Advanced Technologies for Gas Turbines

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Leadership in gas turbine technologies is of continuing importance as the value of gas turbine production is projected to grow substantially by 2030 and beyond. Power generation, aviation, and the oil and gas industries rely on advanced technologies for gas turbines. Market trends including world demographics, energy security and resilience, decarbonization, and customer profiles are rapidly changing and influencing the future of these industries and gas turbine technologies. Technology trends that define the technological environment in which gas turbine research and development will take place are also changing - including inexpensive, large scale computational capabilities, highly autonomous systems, additive manufacturing, and cybersecurity. It is important to evaluate how these changes influence the gas turbine industry and how to manage these changes moving forward.

Advanced Technologies for Gas Turbines identifies high-priority opportunities for improving and creating advanced technologies that can be introduced into the design and manufacture of gas turbines to enhance their performance. The goals of this report are to assess the 2030 gas turbine global landscape via analysis of global leadership, market trends, and technology trends that impact gas turbine applications, develop a prioritization process, define high-priority research goals, identify high-priority research areas and topics to achieve the specified goals, and direct future research. Findings and recommendations from this report are important in guiding research within the gas turbine industry and advancing electrical power generation, commercial and military aviation, and oil and gas production.

Publication information

136 pages · 8.5 x 11 · paperback
ISBN Paperback: 0-309-66422-5
ISBN Ebook: 0-309-66423-3
DOI: https://doi.org/10.17226/25630

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National Academies of Sciences, Engineering, and Medicine. 2020. Advanced Technologies for Gas Turbines. Washington, DC: The National Academies Press.

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David E. Crow

DAVID E. CROW, NAE, is a Distinguished Professor-in-Residence in the Department of Mechanical Engineering at the University of Connecticut and a consultant. He retired from Pratt and Whitney in April of 2002. Dr. Crow joined Pratt and Whitney in 1966 as an analytical engineer and has broad experience in multiple engineering disciplines and manufacturing. He is actively involved National Science Foundation studies on aeronautics. He is also a member of the Connecticut Academy of Scientists and Engineers. He belongs to the American Society of Mechanical Engineers, the Society of Automotive Engineers, the American Institute of Aeronautics and Astronautics, and the ASME Foundation. Dr. Crow is also on the Engineering Advisory Board at University of Connecticut and a member of the University of Missouri-Rolla Academy of Mechanical Engineers. Dr. Crow graduated from the University of Missouri-Rolla with a B.S. in mechanical engineering, and from Rensselaer Polytechnic Institute with an M.S. in mechanical engineering. He received his Ph.D. in mechanical engineering from the University of Missouri-Rolla. He has served on the Academies’ Board on Army Science and Technology, the Panel on Review of the Engineering Laboratory at the National Institute of Standards and Technology and the Committee on Human Spaceflight: Technical Panel.

Tresa M. Pollock

TRESA M. POLLOCK, NAE, is the ALCOA Distinguished Professor of Materials at the University of California, Santa Barbara. Previously she was a professor in the Department of Materials Science and Engineering at Carnegie Mellon University and at the University of Michigan. Research interests include the mechanical and environmental performance of materials in extreme environments, unique high temperature materials processing paths, ultrafast laser-material interactions, alloy design and 3-D materials characterization. Recent research has focused on thermal barrier coatings systems and platinum group metal-containing bond coats, new intermetallic-containing cobalt- base materials, vapor phase processing of sheet materials for hypersonic flight systems, growth of nickel-base alloy single crystals with a new liquid tin-assisted Bridgman technique, development of new femtosecond laser-aided 3-D tomography techniques and development of models for Integrated Computational Materials Engineering efforts. She is a fellow of TMS and ASM International, an associate editor of Metallurgical and Materials Transactions, and a former president of the Minerals, Metals, and Materials Society. She holds a Ph.D. in materials science and engineering from the Massachusetts Institute of Technology. She has served on the Academies’ National Materials and Manufacturing Board,the Panel on Materials Science and Engineering at the Army Research Laboratory, and the Panel on Armor and Armaments for the Army Research Laboratory Technical Assessment Board.

Sean Bradshaw

SEAN BRADSHAW is the senior manager of the Hot Section Engineering (HSE) Advanced Methods Group at Pratt and Whitney. He is also an adjunct professor of mechanical engineering at Columbia University, where he teaches courses in thermal-fluids engineering and aerospace propulsion. Previous assignments at Pratt and Whitney include serving as technical team lead in combustor aerodynamics for commercial, military, and technology development programs and as an individual contributor responsible for commercial and military high pressure turbine blade cooling design. His current responsibilities include development, deployment, and support of advanced tools and methods for hot section aerothermal, structural, and lifing analysis. He works directly with technical teams to solve problems focused on engine safety, reliability, and affordability and to develop strategic plans to identify and fill analytical tool and process needs as well as support and maintain existing tools. Dr. Bradshaw holds five patents. He earned a Ph.D. in aeronautics and astronautics from the Massachusetts Institute of Technology. He has not previously served on an Academies’ committee.

Michael J. Foust

MICHAEL J. FOUST is the manager for the engineering section at GE Aviation in Systems Design Technologies. He leads a global team responsible for engine system design technologies for engine dynamics, aeromechanics, clearances, and engine mounts for all commercial, military, and aeroderivative engines. Dr. Foust held various roles of increasing responsibility in the areas of combustion design, engine systems design, Six Sigma, and customer support. Most recently, he was manager for combustion aero design. At GE, he has been a major contributor in technology development of the low emissions twin annular premixing swirler combustor and received four patents. He was instrumental in engine certification of the GP7200 engine for the Airbus A380, with a focus on certification of the combustor and high pressure turbine. His leadership experiences included development of combustors for the GEnx, Leap, Passport 20, GE9x, GE38, ADVENT, and LMS100 engines. In his current role, Dr. Foust leads his team in rotordynamics, fan and compressor aeromechanics, and turbomachinery clearances for engine programs such as GE9x, Leap, Passport 20, LM9000, and various military applications. Dr. Foust is a member of the ASME IGTI Combustion, Fuels, and Emissions technical committee. He earned his Ph.D. in mechanical engineering from the Pennsylvania State University. He has not previously served on an Academies committee.

Brian Graham

BRIAN GRAHAM is a principal engineer of services materials technology at General Electric (GE) Aviation, where he has more than 30 years of experience supporting manufacturing, engineering, and engine services. Most recently, he managed the Materials Technology group within GE’s Additive business supporting parameter development, powder technology, design applications, and materials behavior for laser powder bed processes. Previously, he held leadership positions supporting airfoils coatings, repair technology development, as well as engineering manager at the Aviation Component Service Center in Cincinnati. Mr. Graham holds a B.S. in metallurgical engineering from the University of Cincinnati. He has not previously served on an Academies’ committee.

Seyfettin C. Gulen

JOHN GÜLEN is a senior principal engineer and a distinguished engineer and scientist in the Engineering Technology Group of Bechtel Infrastructure and Power, Inc., located in Reston, VA. Previously, Dr. Gülen was a principal engineer in General Electric’s Power Systems Division (later GE Energy) in Schenectady, NY. At Bechtel, Dr. Gülen is responsible for new technology assessment (e.g., supercritical CO2, CSP, and energy storage), steam and gas turbine performance, operability and risk analysis, turbo-machinery system design, analysis and optimization. Early in his career, Dr. Gülen worked in ESPC, Inc., focusing on transient modeling of the novel Cascaded Humidified Advanced Turbine (CHAT) cycle and the data analysis of the Compressed-Air Energy Storage (CAES) plant in McIntosh, AL. Between 1996 and 2000, Dr. Gülen worked in Thermoflow, Inc., in Massachusetts on the development of industry-leading heat balance, plant cost, and performance monitoring software such as GTPRO, ThermoFlex, and PEACE. Upon joining GE in 2000, Dr. Gülen worked in a variety of roles with increasing responsibilities in various GE Energy organizations. He made significant contributions to New Product Initiation Tollgates 1-3 of 109FB-SS combined cycle (CC) power plant with A15 HEAT™ Steam Turbine, Baglan Bay 109H-SS CC Power Plant Characterization Test in 2003, IGCC 207FB NPI TG1-3 system design and performance modeling. Dr. Gülen is an ASME Fellow. He earned his Ph.D. in mechanical engineering from Rensselaer Polytechnic Institute in Troy, NY. He has not previously served on an Academies’ committee.

Allister James

ALLISTER JAMES is the senior expert for materials at Siemens Energy Inc., where he works with the Additive Manufacturing Materials team. Previously at Siemens, Dr. James was the manufacturing lead for oxide-oxide ceramic matrix composites; the materials lead for the Advanced Hydrogen Turbine Program, and the group leader for superalloys. Prior to joining Siemens he was the program manager for the development of the alloy RR1000 at Rolls-Royce Aerospace in the United Kingdom. At Siemens Energy, Dr. James has led the Superalloys Group with responsibility for the validation, manufacture, and service support of alloys for hot section turbine components. His current interests are focused on the development additively manufactured turbine components using selective laser melting. At Rolls-Royce Dr James was responsible for the development of RR1000, an alloy for compressor and disc applications. He continues to support the manufacture of discs and drums for Rolls-Royce aero-derivative engines for Siemens. He has been awarded 40 patents in the field of materials and manufacturing. He earned his Ph.D. in materials from the University of Birmingham, United Kingdom. He has not previously served on an Academies’ committee.

Timothy C. Lieuwen

TIMOTHY C. LIEUWEN, NAE, serves as executive director of the Strategic Energy at the Institute at Georgia Technology. He is also a Regents’ Professor and the David S. Lewis, Jr. Chair in the School of Aerospace Engineering. He is also founder and chief technology officer of TurbineLogic, an analytics firm working in the gas turbine industry. Dr. Lieuwen is an international authority on gas turbine technologies, both from a research and development perspective and from a field/operational perspective. He has authored or edited four books, including the textbook Unsteady Combustor Physics. He has also authored 350 other publications and received four patents, all of which are licensed to the gas turbine industry. He is editor-in-chief of the Aerospace Industries Association (AIAA) Progress book series. He is also past chair of the Combustion, Fuels, and Emissions technical committee of American Society of Mechanical Engineers (ASME) and has served as associate editor of Combustion Science and Technology, Proceedings of the Combustion Institute, and AIAA Journal of Propulsion and Power. He is a fellow of ASME and AIAA, and a recipient of the AIAA Lawrence Sperry Award, ASME’s George Westinghouse Gold Medal, National Science Foundation CAREER Award, and various best paper awards. Board positions include appointment by the Secretary of Energy to the National Petroleum Counsel, board of governors of Oak Ridge National Lab, and board member of the ASME International Gas Turbine Institute. He has also served on a variety of federal review and advisory committees. He holds a Ph.D. in mechanical engineering from Georgia Tech. He has served on the Academies’ Review of NASA Test Flight Capabilities and the Decadal Survey of Aeronautics.

Michael Maloney

MICHAEL J. MALONEY, NAE, is the director of the Alloy and Coating Material and Manufacturing Process Development Group at Pratt & Whitney Aircraft Engines. Previously Dr. Maloney was manager of the Advanced Coatings Development Group and before that a senior engineer. At Pratt & Whitney, Dr. Maloney has led the development, implementation, manufacturing support and field support of turbine engine coating systems. The coating systems consist of oxidation resistant metallic coatings, thermal barrier coatings, wear resistant coatings, and abradable seal coatings. Dr. Maloney has also led the development, implementation, manufacturing support, and field service support of nickel, cobalt, titanium, steel and aluminum alloys used throughout the gas turbine engine. Primary areas of research and development have consisted of ceramic thermal barrier coatings and metallic oxidation and corrosion resistant coatings. These technologies are now utilized in the hot section of the new generation of advanced commercial and military gas turbine engines. He is a member of the Connecticut Academy of Science and Engineering. He has been granted 44 U.S. patents in the area of materials and manufacturing processes relating to gas turbine engines. He earned his Ph.D. in metallurgy with a minor in ceramics from the Massachusetts Institute of Technology. He has not previously served on an Academies committee.

Parviz Moin

PARVIZ MOIN, NAS/NAE, is the Franklin P. and Caroline M. Johnson Professor of Mechanical Engineering and the Director of the Center for Turbulence Research (CTR) at Stanford University. Established in 1987, CTR is devoted to fundamental studies of multi-physics turbulent flows, and is widely recognized as the international focal point for turbulence research, attracting diverse groups of researchers from engineering, mathematics and physics. Dr. Moin pioneered the use of Direct Numerical Simulation and Large Eddy Simulation techniques for the study of turbulence physics, control, and modeling of fluid mechanics, and has written widely on the structure of turbulent shear flows. His current research interests include the interaction of turbulent flows and shock waves; aerodynamic noise; hydro-acoustics; aero-optics; combustion; numerical analysis; turbulence control; large eddy simulation; and parallel computing. Dr. Moin is the co-editor of the Annual Review of Fluid Mechanics and associate editor of the Journal of Computational Physics. He is the recipient of NASA's Exceptional Scientific Achievement Medal, the American Institute of Aeronautics and Astronautics (AIAA)’s Lawrence Sperry Award, American Physical Society’s Fluid Dynamics Prize, AIAA Fluid Dynamics Award, and the NASA Outstanding Leadership Medal. He was honored with an Einstein Professorship by the Chinese Academy of Sciences in 2009, and he was inducted to the Royal Spanish Academy of Engineering in 2014. He is a fellow of the American Physical Society and the AIAA, as well as a member of the, American Academy of Arts and Sciences Dr. Moin received a Ph.D. in mechanical engineering from Stanford University. He served as a former chair of the Engineering Sciences Section of the National Academy of Sciences and the Aeronautics and Space Engineering Board.

Karen A. Thole

KAREN A. THOLE is a professor of mechanical engineering at the Pennsylvania State University. Dr. Thole’s scholarship in research has been focused on experimental fluid mechanics and heat transfer, particularly as applied to developing new cooling methods for gas turbine components. More recently, she has used advanced manufacturing methods to further develop new cooling methods for turbine airfoils. She founded two experimental research laboratories at Pennsylvania State University: the Experimental and Computational Convection Lab (ExCCL) and the Steady Thermal Aero Research Turbine (START) Lab, with both being selected as centers of excellence for one of the major gas turbine manufacturers. She has published nearly 200 archival journal papers and conference proceedings and holds three patents. Many of the cooling technologies she researched are now used on the engines that power the Joint Strike Fighter and commercial jets. She has served as the chair of the board of directors for the International Gas Turbine Institute of the American Society of Mechanical Engineers (ASME), chair of the ASME Energy Conversion and Storage Segment, and a member of the NASA Advisory Council’s Aeronautics Committee. Dr. Thole was a recipient of a National Science Foundation Career Award, was recognized by the White House as a 2011 Champion of Change in STEM, and as a Society of Women Engineers’ Distinguished Engineering Educator. She also received ASME’s George Westinghouse Gold Medal for her work in power generation and the ASME’s Edwin F. Church award for her contributions to mechanical engineering education. She holds a Ph.D. in mechanical engineering from the University of Texas, Austin. She has served on the Academies’ Committee on Propulsion and Energy Systems to Reduce Commercial Aviation Carbon Emissions.

Frederic Villenueve

FREDERIC VILLENEUVE is head of Digital Innovations within the Siemens Power and Gas Product Research and Development (R&D) business segment. He is in charge of the R&D digitalization strategy, and he leads a portfolio owner of digital solutions for power systems based on machine learning and data science. He has been with Siemens for more than 10 years, starting as a probabilistic design engineer where he developed for Siemens the Gas Turbine Technology Portfolio Optimization framework, served as team lead to develop a gas turbine group focused on advanced methods for thermo-mechanical analysis, and managed the Aerodynamics and Methods group. In this responsibility, he led the portfolio of new technologies to improve the aerodynamics performance of the next generation of Siemens gas turbines. More recently, Dr. Villeneuve was the product owner of the next generation gas turbine design environment at Siemens, where he developed a gas turbine design platform enabling shorter design life cycle through design data, standardized design processes, and overall system management. He is a recipient of the George Westinghouse Silver Medal Achievement Award for distinguished service in the power field of mechanical engineering from the American Society of Mechanical Engineers (ASME). He has also received the Council of Outstanding Young Engineer Award from Georgia Tech. He has a Ph.D. in aerospace engineering from Georgia Institute of Technology. He has not previously served on an Academies’ committee.

Charles H. Ward

CHARLES H. WARD is chief of the Manufacturing and Industrial Technologies Division at the U.S. Air Force’s Air Force Research Laboratory in the Materials and Manufacturing Directorate. He is also an adjunct faculty member of materials engineering at the University of Dayton and editor-in-chief of the Integrating Materials and Manufacturing Innovation journal. Previously, Dr. Ward led the efforts by the Materials and Manufacturing Directorate in integrated computational materials science and engineering, and he was co-chair of the Materials Genome Initiative Subcommittee under the National Science and Technology Council. He has also served as chief of the Metals, Ceramics, and Nondestructive Evaluation Division of the Materials and Manufacturing Directorate, staff officer to the Assistant Secretary of the Air Force for Acquisition, and Air Force liaison for materials research and development in Europe. He has served as manager for the Air Force's basic research program in metals and as technology maturation manager on the F-35 propulsion program. His past research studied the microstructure-property relationships in titanium and titanium aluminide alloys. More recently, he has focused on efforts to build a materials data infrastructure and model-based definitions of materials and processes. He is a fellow of ASM International. He received his Ph.D. in materials science and engineering from Carnegie Mellon University. He has not previously served on an Academies’ committee.

Bernhard Winkelmann

BERNHARD WINKELMANN is director of Technology and Gas Turbine New Product Development at Solar Turbines, Incorporated. Previously, Mr. Winkelman served in leadership roles concerning strategic business initiatives within the Oil and Gas and Customer Services organizations at Solar Turbines. He has led research and development, engineering, manufacturing, and testing of various turbomachinery products. Currently, Mr. Winkelmann is the executive sponsor for the Solar Turbines–Penn State University Center of Excellence for Gas Turbines, which is in its first year has already commissioned several gas turbine-related research projects in combustion, heat transfer, aero-acoustics, and additive manufacturing. Mr. Winkelmann has also served as executive chairman for the International Gas Turbine Institute of the American Society of Mechanical Engineers. He earned his M.S. in mechanical engineering, turbomachinery, and design from the University of Applied Sciences in Bochum, Germany. He has not previously served on an Academies’ committee.

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