Onset of Arizona Road Dust in High Temperature Environment on a Cooled HASTELLOY X Surface

Abstract

In the past several decades there has been an increased interest in sand, dust, and ash particulates ingestion study for gas turbine engine applications. Recently, there has been an increase in commercial and military fleets operating in medium to highly dusty environments, such as areas in Africa, the Middle East, and Asia. Dusty environments can cause blockage in turbine cooling circuits which can lead to early engine maintenance or removals. Ingested debris can melt, forming glassy or molten deposits on various hot section components in gas turbine engines. This thesis evaluates the onset of deposit formation using an experimental rig to perform testing in high temperature environment. In general, deposits on turbine components can affect the operating capacity and the overall operating efficiency of gas turbine engines. Particulate ingestion events can be catastrophic and cost millions of dollars in maintenance and repairs.

The experimental work in this thesis focused only on quantifying the initial deposit formation in high temperature environment to aid in the development of resilient engine design and operational diagnostics. Testing was performed using HASTELLOY® X coupons and Arizona Road Dust with main gas flow temperatures between 1050°C and 1100°C. Arizona Road Dust sample with sizing between 2µm and 40µm were used for experimental testing. The sensitivity of the initial deposit formation on cooled HASTELLOY® X coupon surface was investigated by using an inline air heater. Three cooling test conditions: no cooling, 500°C cooling, and 250°C cooling, were used to alter the surface temperature of the coupon during testing. Results from testing indicated cooling test conditions used have a small impact on deposit formation.