In many arid regions, particle ingestion can occur within propulsive gas turbines. The ingested particles can severely impact performance and may damage many primary gas path components through erosion or deposition. Characterizing crystalline deposits on metallic substrates can allow for the prediction of deposition to improve component resilience and develop health monitoring algorithms. This work investigates the effect of temperature and angle on sand deposits and attempts to quantitatively characterize the deposition of Arizona Test Dust (ATD) onto Hastelloy X. The first study presented in this thesis describes a preliminary investigation of sand deposition at temperatures and velocities similar to those found in the turbine section of propulsive gas turbine engines and presents an equation for predicting deposition as a function of gas path temperature and impact angle. The sand and air mixture maintained a constant flow velocity of approximately 70 m/s, impact angle was varied from 30° to 90°, and the gas path temperature was varied from 1000 °C to 1100 °C. The number of deposits was found to linearly increase with temperature for all coupon angles tested. The model was able to explain approximately 67% of the deposition that occurs, with the remaining percentage due to other factors such as injection rates and surface temperature. The second study describes an improved investigation of sand deposition and presents an equation for predicting deposition as a function of surface temperature and impact angle. This study characterizes deposition using percent coverage in addition to deposits per square millimeter. Deposition is a quadratic function of both near surface coupon temperature and coupon angle. The model using deposits per mm2 was able to explain 96.3% of the deposition that occurred and the model using percent coverage was able to explain 98.9% of the deposition that occurred. / Master of Science

Increasing commercial and military aircraft operations in arid environments are increasing the likelihood of sand and dust ingestion. Turbine engines are particularly susceptible to the ingestion of sand and dust, which can erode cold-section components and deposit onto hot-section components. Ultimately, the erosion and deposits will shorten the operational lifespan of these engines and limit their availability thereby increasing maintenance costs and risking safety. Mitigating these risks has become more prevalent in recent years due to increasing combustion temperatures in effort to increase fuel efficiency. Increasing combustion temperatures directly increases deposit formation onto hot-section components. Monitoring deposit formation on existing turbine engine platforms and improving deposit resilience on new designs has been the industry focus for the last two decades. This study focused on statistically modeling the initial onset of microparticle deposits onto an analogous hot-section surface. Generally, as deposits accumulate onto a hot-section surface, the existing deposit formation is more likely to bond with incoming particulate at a faster rate than an exposed bare surface. Predicting the initial deposits onto a bare surface can determine the accelerated deposition rate depending on subsequent particulate impinging onto the surface. To emulate the initial deposits, a HASTELLOY® X test coupon was exposed to 20 μm to 40 μm samples of Arizona Road Test Dust (ARD) at varying loadings and aerosol densities. The Virginia Tech Aerothermal Rig was used for all test scenarios at flow-particle temperatures between 1000°C to 1100°C. Several statistical models were developed as a function of many independent variables, culminating with a final sticking probability (SP) model. Overall, the SP of individual ARD particulate is a primary function of flow-particle temperature and normal impact momentum. Tangential impact momentum of a particle will decrease the SP, while surface temperatures reaching isothermal conditions with the flow will increase SP. However, there are specific cases where lower surface temperatures and high particle temperatures result in a high SP. Particle size was a strong predictor of SP where particles between 10 μm to 19 μm were 5 to 10 times greater than the 19 μm to 40 μm range. Additional studies will be necessary to examine some additional parameters that become more prominent with smaller particle sizes. Ultimately, the intention of the models is to assist turbine engine designers to improve resilience to deposit formation on hot-section components. / PHD

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. / Master of Science

The design and performance evaluation of in-duct, isokinetic samplers capable of testing flat sheet, nuclear-grade High Efficiency Particulate Air (HEPA) filters simultaneously with a radial filter testing system is discussed in this study. Evaluations within this study utilize challenge aerosols of varying particle diameters and masses such as hydrated alumina, Arizona test dust, and flame-generated acetylene soot. Accumulated mass and pressure drop for each in-duct sampler is correlated to the full-scale radial filter accumulated mass from initial to 10 in w. c. of loading. SEM imaging of samples at 25%, 50%, 75% and 100% loading verifies particle sizes with instrumentation used, revealing filter clogging resulting from particle impaction and interception. The U.S Department of Energy requires prototype nuclear-grade HEPA filters to be qualified under ASME AG-1 standards. The data obtained can be used to determine baseline performance characteristics on pleated radial filter medium for increased loading integrity and lifecycle endurance.