Kaveri Engine

[Karthi]

Crack in HPT T1 blade tip


Another major problem found in Kaveri was first stage LPT blades vibrations.

In any gas turbine design cycle, blade design is a crucial element which needs maximum attention to meet the aerodynamic performance, structural safety margins, manufacturing feasibility, material availability etc. most of the failures occur during engine development test and in-service, in rotor and stator blades due to fatigue and resonance failures.


Flow instability is one of the most severe challenges in aeroengine design and operation. It can induce violent blade vibration leading to structural damage, result in unacceptable noise level, and reduce the performance of aircraft engines. Unsteady flow instability occurs when the compressor is operated on the specific status. And this unsteady flow phenomenon not only has an important effect on the performance stability of compressor, but also may be an exciting source for the asynchronous vibration of rotor blades.

When high level vibration occurs on the first stage of rotor blades, the noise spectrum presents a sharp peak and the propagation state of the characteristic frequency is a helix structure in the compressor.


The highest levels of rotor blade stress occur at resonance frequencies and during unsteady compressor operating conditions. There are several kinds of unsteady aircraft engine operation conditions: ones associated with combustion, aero-elastic unsteadiness such as rotor blade flutter as well as aerodynamic instability caused by rotating stall zones and compressor surges

 

[IndianHawk]

By your logic, buying 36 Rafael because Tejas is a dud, right

Lol lca is light rafale is medium no comparison between them . J20 and su34 both are heavy and in same league . If j20 is capable no one would touch su35. Lol .

 

[Alfalfa]

I did some calculations and I get exact TET

so this means higher thrust?? sorry just a noob here....

 

[NeXoft007]

With so much technological know-how and break-through achieved through decades of hard work & sweat, it would be now a gigantic blunder to shut down Kaveri program. India will only end up becoming a laughing stock amongst the big gas turbine companies & they will leave no opportunity to milk us dry.

Gas Turbines application is literally universal, from naval ships to air vehicles to railways and even civilian power generation. The market is huge, and I foresee India grabbing a chunk of it by the end of this decade.

 

[Karthi]

We have HTFE , HTSE , Shakthi and Kaveri Engine , we should develop various low thrust jet engines , which are fairly easy to develop rather a fully fledged 100KN afterburning engine .

We can use those in various Stealth UAVs , 4*40KN Engine is enough for a medium weight Stealth bomber , and can also be use in various HALE, MALE UAV s , AI powered Unmanned attack Aircraft's and Helicopters . This will help us to close the Squadron gap .


Experience of developing these small engines and maintaining tgese Engines will gave us a lot of knowledge and data to further develop our jet engine capabilities

 

[NeXoft007]

Our military doctrine have no need for a long range bomber.

 

[Astra2019]

so this means higher thrust?? sorry just a noob here....

this means you can apply simple thermodynamics principle to compare jet engines. And I also got the answer why increasing bypass ratio increases trust and efficiency.
And some people think GTRE was unable to achieve high compression ratio, but GTRE restrict compression ratio to 21.5 because compression increases temperature of gas.
For example 21.5 compression ratio increases temperature of gas to 450° celsius and compression ratio of 30 increases temperature of gas to 800° celsius and we know Turbine inlet temperature is only 1427°C.
So 30 compression ratio only leave 1427-800=627° celsius margin of heat addition by fuel.So we cannot add enough energy To gas power the turbine.

 

[Aaj ka hero]

this means you can apply simple thermodynamics principle to compare jet engines. And I also got the answer why increasing bypass ratio increases trust and efficiency.
And some people think GTRE was unable to achieve high compression ratio, but GTRE restrict compression ratio to 21.5 because compression increases temperature of gas.
For example 21.5 compression ratio increases temperature of gas to 450° celsius and compression ratio of 30 increases temperature of gas to 800° celsius and we know Turbine inlet temperature is only 1427°C.
So 30 compression ratio only leave 1427-800=627° celsius margin of heat addition by fuel.So we cannot add enough energy To gas power the turbine.

Also, at that temperature material selection for last stage of Compressor also has to be developed, what I mean is new materials have to be developed and they are being designed as of now, that's why you all see k series engines.

 

[HariPrasad-1]

Also, at that temperature material selection for last stage of Compressor also has to be developed, what I mean is new materials have to be developed and they are being designed as of now, that's why you all see k series engines.

I think it is not a big Challenge 2 develop the the material of cold areas I.e. areas prior to combustion chamber. However, it is very difficult to to make the material of hot areas where the temperature goes above 1600 degree centigrade. Here the main challenges are making of those parts, particularly processes. You can have the metallurgy of those things but the process of making is very important and critical. We can easily have the material use in single crystal blade but forging of those blades is very important.From directionally solidified blade to single crystal blades and now we are heading towards making those parts with 3D printing (Not all).

 

[no smoking]

Lol lca is light rafale is medium no comparison between them . J20 and su34 both are heavy and in same league . If j20 is capable no one would touch su35. Lol .

That is only true in fanboys' world. No one has the unlimited resources to turn her air force into purely 5G planes in near future.

USAF is buying F-15X as complement to F-35.
Russia is making more Su-35 even though they have Su-57.

Fanboys always forget China still got 600-800 J-7/J8 in her fleet, which will be retired in next 10-15 years. Do you think they are going to build 600-800 J-20 to replace them in next 15 years? The answer is: NO!

Firstly, they don't have the money and resource to build that number of J-20;
Secondly, J-20 itself won't reach the full capability until WS-15 is mature, which needs another 10 years at least. No one is going to mass produce J-20 until it fulfill the design target;
Thirdly, WS-15 itself will need a few years to expand the production capability, if we consider 2025 is the first year this engine installed on J-20, then 5 years to fix problems and another 5 years to increase production. So, ideally, J-20 will enter full speed production in 2035.

So, China will need another 4g jet to fill this 15 years window. There is no much potential left in J-10, the only option is Su-35.

 

[Defcon 1]

That is only true in fanboys' world. No one has the unlimited resources to turn her air force into purely 5G planes in near future.

USAF is buying F-15X as complement to F-35.
Russia is making more Su-35 even though they have Su-57.

Fanboys always forget China still got 600-800 J-7/J8 in her fleet, which will be retired in next 10-15 years. Do you think they are going to build 600-800 J-20 to replace them in next 15 years? The answer is: NO!

Firstly, they don't have the money and resource to build that number of J-20;
Secondly, J-20 itself won't reach the full capability until WS-15 is mature, which needs another 10 years at least. No one is going to mass produce J-20 until it fulfill the design target;
Thirdly, WS-15 itself will need a few years to expand the production capability, if we consider 2025 is the first year this engine installed on J-20, then 5 years to fix problems and another 5 years to increase production. So, ideally, J-20 will enter full speed production in 2035.

So, China will need another 4g jet to fill this 15 years window. There is no much potential left in J-10, the only option is Su-35.

Even if what you say is true, why is china not replacing J7 with advanced versions of J11? After all, it is almost the same design as Su35 and considering the fact that China can develop a 5th gen fighter like J20, J11 electronics should easily be able to match Su35. There is no proper need buy Su35 unless chinese electronics cannot match Su35. And if they can't, this raises questions on effectiveness of J20 as a fighter.

 

[Karthi]

What’s the shape & size of 6th gen fighters…?

So, the individual fighter aircraft of the 6th generation is indeed going to be a mid-sized asset which belongs to a larger team of assets and controllers. The aircraft would incorporate a stealthy shape with top mounted intake(s) for its low bypass, turbofan, after-burning, engine(s), and would house internal weapons in its belly and wing-fuselage joints. It would incorporate the smallest size practicable. The size would probably be half that of a jet fighter, just adequate for two medium calibre, air-to-ground cruise missiles and two air-to-air BVR missiles, with (only) the nose, large enough to accommodate a fighter AESA radar. The max all-up-weight would probably be in 8-tonne category with a total powerplant rating of about 25 kN in dry power and 40 kN with reheat. A transonic flying-wing, stealthy shape with non-reheated engine(s) would probably be the choice for surveillance and attack roles, while a supersonic, low observable shape with reheated engine(s) may be the preferred option for interceptor and air defence roles.

Sixth gen aerial combat is ready to unfold in two graduated steps. The first could be termed as 5th+ gen of MUM-Team combat (Manned-Unmanned team), while the second step would truly embody the 6th gen characteristics of fully autonomous drone-combat.


This is a sixth generation concept from an Indian blogger . We can achieve this using our current engine technology

 

[Alok Arya]

TBC by EE beam technology. The result of this is very encouraging.

 

[Karthi]

Indigenously developed and integrated with the help of foreign collaborator M/s International centre for Electron beam technologies, Kiev, Ukraine

Specifications

Depending on requirements, Electron Beam Physical Vapour unit has been fitted with traditional evaporators (water-cooled crucibles with vertical shafts for displacement of evaporation ingots). The load chamber has the capability of cleaning of the job surfaces and fixing of jobs before moving into the working chamber. Electron beam guns are fitted with a two-stage system of differential high-vacuum pumping, allowing implementation of the evaporation process, it has capabilities with purging of various gases into the working chamber.

Details

A high energy electron beam physical vapour deposition (EBPVD) coating process which allows high deposition rates, precise composition and microstructural control capable of depositing thermal barrier coatings with MCrAlY as a bondcoat and high temperature oxidation resistant coatings that are used on gas turbine blades of aero-engine and power generating industries. The facility is capable of depositing coating of thickness ranging from a micron to a few mm, and also coatings with graded structure and properties.


More details about the system

 

[Karthi]

+
A large window of coating thickness (10µm-2 mm) Ability to coat thin foils, strips, sheets & heavy blanks

Currently in applications at the HAL for helicopter and aero-engine. https://t.co/QTNVzmtwj8


Later part of Amit R Kashyap tweet

 

[Karthi]

Jet engine parts manufacturing by TATA for Rolls Royce and GE


Rolls Royce Engines Parts:- Tata Advanced Systems have partnered with Rolls – Royce for precision manufacturing and supply chain for the TRENT and BR700 engine programs. Dedicated facility set up within 6 months from award of contract and more than 100,000 precision parts delivered to Rolls- Royce. Won the "Trusted to Deliver Excellence" Award and was nominated for the "Best New Supplier" Award at the Rolls Royce Aerospace Global Supplier Conference 2016 in Berlin.


GE LEAP Engines Parts:- TATA Advanced Systems have been contracted for Precision Manufacturing, supply chain for LEAP engine Program for GE

 

[Assassin 2.0]

 

[Karthi]

Japanese XF 9. XF-9-1 is half-meter shorter and 30 centimeters slimmer than the PW F-119 of F22 Raptor . And produces almost equal thrust . Similar thrust less dimensions help to more internal space . Feeling jealous actually .

 

[lcafanboy]

Sukhoi 30 to be turned into super sonic test bed for testing jet engines like Kaveri, K9, K10...

 

[Karthi]

Sukhoi 30 to be turned into super sonic test bed for testing jet engines like Kaveri, K9, K10...

Nothing official till now , I think .