The research of the DLR-Institute of Test and Simulation for Gas Turbines is focused on new and innovative technologies in the area of aero engines, stationary gas turbines and turbo machinery. The aim is to enable mobility and the generation of electricity that is climate neutral or even free of pollutants. The scientific and technical challenges for aero engines and turbo machines derive from the extreme operating conditions of these machines. This results in high rotational speeds and pressure levels, high temperatures and corrosive operating environments, all of which occur at the same time, coupled with the demanding requirements for long lifetimes and high reliability. As a consequence, the structures and materials are subject to unprecedented levels of mechanical, aerodynamic, thermal and chemical-corrosive loads.
In addition, climate neutral or even pollutant free solutions for aero engines or turbo machines depend strongly on the introduction of environmentally friendly fuels, including hydrogen. Using hydrogen as fuel invariably leads to an additional set of challenges with hydrogen embrittlement of the materials and water vapour corrosion of the parts’ surfaces being just two examples that significantly reduce the lifetime of parts and materials. Addressing these issues requires innovative solutions in the area of new designs for rotating and non-rotating parts as well as new materials and manufacturing methods (e.g. 3D printing). The effect, impact and functionality of these solutions must be quantifiable by numerical methods, which in turn must be validated by novel test devices and test rigs.
The DLR-institute develops digital twins and simulation models to calculate the aerodynamic loads and to access the damage mechanisms in engine parts and materials resulting from simultaneous mechanical, thermal and chemical-corrosive loads. Multiscale methods are used to quantify the long-term behavior from the microstructure of materials all the way up to engine parts and components. Unique world class test stands and test rigs are developed and operated to experimentally validate the digital models of innovative parts and materials at aero engine and turbo machine relevant performance levels, sizes and loads. All business, simulation and testing processes and data including meta data are modeled using digital ontologies. The processes and data are stored in graph data bases, which serve as the digital knowledge base of the institute.
Services and competences