UNIVERSITI MALAYSIA PAHANG

FACULTY OF MECHANICAL ENGINEERING

MANUFACTURING PROCESSES
BMM3643
SECTION 2

PROJECT REPORT

GROUP 2

MEMBERS:
MOHD MUKHRIS BIN AWANG

MC12012

MOHAMMAD AFIQ BIN ANWAR

MC12018

A. IRLAN DIN BIN A. SULAIMAN

MH12027

MOHD FAQEER NAEEM BIN ABD SAMAD

MC12061

ZULRAIDI BIN MOHD LOTFI

MA12024

Abstract
A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has
an upstream rotating compressor coupled to a downstream turbine, and a combustion
chamber in-between.
The basic operation of the gas turbine is similar to that of the steam power plant except that
air is used instead of water. Fresh atmospheric air flows through a compressor that brings it to
higher pressure. Energy is then added by spraying fuel into the air and igniting it so the
combustion generates a high-temperature flow. This high-temperature high-pressure gas
enters a turbine, where it expands down to the exhaust pressure, producing a shaft work
output in the process. The turbine shaft work is used to drive the compressor and other
devices such as an electric generator that may be coupled to the shaft. The energy that is not
used for shaft work comes out in the exhaust gases, so these have either a high temperature or
a high velocity. The purpose of the gas turbine determines the design so that the most
desirable energy form is maximized. Gas turbines are used to power aircraft, trains, ships,
electrical generators, or even tanks.

Gantt Chart
MANUFACTURING PROCESS : PROJECT
Tittle: Gantt Chart For Designing The Gas Turbine
Week
Task No.

Task Description
W06

Do Preliminary Idea Analysis

Develop Preliminary Product Design

Do Preliminary Product Study

Evaluate and Select Best Product Design

Develop Details Product Design

a. Concept generation and sketch

b. Setting specification and tolerance

c. Finalise model and concept

d. Develop design prototype

e. Report completion

Project Submission and Presentation

W07

W08

W09

W10

W11

W12

W13

W14

1.0- Introduction
In an ideal gas turbine, gases undergo three thermodynamic processes: an isentropic
compression, an isobaric (constant pressure) combustion and an isentropic expansion.
Together, these make up the Brayton cycle.
In a practical gas turbine, mechanical energy is irreversibly transformed into heat when
gases are compressed (in either a centrifugal or axial compressor), due to internal friction
and turbulence. Passage through the combustion chamber, where heat is added and the
specific volume of the gases increases, is accompanied by a slight loss in pressure. During
expansion amidst the stator and rotor blades of the turbine, irreversible energy
transformation once again occurs.
If the device has been designed to power a shaft as with an industrial generator or a
turboprop, the exit pressure will be as close to the entry pressure as possible. In practice it is
necessary that some pressure remains at the outlet in order to fully expel the exhaust gases.
In the case of a jet engine only enough pressure and energy is extracted from the flow to
drive the compressor and other components. The remaining high pressure gases are
accelerated to provide a jet that can, for example, be used to propel an aircraft.
As with all cyclic heat engines, higher combustion temperatures can allow for greater
efficiencies. However, temperatures are limited by ability of the steel, nickel, ceramic, or
other materials that make up the engine to withstand high temperatures and stresses. To
combat this many turbines feature complex blade cooling systems.
As a general rule, the smaller the engine, the higher the rotation rate of the shaft(s) must be
to maintain tip speed. Blade-tip speed determines the maximum pressure ratios that can be
obtained by the turbine and the compressor. This, in turn, limits the maximum power and
efficiency that can be obtained by the engine. In order for tip speed to remain constant, if
the diameter of a rotor is reduced by half, the rotational speed must double. For example,
large jet engines operate around 10,000 rpm, while micro turbines spin as fast as 500,000
rpm.
Thrust bearings and journal bearings are a critical part of design. Traditionally, they have
been hydrodynamic oil bearings, or oil-cooled ball bearings. These bearings are being
surpassed by foil bearings, which have been successfully used in micro turbines and auxiliary
power units.

2.0- Literature Review

2.1 . History
Nowadays, a number of industrial engines made by manufacturers who also
make aircraft engines, such as Rolls-Royce and General Electric, are essentially
similar to their aircraft engine sibling but are mounted on a skid. Support systems
however, both operational and condition monitoring, will not have the same
complexity and degrees of redundancy as the aircraft engine counterpart.
2.2 Gas Turbine Usage
In an aircraft gas turbine the output of the turbine is used to turn the
compressor (which may also have an associated fan or propeller). The hot air flow
leaving the turbine is then accelerated into the atmosphere through an exhaust
nozzle to provide thrust or propulsion power. The jet engine of Fig. 2.1 is a turbofan
engine, with a large diameter compressor-mounted fan. Thrust is generated both by
air passing through the fan (bypass air) and through the gas generator itself. With a
large frontal area, the turbofan generates peak thrust at low (takeoff) speeds making
it most suitable for commercial aircraft.
A turbojet does not have a fan and generates all of its thrust from air that
passes through the gas generator. Turbojets have smaller frontal areas and
generate peak thrusts at high speeds, making them most suitable for fighter aircraft.
In non-aviation gas turbines, part of the turbine power is used to drive the
compressor. The remainder, the "useful power", is used as output shaft power to turn
an energy conversion device such as an electrical generator or a ships propeller. A
typical land -based gas turbine is shown in Fig. 2.2. Such units can range in power
output from 0.05 MW (Megawatts) to as high as 240 MW. The unit shown in Fig. 2.2
is an aeroderivative gas turbine; i.e., a lighter weight unit derived from an aircraft jet
engine. Heavier weight units designed specifically for land use are called industrial or
frame machines.

2.3 Gas Turbine Cycle

A cycle describes what happens to air as it passes into, through, and out of
the gas turbine. The cycle usually describes the relationship between the space
occupied by the air in the system (called volume, V) and the pressure (P) it is under.
The Brayton cycle (1876), shown in graphic form in Fig. 4a as a pressure-volume
diagram, is a representation of the properties of a fixed amount of air as it passes
through a gas turbine in operation. These same points are also shown in the engine
schematic in Fig. 4b.

Air is compressed from point 1 to point 2. This increases the pressure as the
volume of space occupied by the air is reduced. The air is then heated at constant
pressure from 2 to 3 in Fig. 4. This heat is added by injecting fuel into the combustor
and igniting it on a continuous basis. The hot compressed air at point 3 is then
allowed to expand (from point 3 to 4) reducing the pressure and temperature and
increasing its volume. In the engine in Fig. 4b, this represents flow through the
turbine to point 3 and then flow through the power turbine to point 4 to turn a shaft or
a ships propeller. The "useful work" in Fig. 2.3(a) is indicated by the curve 3- 4. This
is the energy available to cause output shaft power for a land-based gas turbine , or
thrust for a jet aircraft. The Brayton cycle is completed in Fig. 2.3 by a process in
which the volume of the air is decreased (temperature decrease) as heat is absorbed
into the atmosphere.

2.4 - Material Improvements manufacturing

Materials used in gas turbines have gone through many incremental improvements
since the first practical turbines were developed in the 1940s. Most R&D efforts led to
improved steel alloys for use in turbine vanes, blades, and inlet blocks. This R&D in turbine
materials and coatings led to two important effects. First, gas turbines were better able to
withstand high temperatures. These more rugged materials allowed for hotter inlet gas to
enter the turbines first stage blades, leading to higher efficiencies. Second, material
improvements led to an increase in rotor life and reliability. Gas and combined cycle plants
could not have achieved popularity and larger market shares without solving problems such
as premature blade cracking or component deformations. Together, the higher temperatures,
higher efficiencies, and improved reliabilities have advanced the deployment of gas turbines
in the power generation market.

Progress in gas turbine material development often came in the form of alternative
stainless steel or metal alloys that had improved heat characteristics. Different parts of gas
turbines use a variety of alloy metals, including varying quantities of cobalt, nickel, and
chromium. In turbine compressors, manufacturers vary in their metals and manufacturing
methods, but initial blades are often made with stainless steel because it is strong and easy to
machine.6 Compressors have not gone through many drastic changes in material over the
years. As in cases from decades ago, tertiary row compressor blades may use a 12 percent
chrome material because of its high strength, good corrosion resistance, and superior
damping characteristics. One example of an addition comes from Westinghouses use of
CuNiIn coating on the compressor blade roots to inhibit fretting.

Rotating turbine blades have also improved with progressions in their materials.
These rotating blades tend towards nickel alloys, which also display improved properties with
iterative change. Early designs used a variety of nickel-based alloys and even some 12
percent chrome material similar to that used for compressor blades. Development led to the
more widespread use of some standard Inconel nickel alloys, which were necessary as firing
temperatures increased. In another example, improving from 520 nickel alloy to 750 and 738
alloys have allowed some manufacturers to maintain or improve high heat tolerances while
simultaneously improving their production characteristics.

Among the most important production characteristics is the determination of whether a blade
is cast or forged. Forging and machining a blade may be easier for some cases, but intricate
designs and complex configurations may require that a blade be castninstead. Other times,
there can be considerable difference between the ability to be able to cast a blade in a press
than it is to painstakingly forge and machine one. The casting may be a simpler
process that is less expensive.
Some turbine material improvements, such as Westinghouses switch to 738 alloy,
have led to the use of more crystallized metals that are directionally solidified and more
amenable to successful and simple production. Metals used previously would be more likely
to crack if they were cast because their internal structure is not as strong as todays alloys.
This incremental progression in alloys has been instrumental in improving gas turbines.

3.0- Product Usage

Gas Turbine in Surface Vehicles
Gas turbines are often used on ships, locomotives, helicopters, tanks, and to a lesser extent,
on cars, buses, and motorcycles.
A key advantage of jets and turboprops for aeroplane propulsion - their superior performance
at high altitude compared to piston engines, particularly naturally aspirated ones - is
irrelevant in most automobile applications. Their power-to-weight advantage, though less
critical than for aircraft, is still important.
Gas turbines offer a high-powered engine in a very small and light package. However, they
are not as responsive and efficient as small piston engines over the wide range of RPMs and
powers needed in vehicle applications. In series hybrid vehicles, as the driving electric
motors are mechanically detached from the electricity generating engine, the responsiveness,
poor performance at low speed and low efficiency at low output problems are much less
important. The turbine can be run at optimum speed for its power output, and batteries
and ultra capacitors can supply power as needed, with the engine cycled on and off to run it
only at high efficiency. The emergence of the continuously variable transmission may also
alleviate the responsiveness problem.
Turbines have historically been more expensive to produce than piston engines, though this is
partly because piston engines have been mass-produced in huge quantities for decades, while
small gas turbine engines are rarities; however, turbines are mass-produced in the closely
related form of the turbocharger.

Tanks
A turbine is theoretically more reliable and easier to maintain than a piston engine, since it
has a simpler construction with fewer moving parts but in practice turbine parts experience a
higher wear rate due to their higher working speeds. The turbine blades are highly sensitive to
dust and fine sand, so that in desert operations air filters have to be fitted and changed several
times daily. An improperly fitted filter, or a bullet or shell fragment that punctures the filter,
can damage the engine. Piston engines (especially if turbocharged) also need well-maintained
filters, but they are more resilient if the filter does fail.
Like most modern diesel engines used in tanks, gas turbines are usually multi-fuel engines.

Manufacturing Processes
Fan Blades:
Each fan blades consists of two blades skins produced by shaping molten titanium in s
hot press.
When removed, each blade skin is welded to a mate, with a hollow cavity in the
center. To increase the strength of the final product, this cavity is filled with a
titanium honeycomb.
Compressor Disk:
For a long time, the most popular way to manufacture
The disc entailed machine cutting a metal blank into a rough approximation of the desired
shape, then heating and stamping
It is to precise specifications.
Today, they use powder metallurgy.
Turbine Blade:
Are made by forming wax copies of the blades and then immersing the copies in a
ceramic slurry bath.
After each copy is heated to harden the ceramic and melt the wax, molten metal is
poured into the hollow left by the melted wax.
Compressor Blade:
Casting an extremely old method is still used to form the compressor blades.
In this process, the alloy from which the blades will be formed is poured into a
ceramic mold, heated in a furnace and cooled. When the mold is broken off the blades
are machined to their final shape.
Combustion Chamber:
Welded together before being mounted on the engine.

 Made of titanium
Exhaust System:
The inner duct and the afterburners of the exhaust system are molded from titanium.
While the outer duct and the nacelle (the engine casing) are formed from Kevlar.

4.0- Impact To Society

Gas Turbine Power Generation - Helping to Protect the
Environment
Global warming is recognized to be one of the major side effects of human industrial activity,
bringing with it climatic changes, rising sea levels, and altered ecosystems.
Research indicates that 50% of the so-called "Greenhouse Effect" is caused by carbon dioxide
emissions, and that 80% of such emissions are a direct result of fossil fuel consumption (oil,
coal, natural gas.)
The most efficient system for producing electricity from natural gas is a combined-cycle
generator with a gas turbine at its core. The main advantages of the gas turbine over other
systems are that it uses natural gas as fuel, and has high heat efficiency and relatively low
fuel consumption. Natural gas is one of the cleanest burning fuels and nowadays even more
interesting source of energy.

5.0- Conclusions
Gas turbine have many different manufacturing processes which are complex and
outstanding. In the engineering field, gas turbine are used widely because it has many
benefits to the society.
Mechanically, gas turbines can be considerably less complex than internal combustion piston
engines.
Simple
turbines
might
have
one
moving
part:
the
shaft/compressor/turbine/alternative-rotor assembly, not counting the fuel system. However,
the required precision manufacturing for components and temperature resistant alloys
necessary for high efficiency often make the construction of a simple turbine more
complicated than piston engines.
More sophisticated turbines (such as those found in modern jet engines) may have multiple
shafts (spools), hundreds of turbine blades, movable stator blades, and a vast system of
complex piping, combustors and heat exchangers.

References
1.
2.
3.
4.

http://www.turbocam.com/blades
http://en.wikipedia.org/wiki/Turbine_blade
http://en.wikipedia.org/wiki/Turbine
http://science.howstuffworks.com/transport/flight/modern/turbine.htm

Appendix

Group members discuss about the turbine manufacturing processes and making reports