FD3/64-2:1!

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racketmotorman
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Re: FD3/64-2:1!

Post by racketmotorman » Wed Nov 18, 2009 10:22 pm

Hi Anders

With low pressure ratio combustors they certainly need to be larger , combustors are compared by their "combustion intensity " .....BTU's / cubic foot/atmosphere/hour , so if the "atmospheres" ie pressure , is low , then the cubic feet need to be greater to compensate .

The engine shouldn't run any "hotter" , the ultimate temperature will depend on what the turbine wheel can survive , but what will be "relatively" hotter is the exhaust due to there being a small pressure ratio across the turb stage and jet nozzle resulting in less temperature drop occuring for the same TIT as a higher pressure ratio engine , .................less pressure/temp drop means less power :-(

OT , .................LOL.....with a compressor sucking >200 hp from the turbine , an extra hp or 2 for brass bushes and thrust bearing , is kinda irrelevant ...............balls at high rpm create a lot of drag , so theres not such a big difference between them and "brass" , balls are best at those lower initial spoolup rpm , thats why they're better on performance automotive turbos where you want every last millisecond of turbo lag to be eliminate, but for us , we're idling at a decent "boost" , so that advantage the balls have is negated to a large extent .

Cheers
John

Axel Borg
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Re: FD3/64-2:1!

Post by Axel Borg » Thu Nov 19, 2009 4:51 pm

Update :D
Attachments
IMG_3939.JPG
Diffusor blades 1mm steel.
IMG_3937.JPG
Base plate material, 3mm steel and 14mm plywood.
IMG_3947.JPG
Rear.
IMG_3948.JPG
Front.
IMG_3949.JPG
Diffusor blades in place.

Johansson
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Re: FD3/64-2:1!

Post by Johansson » Fri Nov 20, 2009 2:48 pm

It is looking better and better! :D

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Re: FD3/64-2:1!

Post by Axel Borg » Fri Nov 20, 2009 9:18 pm

Thank you.

Here is the result of yet a coupple of well spent hours :D
This is the hardest part to make in my opinion. Its about 40% completed in this stage.
IMG_3950.JPG
Guide vane cone.
IMG_3954.JPG
Gluing the paper template on to the cone.
IMG_3959.JPG
40% done...

Axel Borg
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Re: FD3/64-2:1!

Post by Axel Borg » Sun Nov 22, 2009 5:08 pm

Finished cutting out, sanding and finaly welding the NGV blades today. This simple procedure took about 6 hours...
The 1mm stainless steel that the vanes are made of is hard to cut, but ok to sand/grind.
The result is not perfect, but hopefully good enough.
Next step is to make the shaft locator that will slide into the place currently
occupied by the plywood jig.
IMG_3965.JPG
Before welding.
IMG_3967.JPG
After welding.

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Re: FD3/64-2:1!

Post by Axel Borg » Tue Nov 24, 2009 11:45 am

Update; finally finished the NGV parts!
IMG_3969.JPG
Wise from experience, its well spent time truing up the turbine housing.
IMG_3974.JPG
Central part with slide-in-fit.
IMG_3977.JPG
This is how the internal part af the combustion chamber will line up.
IMG_3978.JPG
Adjusteble shaft tube locator in place. This 1mm stainless steel bracket is the only direct heat transfere path from the internal structur of the motor to the ball bearings in the central shaft tube, exept from the shaft itself of course.

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Re: FD3/64-2:1!

Post by Johansson » Wed Nov 25, 2009 6:43 pm

Have you given the material thickness any thought? Relatively large NGV areas and only 1mm stainless sheet, won´t there be a risk of heat warping?

Nice work anyway, looking forward to the first test video! :D

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Re: FD3/64-2:1!

Post by Axel Borg » Wed Nov 25, 2009 8:11 pm

I simply took the material I had laying around in my work shop, but you are right, it might become a problem.
The curvature of the blades gives them a little extra rigidity though, and they give a more trust worthy impression IRL :wink: ....
There are so many things that can go wrong..... :(
Today I have made a air inlet (trumpet shaped) cone of glass fibre, still in the curing process.
I’m currently working on the fuel delivery ring dimensioned for propane.

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Re: FD3/64-2:1!

Post by Axel Borg » Thu Nov 26, 2009 9:16 pm

Update.

I made some progress today as well :D
Attachments
IMG_3985.JPG
The turbine housing section is now tack-welded in place and the outer housing is cut to right length.
IMG_3981.JPG
Steel fuel ring with 10 small brass tubes hard soldered in place.
IMG_3980.JPG
Combustion chamber almost completed, a few radial spacers are yet to be made. The outer circular part is removable.

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Re: FD3/64-2:1!

Post by Fricke » Thu Nov 26, 2009 9:50 pm

Looking good Axel!

I'll be following this thread!

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Re: FD3/64-2:1!

Post by Johansson » Fri Nov 27, 2009 6:15 am

It is starting to look like a gas turbine now, nice work!

Have you calculated the max revs of the compressor, and if so how did you do it?

Axel Borg
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Re: FD3/64-2:1!

Post by Axel Borg » Fri Nov 27, 2009 8:03 am

Thank you for your support guys!

Regarding compressor rev, i just assume, and hope, that it will be able to take half of the original designs rpm:75000rpm/2.
According to Shreckling it is the inner part, "the leading edge" of the compressor blades that will fail first, so adding more carbon fibre around the compressor is not the solution. The compressor he made has survived 90.000rpm as well so 75.000 include a safety margin.
Attachments
IMG_3989.JPG
Inlet glas fiber cone. What do they say? Third time is a charm....Tredje gången gillt!

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Re: FD3/64-2:1!

Post by Axel Borg » Sat Nov 28, 2009 7:58 am

Since I had a couple of mini sparkplugs laying in a box doing no good, I decided to mount one of them in the combustion camber. The size of this motor makes it easy to add such things...
Right now I am working on the shaft tunnel. In this first attempt I will try to build it by welding several pieces of aluminium together. If this does not work I will turn it down from a solid cylinder instead. It’s just such a waste of material.
Attachments
IMG_3996.JPG
Spark plug! High temperature silicon on top.
IMG_3991.JPG
Front cover plate turned down to match the compressor wheel and the intake cone. Cone not yet glued in place.

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Re: FD3/64-2:1!

Post by Johansson » Sun Nov 29, 2009 6:56 pm

It is never a waste of material if you build gas turbine parts out of it. 8)

Axel Borg
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Re: FD3/64-2:1!

Post by Axel Borg » Sun Nov 29, 2009 8:50 pm

The first version of the shaft tunnel is coming along fine. It’s not at all difficult to weld aluminium as long as the argon gas keeps flowing. I always thought it was close to impossible to weld aluminium at home using a ordinary mig-mag machine..
IMG_3998.JPG
Simple but working Laser tachometer hack. The laser diode and the photo diode has been pulled out and re-conected via extension cord. Mounted on the front cover plate.
IMG_4000.JPG
The laser diode and the photo diode

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