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Manufacturing and testing of a power turbine for a micro gas turbine engine
Thesis (MEng)--Stellenbosch University, 2025.
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| Format: | Thesis |
| Language: | English |
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Stellenbosch : Stellenbosch University
2025
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| _version_ | 1867613920524500993 |
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| access_status_str | Open Access |
| author | Greyling, Alexander Christiaan |
| author2 | Van der Spuy, Johan |
| author_browse | Greyling, Alexander Christiaan Van der Spuy, Johan |
| author_facet | Van der Spuy, Johan Greyling, Alexander Christiaan |
| author_sort | Greyling, Alexander Christiaan |
| collection | Thesis |
| dc_rights_str_mv | Stellenbosch UNiversity |
| description | Thesis (MEng)--Stellenbosch University, 2025. |
| format | Thesis |
| id | oai:scholar.sun.ac.za:10019.1/134625 |
| institution | Stellenbosch University (South Africa) |
| language | English |
| last_indexed | 2026-06-10T12:43:48.768Z |
| license_str | Other — see source repository |
| provenance_str_mv | Harvested via OAI-PMH from SUNScholar — Stellenbosch University Repository |
| publishDate | 2025 |
| publishDateRange | 2025 |
| publishDateSort | 2025 |
| publisher | Stellenbosch : Stellenbosch University |
| publisherStr | Stellenbosch : Stellenbosch University |
| record_format | dspace |
| source_str | SUNScholar — Stellenbosch University Repository |
| spelling | oai:scholar.sun.ac.za:10019.1/134625 Manufacturing and testing of a power turbine for a micro gas turbine engine Greyling, Alexander Christiaan Van der Spuy, Johan Van Eck, H. Hildebrandt, T. Stellenbosch University. Faculty of Engineering. Dept. of Mechanical and Mechatronic Engineering. Gas-turbines -- Testing Centrifugal compressors -- Aerodynamics Machinery -- Testing Manufacturing processes Thesis (MEng)--Stellenbosch University, 2025. Greyling, A. C. 2025. Manufacturing and testing of a power turbine for a micro gas turbine engine. Unpublished masters thesis. Stellenbosch: Stellenbosch University [online]. Available: https://scholar.sun.ac.za/items/73e78b61-4d22-4f32-b5b8-8b801329e41d ENGLISH ABSTRACT: A power turbine for the CAT250TJ micro gas turbine engine was manufac-tured and tested. The turbine rotor was made from 21CrMoV5-7 steel. A centrifugal compressor was used as the load for the power turbine. Cold air tests were conducted at speeds of up to 60 000 rpm, during which a maximum power output of 12 kW was measured. Additional tests were performed with the power turbine connected to a CAT250TJ engine, achieving a maximum speed of 55 000 rpm and a maximum power output of 4.5 kW. Performance maps of the micro gas turbine compressor and turbine and the power turbine were generated using computational fluid dynamics (CFD), while the load compressor map was obtained experimentally. A CFD simulation at the design speed indicated that the manufactured design was choked at 95 %of the baseline design’s choked mass flow rate. The maps were used in a one-dimensional simulation in the Flownex® Simulation Environment and the experimental results were replicated successfully. The Flownex® power turbine model showed that the modifications made to the manufactured power turbine resulted in a change in the operating point of the micro gas turbine: the CAT250TJ will operate at 103.9 % of the design speed, 93.6 % of the design mass flow rate, and at 97.2 % of the design fuel consumption while powering the manufactured power turbine. The model also indicated that the manufactured turbine will be able to reach the required speed and power output values of the baseline design (60 000 rpm and 37.8 kW). By scaling the load compressor geometry within the same model, it was predicted that the optimal load compressor for the experimental set-up would have an outlet diameter of 160 mm. AFRIKAANSE OPSOMMING: ’n Kragturbine vir die CAT250TJ mikro-gasturbine is vervaardig en getoets. Die rotor is van 21CrMoV5-7 staal gemaak. ’n Sentrifugale compressor is as las vir die kragturbine gebruik. Koue lugtoetse is teen snelhede tot 60 000 rpm uitgevoer, waartydens ’n maksimum kraguitset van 12kW gemeet is. Verdere toetse is uitgevoer met die kragturbine wat aan ’n CAT250TJ-enjin gekoppel was, en het ’n maksimum snelheid van 55 000 rpm en ’n maksimum kraguitset van 4.5kW behaal. Prestasiekaarte van die mikro-gasturbine se kompressor en turbine, sowel as die kragturbine, is met behulp van berekeningsvloeimeganika (CFD) gegenereer, terwyl die las-kompressorkaart eksperimenteel verkry is. ’n CFD simulasie teen die ontwerpspoed het aangedui dat die vervaardigde ontwerp versmoor het teen 95% van die basislynontwerp se smoor massavloeitempo. Die karate is gebruik in ’n een-dimensionele simulasie in Flownex®, wat die eksperimentele resultate suksesvol weergegee het. Die simulasie beaam dat die vervaardigde kragturbine die spoed en kraglewering (60 000 rpm en 37.8kW) van die oorspronklike ontwerp sal kan haal. Deur die las-kompressor geometrie van dieselfde model te skaleer, is daar voorspel dat die optimale las-kompressor vir die toetsopstelling ’n uitlaat-deursnee van 160mm sal moet hˆe. Sleutelwoorde: mikro-gasturbine, kragturbine, berekeningsvloeimeganika (CFD), een-dimensionele simulasie, eksperimenteel Masters 2025-12-19T07:58:03Z 2025-12-19T07:58:03Z 2025-12 Thesis https://scholar.sun.ac.za/handle/10019.1/134625 en Stellenbosch UNiversity xx, 122 pages : illustrations application/pdf Stellenbosch : Stellenbosch University |
| spellingShingle | Gas-turbines -- Testing Centrifugal compressors -- Aerodynamics Machinery -- Testing Manufacturing processes Greyling, Alexander Christiaan Manufacturing and testing of a power turbine for a micro gas turbine engine |
| title | Manufacturing and testing of a power turbine for a micro gas turbine engine |
| title_full | Manufacturing and testing of a power turbine for a micro gas turbine engine |
| title_fullStr | Manufacturing and testing of a power turbine for a micro gas turbine engine |
| title_full_unstemmed | Manufacturing and testing of a power turbine for a micro gas turbine engine |
| title_short | Manufacturing and testing of a power turbine for a micro gas turbine engine |
| title_sort | manufacturing and testing of a power turbine for a micro gas turbine engine |
| topic | Gas-turbines -- Testing Centrifugal compressors -- Aerodynamics Machinery -- Testing Manufacturing processes |
| url | https://scholar.sun.ac.za/handle/10019.1/134625 |
| work_keys_str_mv | AT greylingalexanderchristiaan manufacturingandtestingofapowerturbineforamicrogasturbineengine |