• Proceedings of the KWS Conference
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• 2002.10a
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• pp.235-243
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• 2002

Ni-base superalloys are used extensively in industry, both in aeroengines and land based turbines. About 60% by weight of most modern gas turbine engine structural components are made of Ni-base superalloys. To satisfy practical demands, the efficiency of gas turbine engines has been steadily and systematically increased by design modifications to handle higher turbine inlet or firing temperatures. However, the increase in operating temperatures has lead to a decrease in the life of components and increase in costs of replacement. Moreover, around 80% of the large frame size industrial/utility gas turbines operating in the world today were installed in the mid-sixties to early seventies and are now 25 to 30 years old. Consequently, there are greater opportunities now to repair and refurbish the older models. Basically, there are two major factors influencing the weldability of the cast alloys: strain-age cracking and liquation cracking. Susceptibility to strain-age cracking is due to the total Ti plus AI content of the alloy; Liquation cracking is due either to the presence of low melting constituents or constitutional liquation of constituents. Though Rene 41 superalloy has 4.5wt.% total Ti and Al content and falls just below the safe limit proposed by Prager et al., controlled grain size and special heat treatments are needed to obtain crack-free welds. Varying heat treatments and filler materials were used in a laboratory study, then the actual welding of service parts was carried out to verity the possibility of crack-tree weld of components fabricated from Rene 41 superalloy. The microstructural observations indicated that there were two kinds of carbides in the FCC matrix. MC carbides were located along the grain boundaries, while M$_{23}$C$_{6}$ carbide was located both inter and intra granularly. Two kinds of filler materials, Rene 41 and Hastelloy X were used to gas tungsten arc weld a patch into the sheet metal, along with varying pre-weld heat treatments. The microstructure, hardness and tensile tests were determined. The service distressed parts were categorized into three classes: with large cracks, with medium cracks and with small or no visible cracks. No significant difference in microstructure among the specimens was observed. Specimens were cut from the corner and the straight edge of the patch repair, away from the corner. The only cracks present were found to be associated with inadequate surface preparation to remove oxidation. Guidelines for oxide removal and the welding procedures developed in the research enabled crack-free welds to be produced.d.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 2017.05a
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• pp.889-891
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• 2017

Usually piston or rotary engines are installed at UAV's under 100 kg payload class. Those engine are less expensive and easy to get, but they require higher operating and maintenance costs due to shorter life and unique fuel usage. They are also too noisy to operate in urban area and have too strong vibration to carry sophisticated payloads. On the contrary, a gas turbine engine has drawbacks like higher specific fuel consumption and weight to power ratio, even it has many operating and maintenance benefits. This study aims to design a small turboshaft engine with a recuperator to overcome those demerits. A tilt rotor UAV(TR-60) developed by KARI was chosen as an imaginary target aircraft, and engine power and size were derived from it. This paper describes engine requirements, design process, and initial reference point cycle design.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.43 no.12
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• pp.1097-1107
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• 2015

General VTOL aircraft uses gas turbine engine which has high power to weight ratio. However, in the VTOL UAV in small sector, the gas turbine as a prime mover is not adequate because of the limitation of the high fuel consumption ratio of the gas turbine. In this research, The Series Hybrid-Electric Propulsion System(SHEPS) has been proposed and technology survey & comparison analysis has conducted to constitute propulsion system for engine, electric motor and battery. To achieve this object a 65kg-class P-UAV from "Company I" was used. And to estimate the validity of power control algorithm and developed power management control, Matlab/simulink$^{(R)}$ has been used for the simulation. As a result, the developed algorithm worked comparatively well and the research has predicted that SHEPS was satisfied enough for 7 hour of endurance for mission profile.

• Proceedings of the KSME Conference
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• 2001.06d
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• pp.840-845
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• 2001

Development of a small gas-turbine combustor for 100kW class APU(Auxiliary Power Unit) has been performed. This combustor is a reverse-annular type and has a tangential swirler in the liner head to improve the fuel/air mixing and flame stability. Three main and three pilot fuel injectors of the simplex pressure-swirl type are used. The performance target at the design condition includes a turbine inlet temperature of 1170K, a combustion efficiency of 99%, a pattern factor of 30%, and an engine durability of 3000 hours. Under developing the combustor, we conducted performance test of our first prototype(TS1) with some variants. As a result of the test, the performance targets of the combustor are satisfied except that the pattern factor is about 4% higher than target value. So, we redesigned the second prototype(TS2) and conduct performance test with the critical focus on pattern factor and exit mean temperature. We adopted TS2 four variant to check the improvement of pattern factor. As the result, the pattern factors of several variants were satisfied with the performance target. Finally, We chose the TS2A variant as a final combustor for our APU model.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 2017.05a
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• pp.198-200
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• 2017

An Auxiliary Power Unit (APU) is a small gas turbine engine that is mounted on an aircraft and serves to supply energy for ground and air starting of the main engine. APU also supplies emergency and auxiliary power for the aircraft. APU for aircraft is simple and compact in structure, but because it is mounted on manned aircraft, high reliability is required, so it must be proved its reliability through qualification procedure. The Korea Aerospace Research Institute and Hanwha Techwin successfully completed the design / analysis, fabrication, assembly, development test and certification test of APU for helicopter based on accumulated domestic R & D capability and experience from 2007 to 2012. In this paper, the development and certification process of auxiliary power unit for helicopter is summarized.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.30 no.5
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• pp.118-126
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• 2002

The Altitude Engine Test Facility(AETF) was built at the Korea Aerospace Research Institute and has been being operated for the gas turbine engines in the class of 3,000 lbf thrust. To enhance the confidence level of AETF to the international level, a series of studies and facility modification have been conducted to improve the measurement uncertainty and reliability. In this paper, some part of the facility evaluation tests performed with a single spool turbojet engine are introduced. Tests were performed simulating the flight conditions as steady state, sea level for various flight speeds (i.e., Mn=0.3, 0.5, 0.7, 0.9). The obtained test results are compared with the predicted values of the engine DECK. The measurement uncertainties of airflow, net thrust, fuel flow and SFC showed 0.791~0.914%, 0.851~1.706%, 1.372~7.348% and 1.642~5.205%, respectively. Thus, from this research, the improvement methods of uncertainties on AETF has been confirmed.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.32 no.9
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• pp.659-668
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• 2008

Combustion instability has been considered as very important issue for developing gas turbine and rocket engine. There is a need for fundamental understanding of combustion instability. In this study, combustion instability was numerically and experimentally investigated in a dump combustor with bluff body. The fuel and air mixture had overall equivalence ratio of 0.9 and was injected toward dump combustor. The pressure oscillation with approximately 256Hz was experimentally obtained. For numerical simulation, the standard k-$\varepsilon$ model was used for turbulence and the hybrid combustion model (eddy dissipation model and kinetically controlled model) was applied. After calculating steady solution, unsteady calculation was performed with forcing small perturbation on initial that solution. Pressure amplitude and frequency measured by pressure sensor is nearly the same as those predicted by numerical simulation. Furthermore, it is clear that a combustion instability involving vortex shedding is affected by acoustic-vortex-combustion interaction. The phase difference between the pressure and velocity is $\pi$/2, and that between the pressure and heat release rate is in excitation range described by Rayleigh, which is obvious that combustion instability for the bluff body combustor meets thermoacoustic instability criterion.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.26 no.6
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• pp.805-810
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• 2002

Development of a small gas-turbine combustor for 100㎾ class APU(Auxiliary Power Unit) has been performed. This combustor is a reverse-annular type and has a tangential swiller in the liner head to improve the fuel/air mixing and flame stability. Three main and three pilot fuel injectors of the simplex pressure-swirl type are used. The performance target at the design condition includes a turbine inlet temperature of l170k, a combustion efficiency of 99%, a pattern factor of 30%, and an engine durability of 3000 hours. Under developing the combustor, we conducted the performance test of our first prototype(TS1) with some variants. As a result of the test, the performance targets of the combustor are satisfied except that the pattern factor is about 4% higher than the target value. Therefore, the second prototype(TS2) was redesigned and the performance test was conducted with the critical focus on the pattern factor and the exit mean temperature. We adopted TS2 four variants to check the improvement of the pattern factor. As a result, the pattern factors of several variants were satisfied with the performance target. Finally, the TS2A variant was chosen as a final combustor fur our APU model.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.41 no.4
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• pp.293-301
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• 2017

A Sub-kWe small-scale experimental test loop was manufactured to investigate characteristics of the supercritical carbon dioxide power cycle. A high-speed turbo-generator was also designed and manufactured. The designed rotational speed of this turbo-generator was 200,000 rpm. Because of the low expansion ratio through the turbine and low mass flowrate, the rotational speed of the turbo-generator was high. Therefore, it was difficult to select the rotating parts and design the turbine wheel, axial force balance and rotor dynamics in the lab-scale experimental test loop. Using only one channel of the nozzle, the partial admission method was adapted to reduce the rotational speed of the rotor. This was the world's first approach to the supercritical carbon dioxide turbo-generator. A cold-run test using nitrogen gas under an atmospheric condition was conducted to observe the effect of the partial admission nozzle on the rotor dynamics. The vibration level of the rotor was obtained using a gap sensor, and the results showed that the effect of the partial admission nozzle on the rotor dynamics was allowable.