-17 Co 1088 HVOF CrC-NiCr 987 HVOF Tribaloy 800 532 HVOF Tribaloy 400 609 PS WC-17 Co 1040 PS Tribaloy 400 ----
3.0 ONE COMMON SHAFT RUNNER MATERIAL AMS 6265 (9310 steel) HARDNESS: RC 36-40
Test Materials
• Carbon Seal Grades
– Graphitar 39, SH 100 – Graphitar 67, SH 75 – – – – – – –
• • • • •
Loads 2 to 5 lbs (5.4 to 13.6 psi) Coating surface finish 4 & 8 µ-in Ra Carbon seal finish ~2 µ-in Ra Ambient oil temp 225 F Mil-L-7808 oil at about 0.025 gph per jet
Carbon Seal Team
• • • •
Aircraft Engine
GEAE – OEM Lead, Test Plan, Matls Engineering Diversitech – Mechanical Engineering Rexnord – Carbon Seal Mfg, Test Rig Design, Testing Others
2 Oil jets
wk.baidu.com
Aircraft Engine
High speed spindle
4 Carbon face seals
Housing
Four carbon seal cartridges 2 Oil drains
Rexnord Carbon Seal Test Rig
Aircraft Engine
Test Matrix (cont.)
Aircraft Engine
Test # X456- Set-up # Position # 33 9 1 34 9 2 35 9 3 36 9 4 37 10 1 38 10 2 39 10 3 40 10 4 41 11 1 42 11 2 43 11 3 44 11 4 45 12 1 46 12 2 47 12 3 48 12 4 49 13 1 50 13 2 51 13 3 52 13 4 53 14 1 54 14 2 55 14 3 56 14 4 57 15 1 58 15 2 59 15 3 60 15 4 61 16 1 62 16 2 63 16 3 64 16 4 Shaft Coating Finish Carbon USGPS WC-17Co 4 67 PS WC-17Co 4 67 EHC 8 39 EHC 8 67 HVOF WC-17Co 8 39 HVOF WC-17Co 8 67 HVOF Tribaloy 400 8 67 HVOF Tribaloy 400 8 39 HVOF Tribaloy 800 4 67 HVOF Tribaloy 800 4 39 HVOF Tribaloy 400 8 67 HVOF Tribaloy 400 8 39 HVOF Cr3C2-20NiCr 4 67 HVOF Cr3C2-20NiCr 4 67 HVOF Tribaloy 800 4 39 HVOF Tribaloy 800 4 67 HVOF WC-17Co 8 39 HVOF WC-17Co 8 67 PS WC-17Co 8 39 PS WC-17Co 8 39 PS Tribaloy 400 8 67 PS Tribaloy 400 8 67 HVOF Cr3C2-20NiCr 8 39 HVOF Cr3C2-20NiCr 8 39 PS Tribaloy 400 4 39 PS Tribaloy 400 4 39 EHC 8 39 EHC 8 67 PS Tribaloy 400 8 67 PS Tribaloy 400 8 67 HVOF WC-17Co 4 39 HVOF WC-17Co 4 67 Speed Seal Housing # 13,500 1 13,500 4 13,500 3 13,500 2 7,000 4 7,000 2 7,000 3 7,000 1 13,500 4 13,500 2 13,500 3 13,500 1 7,000 2 7,000 4 7,000 3 7,000 1 7,000 1 7,000 3 7,000 2 7,000 4 13,500 1 13,500 4 13,500 2 13,500 3 13,500 4 13,500 1 13,500 2 13,500 3 7,000 3 7,000 2 7,000 4 7,000 1
Test Materials
1.0
Aircraft Engine
VARY EHC ALTERNATIVE MATERIALS AND PROCESSES
HVOF Process
Composition, Wgt % WC-17 Co Cr3C2-20 (Ni,Cr) Co-28 Mo-17 Cr-3 Si* Co-28 Mo-8 Cr-2 Si** * Tribaloy 800 ** Tribaloy 400 Powder Diamaloy 2005 Amdry 5260/Diam 3007 Diamaloy 3001 Diamaloy 3002
Aircraft Engine
Face Seal
Shaft
Rotor
• Gearboxes • Sumps • Shafts
• Type depends on component design and assembly methods • Air and Oil Seals
3D Model of Carbon Seal Rig
Aircraft Engine
Speed Seal Housing # 13,500 3 13,500 1 13,500 4 13,500 2 7,000 2 7,000 1 7,000 3 7,000 4 7,000 3 7,000 1 7,000 4 7,000 2 13,500 1 13,500 3 13,500 4 13,500 2 13,500 1 13,500 2 13,500 3 13,500 4 7,000 3 7,000 2 7,000 4 7,000 1 13,500 2 13,500 4 13,500 3 13,500 1 7,000 2 7,000 4 7,000 1 7,000 3
Aircraft Engine
Test Hardware Photos
Carbon Seal
Aircraft Engine
Unworn reference datum surface
Wear area
Rotor Contact Area
Aircraft Engine
Rotor - coated carbon seal contact area (seal runner coating)
Stator carbon seals, 4 locations
2 rotors, runner coated fwd & aft sides
Aircraft Engine
TEST APPROACH
Test Conditions
Aircraft Engine
• Each test is 4 time segments of 12 hrs each • 2 Spindle Speeds
Aircraft Engine
Gas Turbine Engine Carbon Seal Tests
J.D.Schell – GE Aircraft Engine G.Holloway – Diversitech,Inc. R.Engelmann – Rexnord Corp.
KSC/11-19-2003
PS Process
Composition, Wgt % WC-17 Co Co-28 Mo-8 Cr-2 Si** Powder Metco 73F-NS-1 Metco 66F-NS
2.0 COVERED RANGE OF CARBON MATERIALS CARBON MATERIAL US GRAPHITE GRADE 39 US GRAPHITE GRADE 67 SCLEROSCOPE HARDNESS 100 75
• Rotor Material, 9310 steel RC 36-40
Test Matrix
Test # X456- Set-up # Position # 1 1 1 2 1 2 3 1 3 4 1 4 5 2 1 6 2 2 7 2 3 8 2 4 9 3 1 10 3 2 11 3 3 12 3 4 13 4 1 14 4 2 15 4 3 16 4 4 17 5 1 18 5 2 19 5 3 20 5 4 21 6 1 22 6 2 23 6 3 24 6 4 25 7 1 26 7 2 27 7 3 28 7 4 29 8 1 30 8 2 31 8 3 32 8 4 Shaft Coating Finish Carbon USGHVOF Tribaloy 400 8 39 HVOF Tribaloy 400 8 67 HVOF Tribaloy 800 4 39 HVOF Tribaloy 800 4 67 HVOF Cr3C2-20NiCr 8 39 HVOF Cr3C2-20NiCr 8 39 PS WC-17Co 4 67 PS WC-17Co 4 67 PS Tribaloy 400 4 39 PS Tribaloy 400 4 39 HVOF WC-17Co 4 39 HVOF WC-17Co 4 67 HVOF WC-17Co 8 39 HVOF WC-17Co 8 67 PS WC-17Co 8 39 PS WC-17Co 8 39 HVOF WC-17Co 4 39 HVOF WC-17Co 4 67 HVOF Cr3C2-20NiCr 4 67 HVOF Cr3C2-20NiCr 4 67 HVOF Tribaloy 800 4 67 HVOF Tribaloy 800 4 39 EHC 8 39 EHC 8 67 PS Tribaloy 400 8 67 PS Tribaloy 400 8 67 HVOF WC-17Co 8 67 HVOF WC-17Co 8 39 EHC 8 39 EHC 8 67 HVOF Tribaloy 400 8 67 HVOF Tribaloy 400 8 39
– Peppers Machine Shop: Seal Runner Mfg – Hitemco: Seal Runner Coatings – Westfield Gage: EHC and Coatings Grind & Lapping
Carbon Seals in GTEs
Radial Seal
Aircraft Engine
CARBON TEMPERATURE(CLOSE TO RUBBING SURFACE INTERFACE) SURFACE FINISHES OF RUBBING FACES(CARBON AND RUBBING RING) HARDNESS OF CARBON AND COATING MATERIALS SPINDLE SPEED CARBON SPRING LOAD (INTERFACE PRESSURE) OIL INLET AND EXIT TEMPERATURES COLLECTED OIL SAMPLES FOR ANALYSIS
Unworn reference datum surface
Rotor & Seal Runner Coating
Aircraft Engine
Coating
Aircraft Engine
Test Data
Measured Data
PARAMETERS MEASURED • • • • • • • • • CARBON WEAR COATING WEAR ON RUNNERS
Aircraft Engine
• Seal Runner Coatings (DPH)
EHC (hard chrome) ---HVOF WC-17 Co 1088 HVOF CrC-NiCr 987 HVOF Tribaloy 800 532 HVOF Tribaloy 400 609 PS WC-17 Co 1040 PS Tribaloy 400 ----
3.0 ONE COMMON SHAFT RUNNER MATERIAL AMS 6265 (9310 steel) HARDNESS: RC 36-40
Test Materials
• Carbon Seal Grades
– Graphitar 39, SH 100 – Graphitar 67, SH 75 – – – – – – –