Skip to main content
SpringerLink
Log in

Manufacturing and mechanical evaluation of cooled cooling air (CCA) heat exchanger for aero engine

  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

Recent studies on improving the efficiency of gas turbine engines have focused on increasing the inlet temperature of gas flowing into the turbine. For the high inlet temperature, it requires the development of a super-alloy based material that can withstand harsh operating conditions. However, it is essential to utilize alternative solutions such as turbine blade cooling technology. Unfortunately, lightweight, high performance, and high mechanical reliable heat exchangers for aircraft have not yet been examined because of the difficulties associated with design optimization and reliability verification under high temperatures and pressures. The purpose of this study is to develop a manufacturing process for a heat exchanger that can be used in aircraft gas turbine engines. The manufacturing process involved preparing fine tubes through multi-step drawing and annealing processes, and joining these to a tube sheet through brazing. In this work, we reported on the total fabrication processes and mechanical integrity tests of a cooled cooling air (CCA) heat exchanger for the aircraft turbine engine. Through the work, a prototype model of a heat exchanger based on a gas turbine assembly was then developed using each of the individual processes. An X-ray CT test and an endoscopy test were performed to inspect the heat exchanger. The results indicated good manufacturing integrity; thus, the developed heat exchanger can be used for cooling turbine blades

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. McDonald, C. F., “Gas Turbine Recuperator Technology Advancements,” Proc. of International Gas Turbine and Fluids Engineering Conference and Products Show, Paper No. 72-GT-32, 1972.

    Google Scholar 

  2. Lee, C. Y., Kim, D. H., and An, Y. H., “Development Trend of Gas Turbine Cooling Technology in Turbine Blade and Vane,” Proc. of the KFMA Annual Meeting, pp. 60–62, 2013.

    Google Scholar 

  3. Kim, S. H., Park, J. S., Jung, E. Y., Lee, Y. J., and Cho, H. H., “Effect of Cooling Systems to Overall System Performance in Gas Turbine Blade,” Proc. of the Korean Society of Mechanical Engineers, pp. 26–27, 2014.

    Google Scholar 

  4. Joe, J.-R., Jeong, W.-J., Song, S.-H., Park, J.-S., Jeong, H.-S., et al., “Dynamic Analysis on Flow-Induced Vibration in Heat Exchanger Tube Bundle,” Proc. of the Korean Society of Marine Engineering, pp. 475–477, 2010.

    Google Scholar 

  5. Park, J. Y., Jeong, H. S., Han, J. Y., Kim, M. W., Kang, D. W., et al., “Research of Brazing Shape for Brazed Plate Heat Exchanger,” Proc. of KSPE Conference, pp. 687–688, 2009.

    Google Scholar 

  6. Jeong, H.-S., Ha, M.-Y., and Cho, J.-R., “Theoretical and FEAnalysis for Inconel 625 Fine Tube Bending to Predict Springback,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 12, pp. 2143–2148, 2012.

    Article  Google Scholar 

  7. Jeong, H.-S., Cho, J.-R., Jeon, J.-W., and Park, S.-H., “Investigation into Structural Reliability of a Brazed Part in Cross-Corrugated Plates,” Int. J. Precis. Eng. Manuf., Vol. 15, No. 2, pp. 251–258, 2014.

    Article  Google Scholar 

  8. Yun, Y.-H., Kim, H.-J., Kim, C.-S., and Cho, S.-M., “Development and Strength Evaluation of Ring Projection Welding Process of the Microminiature Tube and Tubesheet,” Journal of Welding and Joining, Vol. 27, No. 2, pp. 63–68, 2009.

    Article  Google Scholar 

  9. Kang, S. H., Park, S. H., Son, C. M., Ha, M. Y., Min, J. K., et al., “Analysis of Two Way Fluid Structure Interaction and Local Material Properties of Brazed Joints for Estimation of Mechanical Integrity,” Transactions of the Korean Society of Mechanical Engineers. A, Vol. 37, No. 1, pp. 9–16, 2013.

    Article  Google Scholar 

  10. Smith, W. F., “Structure and Properties of Engineering Alloys,” McGraw-Hill, pp. 494–498, 1993.

    Google Scholar 

  11. Kang, C. Y., Kim, D. U., Kim, S. H., and Woo, I. S., “Brazing Technology of Aircraft and Aerospace Equipments,” Journal of Korea Welding and Joining Society, Vol. 17, No. 2, pp. 1–8, 1999.

    Google Scholar 

  12. Special Metals, INCONEL alloy 625-Special Metals, http://www. specialmetals.com/assets/documents/alloys/inconel/inconel-alloy-625.pdf (Accessed 12 JUL 2016)

  13. Lee, Y.-W. and Kim, J.-H., “Influence of Brazing Temperature on Strength and Structure of SUS304 Stainless Steel Brazed System with BNI-2 Filler Metal: Fundamental Study on Brazeability with Ni-based Filler Metal (II),” Korean Journal of Materials Research, Vol. 17, No. 3, pp. 179–183, 2007.

    Article  Google Scholar 

  14. Jiang, W., Gong, J., and Tu, S., “Effect of Brazing Temperature on Tensile Strength and Microstructure for a Stainless Steel Plate-Fin Structure,” Materials & Design, Vol. 32, No. 2, pp. 736–742, 2011.

    Article  Google Scholar 

  15. Chen, W.-S. and Shiue, R.-K., “Brazing Inconel 625 using Two Ni/(Fe)-based Amorphous Filler Foils,” Metallurgical and Materials Transactions A, Vol. 43, No. 7, pp. 2177–2182, 2012.

    Article  Google Scholar 

  16. Moaveni, S., “Finite Element Analysis: Theory and Application with ANSYS,” Pearson Prentice Hall, 4th Ed., Chap. 6, 2014.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. R&D Center, DongWha Entec, Noksansandan261-ro, Gangseo-gu, Busan, 46753, South Korea

    Chang-Soo Kim & Hyeon-Jun Kim

  2. Department of Mechanical Engineering, Korea Maritime and Ocean University, Taejong-ro 727, Youngdo-gu, Busan, 49112, South Korea

    Jong-Rae Cho

  3. Department of Mechanical Engineering, Pusan National University, Busandaehak-ro 6 beon-gil, Geumjeong-gu, Busan, 46241, South Korea

    Sang-Hu Park & Man-Yeong Ha

Authors
  1. Chang-Soo Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hyeon-Jun Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jong-Rae Cho
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Sang-Hu Park
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Man-Yeong Ha
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Jong-Rae Cho or Man-Yeong Ha.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kim, CS., Kim, HJ., Cho, JR. et al. Manufacturing and mechanical evaluation of cooled cooling air (CCA) heat exchanger for aero engine. Int. J. Precis. Eng. Manuf. 17, 1195–1200 (2016). https://doi.org/10.1007/s12541-016-0143-4

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-016-0143-4

Keywords

Search

Navigation