Browsing Posts tagged Engine

Boating Tutor – Boat Hull Designs and Engine Types

There are a variety of shapes and sizes for boat “hulls” or boat bottoms. A hull is designed to either displace or plane through the water. Small powerboats are usually built with planing hulls. They are designed to rise up and ride on top of the water at high speeds. Sailboats on the other hand use displacement hulls which allows the larger boat to move through the water smoothly.

Hull Types come in Flat bottom, Round bottom, Deep-V hull and Multi-hull.

Flat bottom hull boats are generally designed for slow speeds and calm waters. They tend to be less stable than other hull types in rough water.

Round bottom hull boats move smoothly through the water with little effort. A canoe is an example of a round bottom hull boat. Boaters have to be more cautious when loading, entering and exiting a round bottom boat because these boats can roll very easily.

Deep-V hull boats move through rough water, at higher speeds with a mother ride than a flat bottom or round bottom boat. This the most common hull type for powerboats. These boats require a larger engine than a flat or round bottom boat.

Multi-hull boats require plenty of room to steer and turn and are the most stable of the hull types. Pontoon boats and Catamarans are boats that use the multi-hull design.

Boats not only have different hull types, they are powered by different engine types (outboard, inboard and stern drives).

Outboard engines are typically two-stroke engines which require oil to be mixed with fuel to lubricate the engine, similar to gas powered weed eaters. An outboard engine is mounted on the transom of the boat and is controlled by a hand tiller or steering wheel which moves the entire engine as steering is changed.

Inboard engines are typically four-stroke automotive engines which have been modified for use on the water. These type engines are mounted inside the hull of the boat and powers the drive shaft which is connected to the propeller. Directly behind the propeller is the rudder which controls steering.

Stern Drive engines are commonly known as inboard/outboard engines. They have features found on both inboard and outboard engines. Stern drive engines use four-stroke automotive engines, modified for use on water, like inboard engines. Similar to outboard engines, the entire engine moves when the steering is adjusted. Stern drive engines are mounted inside the boat and attached through the transom.

For additional articles on boating visit: Cool Boating Site.

Cool Boating offers a source for all aspects of Boating information, for both the beginner and the experienced boater. Get additional boating information now at: Cool Boating Site. Get Fishing information at: GotAGoFishing.

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Engine vibration of construction machinery maintenance and effective method – construction machinery, engines, shock – construction machinery industry

Construction Machinery Engine How to vibration
Engine is the source of power, and our heart as valuable. As the main source of vibration of construction machinery, engine vibration is a technical tender mentioned, due to some effective ways to reduce the vibration. 1, local oscillator control Source of vibration control throughout the design, manufacture and even the use of the whole process, reflected in the balance as to improve engine performance, dynamic performance, Parts Precision machining and assembly. Engine vibration in the form of work is diverse, the main reasons are: the focus of periodic engine moving along the reciprocating parts Cylinder The role of the inertia force from top to bottom, all rotating parts of the centrifugal inertial force, the role of gas pressure caused by the crankshaft rotation cycle of alternating changes. These unbalanced forces and moments are usually the result by changing the engine design parameters to adjust the frequency of the system to avoid structural resonance, improved resonance characteristics, such as the body through modal analysis and finite element method to study the body’s natural frequency of vibration mode and so on. Reduce machine vibration source and the first from the design stage to avoid the resonance considered in the overall design of systems engineering thinking through the full application of modern design methods, such as limited source design, reliability design, robust design, optimal design, computer aided design and intelligent system and expert system design. 2, vibration isolation 1, rubber vibration isolation The traditional use of elastic support lower engine vibration, vibration isolation device of simple structure, low cost and reliable performance. Rubber bearing is usually installed in Frame , According to the situation by force into compressive, shear and compression shear and other complex. Compression-type structure is simple, easy to manufacture, widely used and because the natural frequency is high, generally limited to the use of the vertical direction. Low shear vibration frequency, but intensity is not high. Compression and shear composite structure combines the advantages of the first two meet durability and reliability requirements, it is the most widely used at home and abroad. In order to rubber bearing isolation system has good isolation performance parameters form requires the same direction, the spring constant, which would also allow some form of size reduction. String 8 2, spiral steel wire rope isolator
Rope as a damping device with low frequency and large damping of the high-frequency performance of low-stiffness varying parameters, which can effectively reduce body vibration. With the traditional rubber vibration source, compared with anti-oil, anti-corrosion, anti-temperature, high temperature resistance, aging resistance, and the advantages of small size, isolation effect depends on its amplitude is. 3, hydraulic isolation Hydraulic support system is the traditional rubber bearing with hydraulic damping structure composed of one, in the low frequency range can provide larger damping, the value of the engine vibration play a significant role in the rapid decay, the lower the dynamic high frequency stiffness, can be reduced Cab Sound Vibration and dry inside. III engine vibration control of construction machinery Projects sometimes can not avoid resonance, thus, increase the system damping used or vibration absorber to reduce vibration. Vibration absorber is pressing band control using viscoelastic damping material has a high energy loss, when the vibration damping material spread, the material internally generated tension, bending and shearing deformation, which consume large amounts of vibration energy, so vibration attenuation. Vibration damping technology with the main advantage is that without changing the original structure, no additional auxiliary equipment, does not require external Energy , Taking up less space efficient is a promising measure vibration and noise reduction. Zhengzhou “Yutong Heavy Industries” production of new products 955A Wheel Loader Take the lead in the selection of shock absorber vibration absorber using this, the use of new technology to achieve the desired effect of reducing vibration and noise.

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Lubrication And Cooling Engine Tools

All of the device tools has two diverse systems, one for refrigeration and one more for lubrication. The lubrication system itself tends, in general, quite intricate and involves a combination of different procedures, as we shall see. The cooling system is autonomous of the previous and focuses primarily on the cooling of the cutting tool or tools. It has a blocked circuit circulation of liquid refrigerant recovery comprising tray, reservoir, rigid pipes, hoses, flow regulators and pump. The cutting fluid also serves as a lubricant to Minimize friction in the machining process.

Lubricating System

The lathe lubrication system  is designed to ensure a precise amount of lubricant, appropriate for each element, among the different mechanical parts that are formed. Various of the essential elements that need to oil are guides to the bench or tree bearings and bearings and shafts.

The procedure used for lubrication and lubricant selection depends on the special characteristics of the organ or mechanism, in particular the relative speed of work, the highest heat specified and the position in the whole engine. Consequently, while the gearbox is ordinarily lubricated by partial immersion in an oil bath and splash, the lubrication bearings are located, either through an secondary duct bearing lubricant, either through what is called “self-lubricating” which requires a special assembly.

The localized lubrication of bearings and axle bearings requires a circuit design that incorporates a gear pump, besides the canals and pipes needed. Other elements, such as guides and ball screws are lubricated carts manually using a dispenser or oil.

Cooling System

Investigations developed in the late nineteenth century (Taylor and others) showed that the cooling and lubrication of the tool improves cutting conditions. Evidently, in a machining operation, which produces metal removal under precise cutting conditions (depth in passing, cutting speed, feed rate) a process of plastic deformation is showed previous to fissure,  which generates a lot of temperature, equivalent to the deformation work. However, the heat intensification at the tip of the tool can turn into unusable in a few seconds of work. However, this circumstances involves a unsustainable cost in frequent replacement of tools with a lousy quality finish of the machined surfaces, and it is needed a guaranteed amount of refrigerant which must be supplied continuously and whose course is directly dependent on the conditions of the cutting process and equipment of the tool and the workpiece.

Not so obvious is that lubrication is beneficial to the cutting process. Indeed, in the initiation as in the progression of the cut, the tool must overcome a quantity of internal resistance in the material to be machined by consuming some power. In addition, contact and the existence of relative action among two materials of diverse solidity are inherent to the process. It is clear that the action of a lubricant film will reduce friction and, consequently, the deformation work and the overall power necessary. The presence of the lubricant will get also lessen the tool wear (edges and angles of cut) and lengthen its life. It is eminent that friction reduction represents a decrease of the Heat reached during the cutting process, thereby improving the efficiency of the cutting fluid as a coolant.

To prevent loss of fluid in the circuit, the lathes are built with a movable protective cabs, preventing  at the same time that chip projections touch the operator of the machine.

Felipe Garcia es consultor de Ibertest Internacional Materials Testing Devices

Mercedes Fan Clutch—blow the Engine Down for Greater Performance

Every well-oiled machine needs some kind of refreshment to cool down. In this case, a powerful engine such as the one installed in a Mercedes Benz needs an efficient cooling system to prevent it from overheating. If this persists, it will retain the optimum engine performance it is expected of a Merc.

A couple of subcomponents are necessary to fill-in the cast, these are: the radiator, auxiliary fan, and the grill (which, not only for aesthetic purposes, permits air in to help cool down the engine). But a subcomponent that makes a great deal in helping the cooling system to perform above expected performance is the Mercedes fan clutch.

Before giving out the details about the fan clutch, let us first get a lowdown of things on why the Mercedes fan clutch is necessary in the functioning of the cooling system. The radiator needs a helping hand from the auxiliary fan to dissipate heat in cooling the engine. In order to draw more cool air, there are vehicles that are being installed with an additional fan in front of the radiator. This extra fan is aimed particularly during hot season or when the vehicle isn’t moving fast enough. On these situations, very small amount of cool air gets in the radiator; hence, the engine isn’t cooled properly.

This is where the Mercedes fan clutch comes in. Outfitted in the radiator, the fan clutch is a device with a small fluid mixture to control the speed of the auxiliary fan. When the engine is cool or even at normal operating temperature, the fan clutch partially disengages the auxiliary fan. This saves power since the engine does not have to fully drive the fan.

The main objective of the Mercedes fan clutch is to make sure that the auxiliary fan will run or spin at the proper speed to prevent the engine from overheating as well as to decrease drive to the fan when it is no longer needed. The fan clutch possesses a fluid mixture that’s partly made up of silicone oil that’s intended for that sole purpose. When the temperature of the air that passes through the radiator gets higher, the heart commands a bimetal coil spring to uncoil or expand. As it expands, it lets a little more oil to come into the fluid coupling before it will start to run or rotate the fan.

Dwyane Thomas is a part time cook and full-time auto-enthusiast. This 31-year old Civil and Environmental graduate is a consultant at one of the engineering firms in Pennsylvania.

Related Engine Oil Additive Articles

Car Care Tips on Washing Your Engine

Besides keeping the outside of your vehicle looking like brand new you also want to make sure you periodically clean the engine compartment. There are many reasons for doing this, including helping prevent rust, to check for oil or fluid leaks and to detect belt wear. To soften the grease and grunge that collects in the engine compartment you should start the engine and let it run for a few minutes and then shut it off. If you can just hold your hand on engine without burning, then it is warm enough to clean. The proper temperature for cleaning the engine is warm but not hot.

While the engine is cooling down you will want to cover the openings on the motor that you do not want to get water in. These include the air intake/ air filter, the distributor, the coil and the oil dip stick/breather. You can use baggies and rubber bands to cover the openings. You also want to check the tightness of the oil filter cap, power steering cap, windshield washer fluid cap, battery filler caps and all other caps.

Now that you have the engine warm and everything is sealed you then spray the engine and engine compartment with a high quality non petroleum based degreaser. You should start at the bottom and work up, that way you won’t be getting your face covered with degreaser.

Allow the degreaser to set for about three to five minutes and then use a 100% cotton towel or a soft brush to start removing the heavily soiled areas. You then re-spray and re-brush any areas that need additional cleaning. Once the entire engine and engine compartment have been cleaned you rinse it thoroughly with water. You don’t have to use a high pressure sprayer a gentle spray will work just as well and you won’t have to worry about getting water in sensitive spots.

Once the engine compartment is clean you can remove the plastic bags and rubber bands. You then dry any puddles and aluminum parts with a soft towel. Use paper towels to thoroughly dry the battery. You now start the engine and allow it to warm up. This will dry the rest of the engine and will evaporate any moisture that has collected.

Once everything is dry and completely cooled you should wax the painted areas of the engine compartment, but not the engine. If the undercoated aluminum areas are dull or have whitish corrosion you can use a mild metal polish to help restore the finish. At this time you should check the battery terminals to make sure they are clean. If they are not clean you can disconnect the cables and clean both the cable terminals and the battery posts with a wire brush.

Then you should check all hinges, throttle cables and shocks to see if they need a thin coating of non silicone lubricant. Then check all fluid levels and remove any stray baggies and you have completed cleaning your engine.

Ryan Draving is the VP of Empire Covers, a leading provider of car mats, motorcycle covers, car covers, and other vehicle covers and accessories. Empire Covers can be found online at: EmpireCovers.com or at their blog EmpireCovers-Blog.com .

Regular Engine Maintenance Improves Gas Mileage

For quite a few years now, gasoline prices have steadily increased, and there seems to be no relief coming in the near future.  These higher prices, combined with the ever-increasing popularity of larger utility vehicles, has popularized the question, what can I do to my engine to improve my gas mileage? Most people understand that regular vehicle servicing like oil changes and tire rotations need to be performed on their vehicles.  They understand that these things ensure their vehicle keeps operating correctly, but they do not know what else they should do to lengthen it’s life.  There are many other small services the average consumer can do, or afford to have done regularly, that not only lengthen the life of their vehicle but also improve gas mileage at the same time.

One answer experts would give when  a consumer asks, what can I do to my engine to improve gas mileage? is to change other filters besides the oil filter which gets changed with regular oil changes.  One of these filters is the engine air filter.  The engine air filter is most often made from paper and blocks harmful debris from the road, such as sand and leaves, from entering the air intake of the engine.  If this filter gets clogged with sand and other debris, the engine’s performance will suffer.  This will adversely affect fuel economy, costing the consumer considerable money at the gas pump over time.

Another filter that can be changed at regular intervals in order to increase fuel economy is the fuel filter.  Although it sounds quite obvious, many people do not understand how important this may be or even know that their vehicle has one.  The fuel filter keeps unwanted silt that may collect in the bottom of the gas tank from reaching the injectors.  Fuel injectors need to spray fuel evenly for good engine performance.  When dirt and silt stops this from happening, engine performance will suffer as will the vehicle’s fuel economy.  One also may consider some of the synthetic fuel additives and fuel injector cleaners for sale on the market as well.  These keep these fuel components clean and operating correctly.  They are very good answers to the question, what can I do to my engine to improve my gas mileage.

Another suggestion most experts would give when addressing this important question, what can I do to my engine to improve my gas mileage? is to consider using synthetic fluids rather than conventional, petroleum based fluids.  For example, traditional oils, when used in one’s engine or transmission, break down faster over time.  They also leave behind far more byproducts, commonly know as hydrocarbons.  This lubricant breakdown can lead to a sludge building up inside the vehicle’s engine or transmission, hurting their performance, and thereby, hurting the fuel economy of the vehicle.  This can also lead to premature repair to the vital parts of these components which also costs the consumer ample amounts of money over time.  These are just a few of the more common ways to protect ones engine and increase fuel economy in these tough economic times.

For over 25 years Vincent Peter Platania,Jr has been marketing, consulting and formulating high performance lubricants.
Source for AMSOIL, the World’s Best Synthetic Lubricants, Motor Oils and Filters
Visit http://www.synthetic-motor-oils.com

Jet engine

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Jet engine

History

Further information: Timeline of jet power

Jet engines can be dated back to the invention of the aeolipile before the first century AD. This device used steam power directed through two nozzles so as to cause a sphere to spin rapidly on its axis. So far as is known, it was not used for supplying mechanical power, and the potential practical applications of this invention were not recognized. It was simply considered a curiosity.

Jet propulsion only literally and figuratively took off with the invention of the rocket by the Chinese in the 13th century. Rocket exhaust was initially used in a modest way for fireworks but gradually progressed to propel formidable weaponry; and there the technology stalled for hundreds of years.

Archytas, the founder of mathematical mechanics, as described in the writings of Aulus Gellius five centuries after him, was reputed to have designed and built the first artificial, self-propelled flying device. This device was a bird-shaped model propelled by a jet of what was probably steam, said to have actually flown some 200 meters.

Ottoman Lagari Hasan elebi is said to have taken off in 1633 with what was described to be a cone-shaped rocket and then to have glided with wings into a successful landing, winning a position in the Ottoman army. However, this was essentially a stunt. The problem was that rockets are simply too inefficient at low speeds to be useful for general aviation.

The earliest attempts at jet engines were hybrid designs in which an external power source first compressed air, which was then mixed with fuel and burned for jet thrust. In one such system, called a thermojet by Secondo Campini but more commonly, motorjet, the air was compressed by a fan driven by a conventional piston engine. Examples of this type of design were Henri Coand’s Coand-1910 aircraft (first jet-propelled aircraft ever built, with the first flight on 16 December 1910), and the much later Caproni Campini N.1, and the Japanese Tsu-11 engine intended to power Ohka kamikaze planes towards the end of World War II. None were entirely successful and the CC.2 ended up being slower than the same design with a traditional engine and propeller combination.

Albert Fon’s ramjet-cannonball from 1915

The Coand-1910,first jet-propelled aircraft ever built

In 1913 Ren Lorin came up with a form of jet engine, the subsonic pulsejet, which would have been somewhat more efficient, but he had no way to achieve high enough speeds for it to operate, and the concept remained theoretical for quite some time.

Even before the start of World War II, engineers were beginning to realize that the piston engine was self-limiting in terms of the maximum performance which could be attained; the limit was due to issues related to propeller efficiency, which declined as blade tips approached the speed of sound. If engine, and thus aircraft, performance were ever to increase beyond such a barrier, a way would have to be found to radically improve the design of the piston engine, or a wholly new type of powerplant would have to be developed. This was the motivation behind the development of the gas turbine engine, commonly called a “jet” engine, which would become almost as revolutionary to aviation as the Wright brothers’ first flight.

Albert Fon’s German patent for jet Engines (January 1928- granted 1932). The third illustration is a turbojet

The key to a practical jet engine was the gas turbine, used to extract energy from the engine itself to drive the compressor. The gas turbine was not an idea developed in the 1930s: the patent for a stationary turbine was granted to John Barber in England in 1791. The first gas turbine to successfully run self-sustaining was built in 1903 by Norwegian engineer gidius Elling. Limitations in design and practical engineering and metallurgy prevented such engines reaching manufacture. The main problems were safety, reliability, weight and, especially, sustained operation.

In Hungary, Albert Fon in 1915 devised a solution for increasing the range of artillery, comprising a gun-launched projectile which was to be united with a ramjet propulsion unit. This was to make it possible to obtain a long range with low initial muzzle velocities, allowing heavy shells to be fired from relatively lightweight guns. Fon submitted his invention to the Austro-Hungarian Army but the proposal was rejected. In 1928 he applied for a German patent on aircraft powered by supersonic ramjets, and this was awarded in 1932.

The first patent for using a gas turbine to power an aircraft was filed in 1921 by Frenchman Maxime Guillaume. His engine was an axial-flow turbojet.

In 1923, Edgar Buckingham of the US National Bureau of Standard published a report expressing scepticism that jet engines would be economically competitive with prop driven aircraft at the low altitudes and airspeeds of the period: “there does not appear to be, at present, any prospect whatever that jet propulsion of the sort here considered will ever be of practical value, even for military purposes.”

Instead, by the 1930s, the piston engine in its many different forms (rotary and static radial, aircooled and liquid-cooled inline) was the only type of powerplant available to aircraft designers. This was acceptable as long as only low performance aircraft were required, and indeed all that were available.

The Whittle W.2/700 engine flew in the Gloster E.28/39, the first British aircraft to fly with a turbojet engine, and the Gloster Meteor

In 1928, RAF College Cranwell cadet Frank Whittle formally submitted his ideas for a turbo-jet to his superiors. In October 1929 he developed his ideas further. . On 16 January 1930 in England, Whittle submitted his first patent (granted in 1932). The patent showed a two-stage axial compressor feeding a single-sided centrifugal compressor. Practical axial compressors were made possible by ideas from A.A.Griffith in a seminal paper in 1926 (“An Aerodynamic Theory of Turbine Design”). Whittle would later concentrate on the simpler centrifugal compressor only, for a variety of practical reasons. Whittle had his first engine running in April 1937. It was liquid-fuelled, and included a self-contained fuel pump. Whittle’s team experienced near-panic when the engine would not stop, accelerating even after the fuel was switched off. It turned out that fuel had leaked into the engine and accumulated in pools. So the engine would not stop until all the leaked fuel had burned off. Whittle was unable to interest the government in his invention, and development continued at a slow pace.

Heinkel He 178, the world’s first aircraft to fly purely on turbojet power

Jendrassik Cs-1, The first Turboprop engine. built in Hungarian Ganz works in 1938

In 1935 Hans von Ohain started work on a similar design in Germany, apparently unaware of Whittle’s work. His first device was strictly experimental and could only run under external power, but he was able to demonstrate the basic concept. Ohain was then introduced to Ernst Heinkel, one of the larger aircraft industrialists of the day, who immediately saw the promise of the design. Heinkel had recently purchased the Hirth engine company, and Ohain and his master machinist Max Hahn were set up there as a new division of the Hirth company. They had their first HeS 1 centrifugal engine running by September 1937. Unlike Whittle’s design, Ohain used hydrogen as fuel, supplied under external pressure. Their subsequent designs culminated in the gasoline-fuelled HeS 3 of 1,100 lbf (5 kN), which was fitted to Heinkel’s simple and compact He 178 airframe and flown by Erich Warsitz in the early morning of August 27, 1939, from Rostock-Marienehe aerodrome, an impressively short time for development. The He 178 was the world’s first jet plane.

The world’s first turboprop was the Jendrassik Cs-1 designed by the Hungarian mechanical engineer Gyrgy Jendrassik. It was produced and tested in the Ganz factory in Budapest between 1938 and 1942. It was planned to fit to the Varga RMI-1 X/H twin-engined reconnaissance bomber designed by Lszl Varga in 1940, but the program was cancelled. Jendrassik had also designed a small-scale 75 kW turboprop in 1937.

Whittle’s engine was starting to look useful, and his Power Jets Ltd. started receiving Air Ministry money. In 1941 a flyable version of the engine called the W.1, capable of 1000 lbf (4 kN) of thrust, was fitted to the Gloster E28/39 airframe specially built for it, and first flew on May 15, 1941 at RAF Cranwell.

A picture of an early centrifugal engine (DH Goblin II) sectioned to show its internal components

A Scottish aircraft engine designer, Frank Halford, working from Whittle’s ideas developed a “straight through” version of the centrifugal jet; his design became the de Havilland Goblin.

One problem with both of these early designs, which are called centrifugal-flow engines, was that the compressor worked by “throwing” (accelerating) air outward from the central intake to the outer periphery of the engine, where the air was then compressed by a divergent duct setup, converting its velocity into pressure. An advantage of this design was that it was already well understood, having been implemented in centrifugal superchargers, then in widespread use on piston engines. However, given the early technological limitations on the shaft speed of the engine, the compressor needed to have a very large diameter to produce the power required. This meant that the engines had a large frontal area, which made it less useful as an aircraft powerplant due to drag. A further disadvantage was that the air flow had to be “bent” to flow rearwards through the combustion section and to the turbine and tailpipe, adding complexity and lowering efficiency. Nevertheless, these types of engines had the major advantages of light weight, simplicity and reliability, and development rapidly progressed to practical airworthy designs.

A cutaway of the Junkers Jumo 004 engine.

Austrian Anselm Franz of Junkers’ engine division (Junkers Motoren or Jumo) addressed these problems with the introduction of the axial-flow compressor. Essentially, this is a turbine in reverse. Air coming in the front of the engine is blown towards the rear of the engine by a fan stage (convergent ducts), where it is crushed against a set of non-rotating blades called stators (divergent ducts). The process is nowhere near as powerful as the centrifugal compressor, so a number of these pairs of fans and stators are placed in series to get the needed compression. Even with all the added complexity, the resulting engine is much smaller in diameter and thus, more aerodynamic. Jumo was assigned the next engine number in the RLM numbering sequence, 4, and the result was the Jumo 004 engine. After many lesser technical difficulties were solved, mass production of this engine started in 1944 as a powerplant for the world’s first jet-fighter aircraft, the Messerschmitt Me 262 (and later the world’s first jet-bomber aircraft, the Arado Ar 234). A variety of reasons conspired to delay the engine’s availability, this delay caused the fighter to arrive too late to decisively impact Germany’s position in World War II. Nonetheless, it will be remembered as the first use of jet engines in service.

In the UK, their first axial-flow engine, the Metrovick F.2, ran in 1941 and was first flown in 1943. Although more powerful than the centrifugal designs at the time, the Ministry considered its complexity and unreliability a drawback in wartime. The work at Metrovick led to the Armstrong Siddeley Sapphire engine which would be built in the US as the J65.

Following the end of the war the German jet aircraft and jet engines were extensively studied by the victorious allies and contributed to work on early Soviet and US jet fighters. The legacy of the axial-flow engine is seen in the fact that practically all jet engines on fixed wing aircraft have had some inspiration from this design.

Centrifugal-flow engines have improved since their introduction. With improvements in bearing technology the shaft speed of the engine was increased, greatly reducing the diameter of the centrifugal compressor. The short engine length remains an advantage of this design, particularly for use in helicopters where overall size is more important than frontal area. Also as their engine components are more robust they are less liable to foreign object damage than axial-flow compressor engines.

Although German designs were more advanced aerodynamically, the combination of simplicity and the lack of requisite rare metals for the necessary advanced metallurgy (such as tungsten, chromium and titanium) for high-stress components such as turbine blades and bearings, etc) meant that the later produced German engines had a short service life and had to be changed after 1025 hours. British engines were also widely manufactured under license in the US (see Tizard Mission), and were sold to Soviet Russia who reverse engineered them with the Nene going on to power the famous MiG-15. American and Soviet designs, independent axial-flow types for the most part, would strive to attain superior performance until the 1960s, although the General Electric J47 provided excellent service in the F-86 Sabre in the 1950s.

By the 1950s the jet engine was almost universal in combat aircraft, with the exception of cargo, liaison and other specialty types. By this point some of the British designs were already cleared for civilian use, and had appeared on early models like the de Havilland Comet and Avro Canada Jetliner. By the 1960s all large civilian aircraft were also jet powered, leaving the piston engine in such low-cost niche roles such as cargo flights.

Relentless improvements in the turboprop pushed the piston engine (an internal combustion engine) out of the mainstream entirely, leaving it serving only the smallest general aviation designs and some use in drone aircraft. The ascension of the jet engine to almost universal use in aircraft took well under twenty years.

However, the story was not quite at an end, for the efficiency of turbojet engines was still rather worse than piston engines, but by the 1970s with the advent of high bypass jet engines, an innovation not foreseen by the early commentators like Edgar Buckingham, at high speeds and high altitudes that seemed absurd to them, only then did the fuel efficiency finally exceed that of the best piston and propeller engines, and the dream of fast, safe, economical travel around the world finally arrived, and their dour, if well founded for the time, predictions that jet engines would never amount to much, were killed forever.

Types

There are a large number of different types of jet engines, all of which achieve forward thrust from the principle of jet propulsion.

Type

Description

Advantages

Disadvantages

Water jet

For propelling water rockets and jetboats; squirts water out the back through a nozzle

In boats, can run in shallow water, high acceleration, no risk of engine overload (unlike propellers), less noise and vibration, highly maneuverable at all boat speeds, high speed efficiency, less vulnerable to damage from debris, very reliable, more load flexibility, less harmful to wildlife

Can be less efficient than a propeller at low speed, more expensive, higher weight in boat due to entrained water, will not perform well if boat is heavier than the jet is sized for

Motorjet

Works like a turbojet but instead of a turbine driving the compressor a piston engine drives it.

Higher exhaust velocity than a propeller, offering better thrust at high speed

Heavy, inefficient and underpowered. Examples include: Coand-1910 and Caproni Campini N.1.

Turbojet

A tube with a compressor and turbine sharing a common shaft with a burner in between and a propelling nozzle for the exhaust. Uses a high exhaust gas velocity to produce thrust. Has a much higher core flow than bypass type engines

Simplicity of design, efficient at supersonic speeds (~M2)

A basic design, misses many improvements in efficiency and power for subsonic flight, relatively noisy.

Low-bypass Turbofan

One- or two-stage fan added in front bypasses a proportion of the air through a bypass duct straight to the nozzle/afterburner, avoiding the combustion chamber, with the rest being heated in the combustion chamber and passing through the turbine. Compared with its turbojet ancestor, this allows for more efficient operation with somewhat less noise. This is the engine of high-speed military aircraft, some smaller private jets, and older civilian airliners such as the Boeing 707, the McDonnell Douglas DC-8, and their derivatives.

As with the turbojet, the design is aerodynamic, with only a modest increase in diameter over the turbojet required to accommodate the bypass fan and chamber. It is capable of supersonic speeds with minimal thrust drop-off at high speeds and altitudes yet still more efficient than the turbojet at subsonic operation.

Noisier and less efficient than high-bypass turbofan, with less static (Mach 0) thrust. Added complexity to accommodate dual shaft designs. More inefficient than a turbojet around M2 due to higher cross-sectional area.

High-bypass Turbofan

First stage compressor drastically enlarged to provide bypass airflow around engine core, and it provides significant amounts of thrust. Compared to the low-bypass turbofan and no-bypass turbojet, the high-bypass turbofan works on the principle of moving a great deal of air somewhat faster, rather than a small amount extremely fast. Most common form of jet engine in civilian use today- used in airliners like the Boeing 747, most 737s, and all Airbus aircraft.

Around 10 to 20 percent quieter than the turbojet engine due to greater mass flow and lower total exhaust speed. It is also more efficient for a useful range of subsonic airspeeds for the same reason; cooler exhaust temperature. Less noisy and exhibit much better efficiency than low bypass turbofans.

Greater complexity (additional ducting, usually multiple shafts) and the need to contain heavy blades. Fan diameter can be extremely large, especially in high bypass turbofans such as the GE90. More subject to FOD and ice damage. Top speed is limited due to the potential for shockwaves to damage engine. Thrust lapse at higher speeds, which necessitates huge diameters and introduces additional drag.

Rocket

Carries all propellants and oxidants on-board, emits jet for propulsion

Very few moving parts, Mach 0 to Mach 25+, efficient at very high speed (> Mach 5.0 or so), thrust/weight ratio over 100, no complex air inlet, high compression ratio, very high speed (hypersonic) exhaust, good cost/thrust ratio, fairly easy to test, works in a vacuum-indeed works best exoatmospheric which is kinder on vehicle structure at high speed, fairly small surface area to keep cool, and no turbine in hot exhaust stream.

Needs lots of propellant- very low specific impulse typically 100450 seconds. Extreme thermal stresses of combustion chamber can make reuse harder. Typically requires carrying oxidiser on-board which increases risks. Extraordinarily noisy.

Ramjet

Intake air is compressed entirely by speed of oncoming air and duct shape (convergent), and then it goes through a burner section where it is heated and then passes through a propelling nozzle

Very few moving parts, Mach 0.8 to Mach 5+, efficient at high speed (> Mach 2.0 or so), lightest of all air-breathing jets (thrust/weight ratio up to 30 at optimum speed), cooling much easier than turbojets as no turbine blades to cool.

Must have a high initial speed to function, inefficient at slow speeds due to poor compression ratio, difficult to arrange shaft power for accessories, usually limited to a small range of speeds, intake flow must be slowed to subsonic speeds, noisy, fairly difficult to test, finicky to keep lit.

Turboprop (Turboshaft similar)

Strictly not a jet at all a gas turbine engine is used as a powerplant to drive a propeller shaft (or rotor in the case of a helicopter)

High efficiency at lower subsonic airspeeds (300 knots plus), high shaft power to weight

Limited top speed (aeroplanes), somewhat noisy, complex transmission

Propfan/Unducted Fan

Turbojet engine that also drives one or more propellers. Similar to a turbofan without the fan cowling.

Higher fuel efficiency, potentially less noisy than turbofans, could lead to higher-speed commercial aircraft, popular in the 1980s during fuel shortages

Development of propfan engines has been very limited, typically more noisy than turbofans, complexity

Pulsejet

Air is compressed and combusted intermittently instead of continuously. Some designs use valves.

Very simple design, commonly used on model aircraft

Noisy, inefficient (low compression ratio), works poorly on a large scale, valves on valved designs wear out quickly

Pulse detonation engine

Similar to a pulsejet, but combustion occurs as a detonation instead of a deflagration, may or may not need valves

Maximum theoretical engine efficiency

Extremely noisy, parts subject to extreme mechanical fatigue, hard to start detonation, not practical for current use

Air-augmented rocket

Essentially a ramjet where intake air is compressed and burnt with the exhaust from a rocket

Mach 0 to Mach 4.5+ (can also run exoatmospheric), good efficiency at Mach 2 to 4

Similar efficiency to rockets at low speed or exoatmospheric, inlet difficulties, a relatively undeveloped and unexplored type, cooling difficulties, very noisy, thrust/weight ratio is similar to ramjets.

Scramjet

Similar to a ramjet without a diffuser; airflow through the entire engine remains supersonic

Few mechanical parts, can operate at very high Mach numbers (Mach 8 to 15) with good efficiencies

Still in development stages, must have a very high initial speed to function (Mach >6), cooling difficulties, very poor thrust/weight ratio (~2), extreme aerodynamic complexity, airframe difficulties, testing difficulties/expense

Turborocket

A turbojet where an additional oxidizer such as oxygen is added to the airstream to increase maximum altitude

Very close to existing designs, operates in very high altitude, wide range of altitude and airspeed

Airspeed limited to same range as turbojet engine, carrying oxidizer like LOX can be dangerous. Much heavier than simple rockets.

Precooled jets / LACE

Intake air is chilled to very low temperatures at inlet in a heat exchanger before passing through a ramjet and/or turbojet and/or rocket engine.

Easily tested on ground. Very high thrust/weight ratios are possible (~14) together with good fuel efficiency over a wide range of airspeeds, mach 0-5.5+; this combination of efficiencies may permit launching to orbit, single stage, or very rapid, very long distance intercontinental travel.

Exists only at the lab prototyping stage. Examples include RB545, Reaction Engines SABRE, ATREX. Requires liquid hydrogen fuel which has very low density and requires heavily insulated tankage.

Uses

Jet engines are usually used as aircraft engines for jet aircraft. They are also used for cruise missiles and unmanned aerial vehicles.

In the form of rocket engines they are used for fireworks, model rocketry, spaceflight, and military missiles.

Jet engines have also been used to propel high speed cars, particularly drag racers, with the all-time record held by a rocket car. A turbofan powered car ThrustSSC currently holds the land speed record.

Jet engine designs are frequently modified to turn them into gas turbine engines which are used in a wide variety of industrial applications. These include electrical power generation, powering water, natural gas, or oil pumps, and providing propulsion for ships and locomotives. Industrial gas turbine can create up to 50,000 shaft horsepower. Many of these engines are derived from older military turbojets such as the Pratt & Whitney J57 and J75 models. There is also a derivative of the P&W JT8D low-bypass turbofan that creates up to 35,000 HP.

Major components

Main article: Components of jet engines

The major components of a jet engine are similar across the major different types of engines, although not all engine types have all components. The major parts include:

Cold Section:

Air intake (Inlet) For subsonic aircraft, the air intake to a jet engine consists essentially of an opening which is designed to minimise drag. The air reaching the compressor of a normal jet engine must be travelling below the speed of sound, even for supersonic aircraft, to allow smooth flow through compressor and turbine blades. At supersonic flight speeds, shockwaves form in the intake system, these help compress the air, but also there is some inevitable reduction in the recovered pressure at inlet to the compressor. Some supersonic intakes use devices, such as a cone or a ramp, to increase pressure recovery.

Compressor or Fan The compressor is made up of stages. Each stage consists of vanes which rotate, and stators which remain stationary. As air is drawn deeper through the compressor, its heat and pressure increases. Energy is derived from the turbine (see below), passed along the shaft.

Bypass ducts Much of the thrust of essentially all modern jet engines comes from air from the front compressor that bypasses the combustion chamber and gas turbine section that leads directly to the nozzle or afterburner (where fitted).

Common:

Shaft The shaft connects the turbine to the compressor, and runs most of the length of the engine. There may be as many as three concentric shafts, rotating at independent speeds, with as many sets of turbines and compressors. Other services, like a bleed of cool air, may also run down the shaft.

Diffuser section: – This section is a divergent duct that utilizes Bernoulli’s principle to decrease the velocity of the compressed air to allow for easier ignition. And, at the same time, continuing to increase the air pressure before it enters the combustion chamber.

Hot section:

Combustor or Can or Flameholders or Combustion Chamber This is a chamber where fuel is continuously burned in the compressed air.

A blade with internal cooling as applied in the high-pressure turbine

Turbine The turbine is a series of bladed discs that act like a windmill, gaining energy from the hot gases leaving the combustor. Some of this energy is used to drive the compressor, and in some turbine engines (ie turboprop, turboshaft or turbofan engines), energy is extracted by additional turbine discs and used to drive devices such as propellers, bypass fans or helicopter rotors. One type, a free turbine, is configured such that the turbine disc driving the compressor rotates independently of the discs that power the external components. Relatively cool air, bled from the compressor, may be used to cool the turbine blades and vanes, to prevent them from melting.

Afterburner or reheat (chiefly UK) (mainly military) Produces extra thrust by burning extra fuel, usually inefficiently, to significantly raise Nozzle Entry Temperature at the exhaust. Owing to a larger volume flow (i.e. lower density) at exit from the afterburner, an increased nozzle flow area is required, to maintain satisfactory engine matching, when the afterburner is alight.

Exhaust or Nozzle Hot gases leaving the engine exhaust to atmospheric pressure via a nozzle, the objective being to produce a high velocity jet. In most cases, the nozzle is convergent and of fixed flow area.

Supersonic nozzle If the Nozzle Pressure Ratio (Nozzle Entry Pressure/Ambient Pressure) is very high, to maximize thrust it may be worthwhile, despite the additional weight, to fit a convergent-divergent (de Laval) nozzle. As the name suggests, initially this type of nozzle is convergent, but beyond the throat (smallest flow area), the flow area starts to increase to form the divergent portion. The expansion to atmospheric pressure and supersonic gas velocity continues downstream of the throat, whereas in a convergent nozzle the expansion beyond sonic velocity occurs externally, in the exhaust plume. The former process is more efficient than the latter.

The various components named above have constraints on how they are put together to generate the most efficiency or performance. The performance and efficiency of an engine can never be taken in isolation; for example fuel/distance efficiency of a supersonic jet engine maximises at about mach 2, whereas the drag for the vehicle carrying it is increasing as a square law and has much extra drag in the transonic region. The highest fuel efficiency for the overall vehicle is thus typically at Mach ~0.85.

For the engine optimisation for its intended use, important here is air intake design, overall size, number of compressor stages (sets of blades), fuel type, number of exhaust stages, metallurgy of components, amount of bypass air used, where the bypass air is introduced, and many other factors. For instance, let us consider design of the air intake.

Terminology

To describe the RPM of a jet engine, abbreviations are commonly used:

For a turboprop engine, Np refers to the RPM of the propeller shaft. For example, a common Np would be about 2200 RPM for a constant speed propeller.

N1 or Ng refers to the speed of the gas generator (gas producer) section (RPM). Each engine manufacturer will pick between those two abbreviation but N1 is mainly used for turbofan engines whereas Ng is mainly used for turboprop or turboshaft engines. For example, a common Np would be on the order of 30,000 RPM.

N2 or Nf refers to the speed of the power turbine section. Each engine manufacturer will pick between those two abbreviations but N2 is mainly used for turbofan engine where Nf is mainly used for turboprop or turboshaft engines. In many cases, even for free turbine engines, the N1 and N2 may be very similar.[citation needed]

Ns refers to the speed of the reduction gear box (RGB) output shaft for turboshaft engines.

In many cases, instead of expressing N-speeds (N1, N2) as a sheer RPM on cockpit displays, pilots are provided with the N-speeds expressed as a percentage of a nominal or maximal value. For example, at full power, the N1 might be 101.5% or 100%. This user interface decision has been made as a human factors consideration, since pilots are more likely to notice a problem with a two- or 3-digit percentage (where 100% implies a nominal value) than with a large, unbounded scalar number.

Common types

Types of jet engines

There are two types of jet engine that are seen commonly today, the turbofan which is used on almost all commercial airliners, and rocket engines which are used for spaceflight and other terrestrial uses such as ejector seats, flares, fireworks etc.

Turbofan engines

Main article: Turbofan

an animated turbofan engine

Most modern jet engines are actually turbofans, where the low pressure compressor acts as a fan, supplying supercharged air not only to the engine core, but to a bypass duct. The bypass airflow either passes to a separate ‘cold nozzle’ or mixes with low pressure turbine exhaust gases, before expanding through a ‘mixed flow nozzle’.

Turbofans are used for airliners because they give an exhaust speed that is better matched for subsonic airliners. At airliners’ flight speed, conventional turbojet engines generate an exhaust that ends up travelling very fast backwards, and this wastes energy. By emitting the exhaust so that it ends up travelling more slowly, better fuel consumption is achieved as well as higher thrust at low speeds. In addition, the lower exhaust speed gives much lower noise.

In the 1960 s there was little difference between civil and military jet engines, apart from the use of afterburning in some (supersonic) applications. Civil turbofans today have a low exhaust speed (low specific thrust -net thrust divided by airflow) to keep jet noise to a minimum and to improve fuel efficiency. Consequently the bypass ratio (bypass flow divided by core flow) is relatively high (ratios from 4:1 up to 8:1 are common). Only a single fan stage is required, because a low specific thrust implies a low fan pressure ratio.

Today’s military turbofans, however, have a relatively high specific thrust, to maximize the thrust for a given frontal area, jet noise being of less concern in military uses relative to civil uses. Multistage fans are normally needed to reach the relatively high fan pressure ratio needed for high specific thrust. Although high turbine inlet temperatures are often employed, the bypass ratio tends to be low, usually significantly less than 2.0.

Rocket engines

Main article: Rocket engine

A common form of jet engine is the rocket engine.

Rocket engines are used for high altitude flights because they give very high thrust and their lack of reliance on atmospheric oxygen allows them to operate at arbitrary altitudes.

This is used for launching satellites, space exploration and manned access, and permitted landing on the moon in 1969.

However, the high exhaust speed and the heavier, oxidiser-rich propellant results in more propellant use than turbojets, and their use is largely restricted to very high altitudes, very high speeds, or where very high accelerations are needed as rocket engines themselves have a very high thrust-to-weight ratio.

An approximate equation for the net thrust of a rocket engine is:

Where F is the thrust, Isp(vac) is the specific impulse, g0 is a standard gravity, is the propellant flow in kg/s, Ae is the area of the exhaust bell at the exit, and P is the atmospheric pressure.

General physical principles

All jet engines are reaction engines that generate thrust by emitting a jet of fluid rearwards at relatively high speed. The forces on the inside of the engine needed to create this jet give a strong thrust on the engine which pushes the craft forwards.

Jet engines make their jet from propellant from tankage that is attached to the engine (as in a ‘rocket’) as well as in duct engines (those commonly used on aircraft) by ingesting an external fluid (very typically air) and expelling it at higher speed.

Thrust

The motion impulse of the engine is equal to the fluid mass multiplied by the speed at which the engine emits this mass:

I = mc

where m is the fluid mass per second and c is the exhaust speed. In other words, a vehicle gets the same thrust if it outputs a lot of exhaust very slowly, or a little exhaust very quickly. (In practice parts of the exhaust may be faster than others, but it is the average momentum that matters, and thus the important quantity is called the effective exhaust speed – c here.)

However, when a vehicle moves with certain velocity v, the fluid moves towards it, creating an opposing ram drag at the intake:

mv

Most types of jet engine have an intake, which provides the bulk of the fluid exiting the exhaust. Conventional rocket motors, however, do not have an intake, the oxidizer and fuel both being carried within the vehicle. Therefore, rocket motors do not have ram drag; the gross thrust of the nozzle is the net thrust of the engine. Consequently, the thrust characteristics of a rocket motor are different from that of an air breathing jet engine, and thrust is independent of speed.

The jet engine with an intake duct is only useful if the velocity of the gas from the engine, c, is greater than the vehicle velocity, v, as the net engine thrust is the same as if the gas were emitted with the velocity c v. So the thrust is actually equal to

S = m(c v)

This equation shows that as v approaches c, a greater mass of fluid must go through the engine to continue to accelerate at the same rate, but all engines have a designed limit on this. Additionally, the equation implies that the vehicle can’t accelerate past its exhaust velocity as it would have negative thrust.

Energy efficiency

Dependence of the energy efficiency () upon the vehicle speed/exhaust speed ratio (v/c) for air-breathing jet and rocket engines

Energy efficiency () of jet engines installed in vehicles has two main components, cycle efficiency (c)- how efficiently the engine can accelerate the jet, and propulsive efficiency (p)-how much of the energy of the jet ends up in the vehicle body rather than being carried away as kinetic energy of the jet.

Even though overall energy efficiency is simply:

= pc

For all jet engines the propulsive efficiency is highest when the engine emits an exhaust jet at a speed that is the same as, or nearly the same as, the vehicle velocity as this gives the smallest residual kinetic energy.(Note:) The exact formula for air-breathing engines moving at speed v with an exhaust velocity c is given in the literature as: is

And for a rocket:

In addition to propulsive efficiency, another factor is cycle efficiency; essentially a jet engine is typically a form of heat engine. Heat engine efficiency is determined by the ratio of temperatures that are reached in the engine to that they are exhausted at from the nozzle, which in turn is limited by the overall pressure ratio that can be achieved. Cycle efficiency is highest in rocket engines (~60+%), as they can achieve extremely high combustion temperatures and can have very large, energy efficient nozzles. Cycle efficiency in turbojet and similar is nearer to 30%, the practical combustion temperatures and nozzle efficiencies are much lower.

Specific impulse as a function of speed for different jet types with kerosene fuel (hydrogen Isp would be about twice as high). Although efficiency plummets with speed, greater distances are covered, it turns out that efficiency per unit distance (per km or mile) is roughly independent of speed for jet engines as a group; however airframes become inefficient at supersonic speeds

Fuel/propellant consumption

A closely related (but different) concept to energy efficiency is the rate of consumption of propellant mass. Propellant consumption in jet engines is measured by Specific Fuel Consumption, Specific impulse or Effective exhaust velocity. They all measure the same thing. Specific impulse and effective exhaust velocity are strictly proportional, whereas specific fuel consumption is inversely proportional to the others.

For airbreathing engines such as turbojets energy efficiency and propellant (fuel) efficiency are much the same thing, since the propellant is a fuel and the source of energy. In rocketry, the propellant is also the exhaust, and this means that a high energy propellant gives better propellant efficiency but can in some cases actually can give lower energy efficiency.

Engine type

Scenario

SFC in lb/(lbfh)

SFC in g/(kNs)

Specific impulse (s)

Effective exhaust velocity (m/s)

NK-33 rocket engine

Vacuum

10.9

309

330

3,240

SSME rocket engine

Space shuttle vacuum

7.95

225

453

4,423

Ramjet

Mach 1

4.5

127

800

7,877

J-58 turbojet

SR-71 at Mach 3.2 (Wet)

1.9

53.8

1,900

18,587

Rolls-Royce/Snecma Olympus 593

Concorde Mach 2 cruise (Dry)

1.195

33.8

3,012

29,553

CF6-80C2B1F turbofan

Boeing 747-400 cruise

0.605

17.1

5,950

58,400

General Electric CF6 turbofan

Sea level

0.307

8.696

11,700

115,000

It can be seen that the subsonic turbofans such as General Electric’s CF6 uses a lot less fuel to generate thrust for a second than Concorde’s turbojet, the 593. However, since energy is force times distance and the distance per second is greater for Concorde, the actual power generated by the engine for the same amount of fuel is higher for Concorde at Mach 2 cruise than the CF6- Concorde’s engines are more efficient for thrust per mile, indeed, the most efficient ever.

Thrust-to-weight ratio

Main article: Thrust-to-weight ratio

The thrust to weight ratio of jet engines of similar principles varies somewhat with scale, but mostly is a function of engine construction technology. Clearly for a given engine, the lighter the engine, the better the thrust to weight is, the less fuel is used to compensate for drag due to the lift needed to carry the engine weight, or to accelerate the mass of the engine.

As can be seen in the following table, rocket engines generally achieve very much higher thrust to weight ratios than duct engines such as turbojet and turbofan engines. This is primarily because rockets almost universally use dense liquid or solid reaction mass which gives a much smaller volume and hence the pressurisation system that supplies the nozzle is much smaller and lighter for the same performance. Duct engines have to deal with air which is 2-3 orders of magnitude less dense and this gives pressures over much larger areas, and which in turn results in more engineering materials being needed to hold the engine together and for the air compressor.

Jet or Rocket engine

Mass, kg

Jet or rocket thrust, kN

Thrust-to-weight ratio

RD-0410 nuclear rocket engine

2000

35.2

1.8

J-58 (SR-71 Blackbird jet engine)

5.2

Concorde’s Rolls-Royce/Snecma Olympus 593

turbojet with reheat

3175

169.2

5.4

RD-0750 rocket engine, three-propellant mode

4621

1413

31.2

RD-0146 rocket engine

260

98

38.5

Space Shuttle’s SSME rocket engine

3177

2278

73.2

RD-180 rocket engine

5393

4152

78.6

F-1 (Saturn V first stage)

8391

7740.5

94.1

NK-33 rocket engine

1222

1638

136.8

Rocket thrusts are vaccuum thrusts unless otherwise noted

Comparison of types

Comparative suitability for (left to right) turboshaft, low bypass and turbojet to fly at 10 km altitude in various speeds. Horizontal axis – speed, m/s. Vertical axis displays engine efficiency.

Turboprops obtain little thrust from jet effect, but are useful for comparison. They are gas turbine engines that have a rotating fan that takes and accelerates the large mass of air but by a relatively small change in speed. This low speed limits the speed of any propeller driven airplane. When the plane speed exceeds this limit, propellers no longer provide any thrust (c-v < 0). However, because they accelerate a large mass of air, turboprops are very efficient.

Turbojets accelerate a much smaller mass of the air and burned fuel, but they emit it at the much higher speeds possible with a de Laval nozzle. This is why they are suitable for supersonic and higher speeds.

Low bypass turbofans have the mixed exhaust of the two air flows, running at different speeds (c1 and c2). The thrust of such engine is

S = m1 (c1 – v) + m2 (c2 – v)

where m1 and m2 are the air masses, being blown from the both exhausts. Such engines are effective at lower speeds, than the pure jets, but at higher speeds than the turboshafts and propellers in general. For instance, at the 10 km altitude, turboshafts are most effective at about Mach 0.4 (0.4 times the speed of sound), low bypass turbofans become more effective at about Mach 0.75 and turbojets become more effective than mixed exhaust engines when the speed approaches Mach 2-3.

Rocket engines have extremely high exhaust velocity and thus are best suited for high speeds (hypersonic) and great altitudes. At any given throttle, the thrust and efficiency of a rocket motor improves slightly with increasing altitude (because the back-pressure falls thus increasing net thrust at the nozzle exit plane), whereas with a turbojet (or turbofan) the falling density of the air entering the intake (and the hot gases leaving the nozzle) causes the net thrust to decrease with increasing altitude. Rocket engines are more efficient than even scramjets above roughly Mach 15.

Altitude and speed

With the exception of scramjets, jet engines, deprived of their inlet systems can only accept air at around half the speed of sound. The inlet system’s job for transonic and supersonic aircraft is to slow the air and perform some of the compression.

The limit on maximum altitude for engines is set by flammability- at very high altitudes the air becomes too thin to burn, or after compression, too hot. For turbojet engines altitudes of about 40 km appear to be possible, whereas for ramjet engines 55 km may be achievable. Scramjets may theoretically manage 75 km. Rocket engines of course have no upper limit.

Flying faster compresses the air in at the front of the engine, but ultimately the engine cannot go any faster without melting. The upper limit is usually thought to be about Mach 5-8, except for scramjets which may be able to achieve about Mach 15 or more, as they avoid slowing the air.

Noise

Noise is due to shockwaves that form when the exhaust jet interacts with the external air. The intensity of the noise is proportional to the thrust as well as proportional to the fourth power of the jet velocity.Generally then, the lower speed exhaust jets emitted from engines such as high bypass turbofans are the quietest, whereas the fastest jets are the loudest.

Although some variation in jet speed can often be arranged from a jet engine (such as by throttling back and adjusting the nozzle) it is difficult to vary the jet speed from an engine over a very wide range. Therefore since engines for supersonic vehicles such as Concorde, military jets and rockets inherently need to have supersonic exhaust at top speed, so these vehicles are especially noisy even at low speeds.

Advanced designs

J-58 combined ramjet/turbojet

The SR-71 Blackbird’s Pratt & Whitney J58 engines were rather unusual. They could convert in flight from being largely a turbojet to being largely a compressor-assisted ramjet. At high speeds (above Mach 2.4), the engine used variable geometry vanes to direct excess air through 6 bypass pipes from downstream of the fourth compressor stage into the afterburner. 80% of the SR-71′s thrust at high speed was generated in this way, giving much higher thrust, improving specific impulse by 10-15%, and permitting continuous operation at Mach 3.2. The name coined for this setup is turbo-ramjet.

Hydrogen fuelled air-breathing jet engines

Jet engines can be run on almost any fuel. Hydrogen is a highly desirable fuel, as, although the energy per mole is not unusually high, the molecule is very much lighter than other molecules. The energy per kg of hydrogen is twice that of more common fuels and this gives twice the specific impulse. In addition, jet engines running on hydrogen are quite easy to buildhe first ever turbojet was run on hydrogen. Also, although not duct engines, hydrogen-fueled rocket engines have seen extensive use.

However, in almost every other way, hydrogen is problematic. The downside of hydrogen is its density; in gaseous form the tanks are impractical for flight, but even in the form of liquid hydrogen it has a density one fourteenth that of water. It is also deeply cryogenic and requires very significant insulation that precludes it being stored in wings. The overall vehicle would end up being very large, and difficult for most airports to accommodate. Finally, pure hydrogen is not found in nature, and must be manufactured either via steam reforming or expensive electrolysis. Nevertheless, research is ongoing and hydrogen-fueled aircraft designs do exist that may be feasible.

Precooled jet engines

Main article: Precooled jet engine

An idea originated by Robert P. Carmichael in 1955 is that hydrogen-fueled engines could theoretically have much higher performance than hydrocarbon-fueled engines if a heat exchanger were used to cool the incoming air. The low temperature allows lighter materials to be used, a higher mass-flow through the engines, and permits combustors to inject more fuel without overheating the engine.

This idea leads to plausible designs like Reaction Engines SABRE, that might permit single-stage-to-orbit launch vehicles, and ATREX, which could permit jet engines to be used up to hypersonic speeds and high altitudes for boosters for launch vehicles. The idea is also being researched by the EU for a concept to achieve non-stop antipodal supersonic passenger travel at Mach 5 (Reaction Engines A2).

Nuclear-powered ramjet

Project Pluto was a nuclear-powered ramjet, intended for use in a cruise missile. Rather than combusting fuel as in regular jet engines, air was heated using a high-temperature, unshielded nuclear reactor. This dramatically increased the engine burn time, and the ramjet was predicted to be able to cover any required distance at supersonic speeds (Mach 3 at tree-top height).

However, there was no obvious way to stop it once it had taken off, which would be a great disadvantage in any non-disposable application. Also, because the reactor was unshielded, it was dangerous to be in or around the flight path of the vehicle (although the exhaust itself wasn’t radioactive). These disadvantages limit the application to warhead delivery system for all-out nuclear war, which it was being designed for.

Scramjets

Main article: Scramjet

Scramjets are an evolution of ramjets that are able to operate at much higher speeds than any other kind of airbreathing engine. They share a similar structure with ramjets, being a specially-shaped tube that compresses air with no moving parts through ram-air compression. Scramjets, however, operate with supersonic airflow through the entire engine. Thus, scramjets do not have the diffuser required by ramjets to slow the incoming airflow to subsonic speeds.

Scramjets start working at speeds of at least Mach 4, and have a maximum useful speed of approximately Mach 17. Due to aerodynamic heating at these high speeds, cooling poses a challenge to engineers.

Environmental considerations

Jet engines are usually run on fossil fuel propellant, and are thus a source of carbon dioxide in the atmosphere. Jet engines can use biofuels or hydrogen, although the production of the latter is usually made from fossil fuels.

Some scientists believe that jet engines are also a source of global dimming due to the water vapour in the exhaust causing cloud formations.

Nitrogen compounds are also formed from the combustion process from atmospheric nitrogen. At low altitudes this is not thought to be especially harmful, but for supersonic aircraft that fly in the stratosphere some destruction of ozone may occur.

Sulphates are also emitted if the fuel contains sulphur.

Safety and reliability

Main article: Air safety

Jet engines are usually very reliable and have a very good safety record. However, failures do sometimes occur.

Compressor blade containment

Main article: Blade off testing

The most likely failure is compressor blade failure, and modern jet engines are designed with structures that can catch these blades and keep them contained within the engine casing. Verification of a jet engine design involves testing that this system works correctly.

Bird strike

Bird strike is an aviation term for a collision between a bird and an aircraft. It is a common threat to aircraft safety and has caused a number of fatal accidents. In 1988 an Ethiopian Airlines Boeing 737 sucked pigeons into both engines during take-off and then crashed in an attempt to return to the Bahir Dar airport; of the 104 people aboard, 35 died and 21 were injured. In another incident in 1995, a Dassault Falcon 20 crashed at a Paris airport during an emergency landing attempt after sucking lapwings into an engine, which caused an engine failure and a fire in the airplane fuselage; all 10 people on board were killed. In 2009, on US Airways Flight 1549, a Airbus A320 aircraft sucked in one bird in each engine. The plane landed in the Hudson River after taking off from LaGuardia International Airport in New York City. There were no fatalities.

Modern jet engines have the capability of surviving an ingestion of a bird. Small fast planes, such as military jet fighters, are at higher risk than big heavy multi-engine ones. This is due to the fact that the fan of a high-bypass turbofan engine, typical on transport aircraft, acts as a centrifugal separator to force ingested materials (birds, ice, etc.) to the outside of the fan’s disc. As a result, such materials go through the relatively unobstructed bypass duct, rather than through the core of the engine, which contains the smaller and more delicate compressor blades. Military aircraft designed for high-speed flight typically have pure turbojet, or low-bypass turbofan engines, increasing the risk that ingested materials will get into the core of the engine to cause damage.

The highest risk of the bird strike is during the takeoff and landing, in low altitudes, which is in the vicinity of the airports.

Uncontained failures

One class of failures that has caused accidents in particular is uncontained failures, where rotary parts of the engine break off and exit through the case. These can cut fuel or control lines, and can penetrate the cabin. Although fuel and control lines are usually duplicated for reliability, the crash of United Airlines Flight 232 was caused when hydraulic fluid lines for all three independent hydraulic systems were simultaneously severed by shrapnel from an uncontained engine failure. Prior to the United 232 crash, the probability of a simultaneous failure of all three hydraulic systems was considered as high as a billion-to-one. However, the statistical models used to come up with this figure did not account for the fact that the number-two engine was mounted at the tail close to all the hydraulic lines, nor the possibility that an engine failure would release many fragments in many directions. Since then, more modern aircraft engine designs have focused on keeping shrapnel from penetrating the cowling or ductwork, and have increasingly utilized high-strength composite materials to achieve the required penetration resistance while keeping the weight low.

See also

Look up jet engine in Wiktionary, the free dictionary.

Look up duct engine in Wiktionary, the free dictionary.

Air turboramjet

Balancing machine

Jet engine performance

Jet aircraft

Jetboat

Variable Cycle Engine

Pulse jet

Turborocket

Rocket engine nozzles

Spacecraft propulsion

Water injection (engines)

Turbojet development at the RAE

References

^ Encyclopedia Britannica: Internal Combustion Engine

^ propeller efficiency

^ Patent number 554,906

^ Gyorgy, Nagy Istvan, “Albert Fono: A Pioneer of Jet Propulsion”, International Astronautical Congress, 1977, IAF/IAA

^ Dugger, Gordon L. (1969). Ramjets. American Institute of Aeronautics and Astronautics, p. 15.

^ Maxime Guillaume,”Propulseur par raction sur l’air,” French patent no. 534,801 (filed: 3 May 1921; issued: 13 January 1922). Available on-line (in French) at: http://v3.espacenet.com/origdoc?DB=EPODOC&IDX=FR534801&F=0&QPN=FR534801 .

^ sod1280.tmp

^ PBS – Chasing the Sun – Frank Whittle

^ BBC – History – Frank Whittle (1907 – 1996)

^ Frank Whittle, “Improvements relating to the propulsion of aircraft and other vehicles,” British patent no. 347,206 (filed: 16 January 1930). Available on-line at: http://v3.espacenet.com/origdoc?DB=EPODOC&IDX=GB347206&F=0&QPN=GB347206 .

^ The History of the Jet Engine – Sir Frank Whittle – Hans Von Ohain Ohain said that he had not read Whittle’s patent and Whittle believed him (Frank Whittle 1907-1996) however the Whittle patent was in German libraries and Whittle’s son had suspicions that Ohain had read or heard of it (The History of the Jet Engine – Sir Frank Whittle a genius betrayed – )

^ Warsitz, Lutz: THE FIRST JET PILOT – The Story of German Test Pilot Erich Warsitz (p. 125), Pen and Sword Books Ltd., England, 2009

^ ch10-3

^
^ a b
^
^
^ Merging Air and Space

^ PRATT & WHITNEY CANADA MAINTENANCE MANUAL – MANUAL PART NO. 3017042 – Introduction – Page 6

^ Email from subject matter expert – Sr. Field Support Representative, Pratt & Whitney Canada Worldwide Support Network 12 Jan 2010

^ In Newtonian mechanics kinetic energy is frame dependent. The kinetic energy is easiest to calculate when the speed is measured in the center of mass frame of the vehicle and (less obviously) its reaction mass/air i.e. the stationary frame before takeoff begins.

^ K.Honicke, R.Lindner, P.Anders, M.Krahl, H.Hadrich, K.Rohricht. Beschreibung der Konstruktion der Triebwerksanlagen. Interflug, Berlin, 1968

^ Rocket Propulsion elements- seventh edition, pg 37-38

^ a b c “Data on Large Turbofan Engines”. Aircraft Aerodynamics and Design Group. Stanford University. http://adg.stanford.edu/aa241/propulsion/largefan.html. Retrieved 22 December 2009. 

^ NOVA transcript

^ a b Wade, Mark. “RD-0410″. Encyclopedia Astronautica. http://www.astronautix.com/engines/rd0410.htm. Retrieved 2009-09-25. 

^ “Konstruktorskoe Buro Khimavtomatiky – Scientific-Research Complex / RD0410. Nuclear Rocket Engine. Advanced launch vehicles”. KBKhA – Chemical Automatics Design Bureau. http://www.kbkha.ru/?p=8&cat=11&prod=66. Retrieved 2009-09-25. 

^ Aircraft: Lockheed SR-71A Blackbird

^ “ROLLS-ROYCE SNECMA OLYMPUS – Jane’s Transport News”. http://www.janes.com/transport/news/jae/jae000725_1_n.shtml. Retrieved 2009-09-25. “With afterburner, reverser and nozzle … 3,175 kg … Afterburner … 169.2 kN” 

^
^ “Konstruktorskoe Buro Khimavtomatiky – Scientific-Research Complex / RD0750.”. KBKhA – Chemical Automatics Design Bureau. http://www.kbkha.ru/?p=8&cat=11&prod=57. Retrieved 2009-09-25. 

^ SSME

^ “RD-180″. http://www.astronautix.com/engines/rd180.htm. Retrieved 2009-09-25. 

^ http://www.astronautix.com/engines/f1.htm

^ Astronautix NK-33 entry

^ High Speed Propulsion

^ SCRAMJET

^ J58

^ NASA history Other Interests in Hydrogen

^ The Skylon Spaceplane

^ Astronautix X30

^ Transport Canada – Sharing the Skies

John Golley (1997). Genesis of the Jet: Frank Whittle and the Invention of the Jet Engine. Crowood Press. ISBN 1-85310-860-X.

David S Brooks (1997). Vikings at Waterloo: Wartime Work on the Whittle Jet Engine by the Rover Company. Rolls-Royce Heritage Trust. ISBN 1-872922-08-2

Lutz Warsitz (2009): THE FIRST JET PILOT – The Story of German Test Pilot Erich Warsitz, Pen and Sword Books Ltd., England, ISBN 9781844158188, English Edition

External links

Wikimedia Commons has media related to: Jet engines

A New pen Rotor Jet Engine That Could Reduce Fuel Consumption

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Animated Jet Engines to understand how it works

RMCybernetics – A simple Homemade Jet Engine

Journey through a jet engine(flash)

How Stuff Works article on how a Gas Turbine Engine works

Influence of the Jet Engine on the Aerospace Industry

An Overview of Military Jet Engine History (Rand Corp., 24 pgs, PDF)

A jet propulsion bicycle

Basic jet engine tutorial (Quicktime Video

Jet powered model of an Airbus A330 at 1/16 scale

Pulsejet in aeromodelling

Interactive jet engine simulator for learning

The official Erich Warsitz website the world first jet pilot

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Heat engines

Stroke cycles

Two-stroke cycle  Four-stroke cycle  Six-stroke cycle

Engine types

Coomber  Free-piston  Gas turbine  Iris  Jet  Orbital  Piston  Rocket  Rotary  Split-single  Steam (reciprocating)  Steam turbine  Stirling  Swing-piston  Tschudi  Wankel

Valves

Cylinder head porting  Corliss  Slide  Manifold  Multi  Piston  Poppet  Sleeve  Rotary valve  Variable valve timing  Camless (solenoid operated valves)

Engine configurations

Single cylinder  Straight  Opposed  Flat  U  V  W  H  Deltic  Radial  Rotary  Stelzer  Controlled Combustion  Bourke  Split cycle

Motion

mechanisms

Cam  Connecting rod  Coomber rotary  Crank  Crank substitute  Crankshaft  Linkages (Evans  Peaucellieripkin  Sector straight-line  Watt)  Scotch Yoke  Swashplate  Rhombic drive  Double acting/differential cylinder

Thermodynamic cycle

Categories: Energy conversion | Gas turbines | Jet engines | English inventionsHidden categories: All articles with unsourced statements | Articles with unsourced statements from October 2009 | Articles with unsourced statements from January 2010

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Engine Leaks Take a Brutal Toll on Cars and Car Parts

If you own a car then you have probably already had some experience with car leaks, at least to some degree. Even new cars can develop leaks that are both annoying and frustrating. In the 1980s and 1990s engine leaks and other automotive leaking problems were the cause of a large majority of auto service appointments.

Now there are better engineering designs and materials used in the automotive manufacturing process. This has resulted in a decrease in customer complaints because new car parts have been noted to have substantially less problems with leak malfunctions.

Keep Engine Leaks at Bay

For those of you that may be unfamiliar with the basics of engine seals here is a list of what a car engine needs in order to be leak-free.

1.      Motor oil

2.      Proper compression

3.      Fitted gaskets

4.      Intact seals

5.      Engine coolant

6.      Fuel

Understanding Engine Seals

Most of the seals that protect your car engine are designed with double lips so that the motor oil can not leak out. One of the seals is designed to contain the oil, and the other is meant to stop any debris from contaminating the oil system. Although these lipped seals do not move they still have a big job to do because the car parts that they are surrounding are in motion. This is why many automotive techs refer to these car accessories as dynamic engine seals.

You will find dynamic seals used on car parts that are either rotating or belt driven. Two examples of these are crankshafts and camshafts. These are crucial elements for your car engine and it only takes a small leak to create a great deal of damage. An oil leak from a camshaft seal can result in ruined valves and timing belts which are both costly repairs.

How Leaks Begin

Small bits of grit, dust and road dirt are always flying about the exterior of auto engines. If there is a small opening in any seal it can allow some of these contaminants to adhere to the inner surface. Then as the shafts are moving they are being abraded by these particles’ sharp edges.

The constant motion of these rotating and belt driven car parts will soon cause small grooves to form along the sides of the shafts. Now the integrity of the seals and shafts are both compromised. Once these irregular grooves have formed on the metal surfaces, leaking will soon follow.

Fixes for Seals

There are times when worn metal surfaces can be repaired instead of being replaced. Some mechanics are able to grind and weld the shafts until the surface area meats the necessary specifications.  There is also a slip-sleeve that is available for some front crankshafts. This product is a fine metal covering that can be applied to the damaged area and will then cover the grooves. These are both elaborate and high priced technical projects that are only suggested for ultra expensive vehicles. Car parts such as engine seals and shafts can be replaced at a more affordable cost.

Gaskets and Engine Leaks

In the past a lot of car accessories and engine parts used gaskets that contained cork. The cork would work for a while but it deteriorated at a relatively quick pace. This material would stop a leak by swelling up and forming a tighter seal, but only after a small amount of oil had leached into the gasket.

Another type of engine gasket was made from RTV silicone and this could create a secure seal but only under special conditions. The silicone base meant that it had to be applied to an engine surface that was absolutely clean and free of any oily residue. Many mechanics had trouble getting the metal surface prepped to these exacting specifications.

Most of today’s new gaskets are made form synthetic rubber compounds. These engine gaskets are reliable and are much less likely to form a leak. This is the type of gasket that is preferred by knowledgeable mechanics and auto enthusiasts.

Gasket Seal Problems

When placing gaskets onto surfaces it seems that many auto techs and mechanics tend to tighten them too much. In order to address this problem there are some newer designs that use metal spacers. These spacers are actually in the gaskets which helps prevent the over tightening seen in the past. Newer car parts such as the cast aluminum engine covers and those made from plastics have also been responsible for protecting gaskets from this common problem.

There are also some gaskets that are more likely to be the source of engine leaks even if they have been properly installed. A car’s head gaskets and those used on the intake manifold are the ones that should be checked first if an engine leak is noted.

Internal Manifold and Head Gaskets

Engine compression, coolants and oil all depend on an intact head gasket seal. The intake manifold gaskets that are on cars are responsible for insuring the integrity of coolants, gas and diesel fumes and air. If these seals are damaged, or compromised you are assured of having leaks from your car that are going to be noticeable.

Engines and Aluminum Car Parts

The fact that so many engine car parts are now made from aluminum is an additional problem. Because of this metal’s expansion and contraction the gaskets must be allowed some movement allowance. This means that a mechanic needs to make sure that when the repairs are done the gaskets are capable of allowing for the movement of internal car parts as the temperature and weather changes.

Torque to Yield Bolts

Gaskets are internal car parts and they are placed in areas where bolts are going to be required. A mechanic can use incorrect bolts or too much torque and this will result in gasket failure. In this type of situation there could be a compression leak or coolant leak from head gaskets as well as warping of the heads. To prevent this from occurring most auto shops are now using the type of car engine bolts that are known as “torque to yield”.

Check and Repair Engine Leaks

No matter how old, or new, your car is you will need to check on any type of coolant engine leak. Just 2-3 tablespoons of an antifreeze liquid seeping into the oil compartment could ruin some vital car parts. Antifreeze and oil is a mix that can ruin the bearings in any car engine.

If you do not want to take your car to a garage you can handle the situation yourself. Certainly there are many different products that you can use to repair gaskets and seals. Your mechanic or auto supply store can help you find the right one for your vehicle. Just remember if you are doing the repairs yourself you need to make sure that you are using a quality product and applying it correctly. Follow the specifications and make sure to clean the surfaces properly and have exact alignment before making the repairs.

The best buy and sell vehicles, car parts, and read car reviews at VehicleRide.com.

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Stirling engine

Name and definition

Robert Stirling was the inventor of the first practical example of a closed cycle air engine in 1816, and it was suggested by Fleeming Jenkin as early as 1884 that all such engines should therefore generically be called Stirling engines. This naming proposal found little favour, and the various types on the market continued to be known by the name of their individual designers or manufacturers, e.g. Rider’s, Robinson’s or Heinrici’s (hot) air engine. In the 1940s, the Philips company was searching for a suitable name for its own version of the ‘air engine’, which by that time it had already been tested with other gases, eventually settling on ‘Stirling engine’ in April 1945. However, nearly thirty years later Graham Walker was still bemoaning the fact that such terms as ‘hot air engine’ continued to be used interchangeably with ‘Stirling engine’ which itself was applied widely and indiscriminately. The situation has now improved somewhat, at least in academic literature, and it is now generally accepted that ‘Stirling engine’ should refer exclusively to a closed-cycle regenerative heat engine with a permanently gaseous working fluid, where closed-cycle is defined as a thermodynamic system in which the working fluid is permanently contained within the system and regenerative describes the use of a specific type of internal heat exchanger and thermal store, known as the regenerator. An engine working on the same principle but using a liquid rather than gaseous fluid existed in 1931 and was called the Malone heat engine.

It follows from the closed cycle operation that the Stirling engine is an external combustion engine that isolates its working fluid from the energy input supplied by an external heat source. There are many possible implementations of the Stirling engine most of which fall into the category of reciprocating piston engine.

Functional description

The engine is designed so that the working gas is generally compressed in the colder portion of the engine and expanded in the hotter portion resulting in a net conversion of heat into work. An internal Regenerative heat exchanger increases the Stirling engine’s thermal efficiency compared to simpler hot air engines lacking this feature.

Key components

Cut-away diagram of a rhombic drive beta configuration Stirling engine design:

Pink  Hot cylinder wall

Dark grey  Cold cylinder wall (with coolant inlet and outlet pipes in yellow)

Dark green  Thermal insulation separating the two cylinder ends

Light green  Displacer piston

Dark blue  Power piston

Light blue  Linkage crank and flywheels

Not shown: Heat source and heat sinks. In this design the displacer piston is constructed without a purpose-built regenerator.

As a consequence of closed cycle operation the heat that drives a Stirling engine must be transmitted from a heat source to the working fluid by heat exchangers and finally to a heat sink. A Stirling engine system has at least one heat source, one heat sink and up to five heat exchangers. Some types may combine or dispense with some of these.

Heat source

Point focus parabolic mirror with Stirling engine at its center and its solar tracker at Plataforma Solar de Almera (PSA) in Spain

The heat source may be combustion of a fuel and, since the combustion products do not mix with the working fluid (that is, external combustion) and come into contact with the internal moving parts of the engine, a Stirling engine can run on fuels that would damage other (that is, internal combustion) engines’ internals, such as landfill gas which contains siloxane.

Some other suitable heat sources are concentrated solar energy, geothermal energy, nuclear energy, waste heat, or even biological. If the heat source is solar power, regular solar mirrors and solar dishes may be used. Also, fresnel lenses have been advocated to be used (for example, for planetary surface exploration). Solar powered Stirling engines are becoming increasingly popular, as they are a very environmentally sound option for producing power. Also, some designs are economically attractive in development projects.

Recuperator

An optional heat exchanger is the recuperator used when high efficiency is desired from combustion fuel input to mechanical power output. As the heater of a fuel-fired engine with high efficiency must operate at a nearly uniform high temperature, there is considerable heat loss from the combustion gases exiting the burner unless this can be cooled by preheating the air needed for combustion. Engines used within combined heat and power systems can instead cool the exhaust gases at the “cold” side of the engine.

Heater

In small, low power engines this may simply consist of the walls of the hot space(s) but where larger powers are required a greater surface area is needed in order to transfer sufficient heat. Typical implementations are internal and external fins or multiple small bore tubes

Designing Stirling engine heat exchangers is a balance between high heat transfer with low viscous pumping losses and low dead space. With engines operating at high powers and pressures, the heat exchangers on the hot side must be made of alloys retaining considerable strength at temperature and also not corrode or creep.

Regenerator

Main article: Regenerative heat exchanger

In a Stirling engine, the regenerator is an internal heat exchanger and temporary heat store placed between the hot and cold spaces such that the working fluid passes through it first in one direction then the other. Its function is to retain within the system that heat which would otherwise be exchanged with the environment at temperatures intermediate to the maximum and minimum cycle temperatures, thus enabling the thermal efficiency of the cycle to approach the limiting Carnot efficiency defined by those maxima and minima.

The primary effect of regeneration in a Stirling engine is to greatly increase the thermal efficiency by ‘recycling’ internally heat which would otherwise pass through the engine irreversibly. As a secondary effect, increased thermal efficiency promises a higher power output from a given set of hot and cold end heat exchangers (since it is these which usually limit the engine’s heat throughput), though, in practice this additional power may not be fully realized as the additional “dead space” (unswept volume) and pumping loss inherent in practical regenerators tends to have the opposite effect.

The regenerator works like a thermal capacitor. The ideal regenerator has very high thermal capacity, very low thermal conductivity parallel to fluid flow, very high thermal conductivity perpendicular to fluid flow, almost no volume, and introduces no friction to the working fluid. As the regenerator approaches these ideal limits, Stirling engine efficiency increases.

The design challenge for a Stirling engine regenerator is to provide sufficient heat transfer capacity without introducing too much additional internal volume (‘dead space’) or flow resistance, both of which tend to reduce power and efficiency. These inherent design conflicts are one of many factors which limit the efficiency of practical Stirling engines. A typical design is a stack of fine metal wire meshes, with low porosity to reduce dead space, and with the wire axes perpendicular to the gas flow to reduce conduction in that direction and to maximize convective heat transfer.

The regenerator is the key component invented by Robert Stirling and its presence distinguishes a true Stirling engine from any other closed cycle hot air engine. However, many engines with no apparent regenerator may still be correctly described as Stirling engines as in the simple beta and gamma configurations with a ‘loose fitting’ displacer, the surfaces of the displacer and its cylinder will cyclically exchange heat with the working fluid providing a significant regenerative effect particularly in small, low-pressure engines. The same is true of the passage connecting the hot and cold cylinders of an alpha configuration engine.

Cooler

In small, low power engines this may simply consist of the walls of the cold space(s), but where larger powers are required a cooler using a liquid like water is needed in order to transfer sufficient heat.

Heat sink

The heat sink is typically the environment at ambient temperature. In the case of medium to high power engines, a radiator is required to transfer the heat from the engine to the ambient air. Marine engines can use the ambient water. In the case of combined heat and power systems, the engine’s cooling water is used directly or indirectly for heating purposes.

Alternatively, heat may be supplied at ambient and the heat sink maintained at a lower temperature by such means as cryogenic fluid (see Liquid nitrogen economy) or ice water.

Configurations

There are two major types of Stirling engines that are distinguished by the way they move the air between the hot and cold sides of the cylinder:

The two piston alpha type design has pistons in independent cylinders, and gas is driven between the hot and cold spaces.

The displacement type Stirling engines, known as beta and gamma types, use an insulated mechanical displacer to push the working gas between the hot and cold sides of the cylinder. The displacer is large enough to thermally insulate the hot and cold sides of the cylinder and displace a large quantity of gas. It must have enough of a gap between the displacer and the cylinder wall to allow gas to easily flow around the displacer.

Alpha Stirling

An alpha Stirling contains two power pistons in separate cylinders, one hot and one cold. The hot cylinder is situated inside the high temperature heat exchanger and the cold cylinder is situated inside the low temperature heat exchanger. This type of engine has a high power-to-volume ratio but has technical problems due to the usually high temperature of the hot piston and the durability of its seals. In practice, this piston usually carries a large insulating head to move the seals away from the hot zone at the expense of some additional dead space.

Action of an alpha type Stirling engine

The following diagrams do not show internal heat exchangers in the compression and expansion spaces, which are needed to produce power. A regenerator would be placed in the pipe connecting the two cylinders. The crankshaft has also been omitted.

1. Most of the working gas is in contact with the hot cylinder walls, it has been heated and expansion has pushed the cold piston to the bottom of its travel in the cylinder. The expansion continues in the hot cylinder, which is 90 behind the cold piston in its cycle, extracting more work from the hot gas.

2. The gas is now at its maximum volume. The hot cylinder piston begins to move most of the gas into the cold cylinder, where it cools and the pressure drops.

3. Almost all the gas is now in the cold cylinder and cooling continues. The cold piston, powered by flywheel momentum (or other piston pairs on the same shaft) compresses the remaining part of the gas.

4. The gas reaches its minimum volume, and it will now expand in the hot cylinder where it will be heated once more, driving the hot piston in its power stroke.

The complete alpha type Stirling cycle

Beta Stirling

A beta Stirling has a single power piston arranged within the same cylinder on the same shaft as a displacer piston. The displacer piston is a loose fit and does not extract any power from the expanding gas but only serves to shuttle the working gas from the hot heat exchanger to the cold heat exchanger. When the working gas is pushed to the hot end of the cylinder it expands and pushes the power piston. When it is pushed to the cold end of the cylinder it contracts and the momentum of the machine, usually enhanced by a flywheel, pushes the power piston the other way to compress the gas. Unlike the alpha type, the beta type avoids the technical problems of hot moving seals.

Action of a beta type Stirling engine

Again, the following diagrams do not show internal heat exchangers or a regenerator, which would be placed in the gas path around the displacer.

1. Power piston (dark grey) has compressed the gas, the displacer piston (light grey) has moved so that most of the gas is adjacent to the hot heat exchanger.

2. The heated gas increases in pressure and pushes the power piston to the farthest limit of the power stroke.

3. The displacer piston now moves, shunting the gas to the cold end of the cylinder.

4. The cooled gas is now compressed by the flywheel momentum. This takes less energy, since when it is cooled its pressure dropped.

The complete beta type Stirling cycle

Gamma Stirling

A gamma Stirling is simply a beta Stirling in which the power piston is mounted in a separate cylinder alongside the displacer piston cylinder, but is still connected to the same flywheel. The gas in the two cylinders can flow freely between them and remains a single body. This configuration produces a lower compression ratio but is mechanically simpler and often used in multi-cylinder Stirling engines.

Other types

Other Stirling configurations continue to interest engineers and inventors. Tom Peat conceived of a configuration that he likes to call a “Delta” type, although currently this designation is not widely recognized, having a displacer and two power pistons, one hot and one cold.

There is also the rotary Stirling engine which seeks to convert power from the Stirling cycle directly into torque, similar to the rotary combustion engine. No practical engine has yet been built but a number of concepts, models and patents have been produced, such as the Quasiturbine engine.

Another alternative is the Fluidyne engine (Fluidyne heat pump), which use hydraulic pistons to implement the Stirling cycle. The work produced by a Fluidyne engine goes into pumping the liquid. In its simplest form, the engine contains a working gas, a liquid and two non-return valves.

The Ringbom engine concept published in 1907 has no rotary mechanism or linkage for the displacer. This is instead driven by a small auxiliary piston, usually a thick displacer rod, with the movement limited by stops.

Free piston engines

Various Free-Piston Stirling Configurations… F.”free cylinder”, G. Fluidyne, H. “double-acting” Stirling (typically 4 cylinders)

“Free piston” Stirling engines include those with liquid pistons and those with diaphragms as pistons. In a “free piston” device, energy may be added or removed by an electrical linear alternator, pump or other coaxial device. This sidesteps the need for a linkage, and reduces the number of moving parts. In some designs friction and wear are nearly eliminated by the use of non-contact gas bearings or very precise suspension through planar springs.

In the early 1960s, W.T. Beale invented a free piston version of the Stirling engine in order to overcome the difficulty of lubricating the crank mechanism. While the invention of the basic free piston Stirling engine is generally attributed to Beale, independent inventions of similar types of engines were made by E.H. Cooke-Yarborough and C. West at the Harwell Laboratories of the UKAERE. G.M. Benson also made important early contributions and patented many novel free-piston configurations.

What appears to be the first mention of a Stirling cycle machine using freely moving components is a British patent disclosure in 1876. This machine was envisaged as a refrigerator (i.e., the reversed Stirling cycle). The first consumer product to utilize a free piston Stirling device was a portable refrigerator manufactured by Twinbird Corporation of Japan and offered in the US by Coleman in 2004.

Thermoacoustic cycle

Thermoacoustic devices are very different from Stirling devices, although the individual path travelled by each working gas molecule does follow a real Stirling cycle. These devices include the thermoacoustic engine and thermoacoustic refrigerator. High-amplitude acoustic standing waves cause compression and expansion analogous to a Stirling power piston, while out-of-phase acoustic travelling waves cause displacement along a temperature gradient, analogous to a Stirling displacer piston. Thus a thermoacoustic device typically does not have a displacer, as found in a beta or gamma Stirling.

History

Illustration to Robert Stirling’s 1816 patent application of the air engine design which later came to be known as the Stirling Engine

The Stirling engine (or Stirling’s air engine as it was known at the time) was invented and patented by Robert Stirling in 1816. It followed earlier attempts at making an air engine but was probably the first to be put to practical use when in 1818 an engine built by Stirling was employed pumping water in a quarry. The main subject of Stirling’s original patent was a heat exchanger which he called an “economiser” for its enhancement of fuel economy in a variety of applications. The patent also described in detail the employment of one form of the economiser in his unique closed-cycle air engine design in which application it is now generally known as a ‘regenerator’. Subsequent development by Robert Stirling and his brother James, an engineer, resulted in patents for various improved configurations of the original engine including pressurization which had by 1843 sufficiently increased power output to drive all the machinery at a Dundee iron foundry.

Though it has been disputed it is widely supposed that as well as saving fuel the inventors were motivated to create a safer alternative to the steam engines of the time, whose boilers frequently exploded causing many injuries and fatalities. The need for Stirling engines to run at very high temperatures to maximize power and efficiency exposed limitations in the materials of the day and the few engines that were built in those early years suffered unacceptably frequent failures (albeit with far less disastrous consequences than a boiler explosion) – for example, the Dundee foundry engine was replaced by a steam engine after three hot cylinder failures in four years.

Later nineteenth century

A typical late nineteenth/early twentieth century water pumping engine by the Rider-Ericsson Engine Company

Subsequent to the failure of the Dundee foundry engine there is no record of the Stirling brothers having any further involvement with air engine development and the Stirling engine never again competed with steam as an industrial scale power source (steam boilers were becoming safer and steam engines more efficient, thus presenting less of a target to rival prime movers). However, from about 1860 smaller engines of the Stirling/hot air type were produced in substantial numbers finding applications wherever a reliable source of low to medium power was required, such as raising water or providing air for church organs. These generally operated at lower temperatures so as not to tax available materials, so were relatively inefficient. But their selling point was that, unlike a steam engine, they could be operated safely by anybody capable of managing a fire. Several types remained in production beyond the end of the century, but apart from a few minor mechanical improvements the design of the Stirling engine in general stagnated during this period.

Twentieth century revival

During the early part of the twentieth century the role of the Stirling engine as a “domestic motor” was gradually taken over by the electric motor and small internal combustion engines. By the late 1930s it was largely forgotten, only produced for toys and a few small ventilating fans. At this time Philips was seeking to expand sales of its radios into areas where electricity was unavailable and the supply of batteries uncertain. Philips’ management decided that a low-power portable generator would facilitate such sales and tasked a group of engineers at the company’s research lab in Eindhoven to evaluate alternatives.

After a systematic comparison of various prime movers, the Stirling engine’s quiet operation (both audibly and in terms of radio interference) and ability to run on a variety of heat sources (common lamp oil  “cheap and available everywhere”  was favoured), the team picked Stirling. They were also aware that, unlike steam and internal combustion engines, virtually no serious development work had been carried out on the Stirling engine for many years and asserted that modern materials and know-how should enable great improvements.

Philips MP1002CA Stirling generator of 1951

Encouraged by their first experimental engine, which produced 16 W of shaft power from a bore and stroke of 30mm 25mm, Philips began a development program. This work continued throughout World War II and by the late 1940s handed over the Type 10 to Philips’ subsidiary Johan de Witt in Dordrecht to be “productionised” and incorporated into a generator set. The result, rated at 200 W from a bore and stroke of 55 mm x 27 mm, was designated MP1002CA (known as the “Bungalow set”). Production of an initial batch of 250 began in 1951, but it became clear that they could not be made at a competitive price and the advent of transistor radios with their much lower power requirements meant that the original rationale for the set was disappearing. Approximately 150 of these sets were eventually produced. Some found their way into university and college engineering departments around the world giving generations of students a valuable introduction to the Stirling engine.

Philips went on to develop experimental Stirling engines for a wide variety of applications and continued to work in the field until the late 1970s, but only achieved commercial success with the ‘reversed Stirling engine’ cryocooler. They did however take out a large number of patents and amass a wealth of information which they licensed to other companies and which formed the basis of much of the development work in the modern era.

Towards the end of the century, several companies developed research prototypes of medium-power engines and in some cases small production series. A mass market was never achieved because the unit costs were very high and some technical problems remained unsolved. Now in the twenty-first century, some commercial success is starting to become feasible, notably with combined heat and power units.

In the field of low-power engines, many plans, kits and finished engines are available commercially. Apart from traditional small models and some larger machines for real use, a new type was introduced in the 1980s: the low-temperature flat plate type.

Theory

Main article: Stirling cycle

A pressure/volume graph of the idealized Stirling cycle

The idealised Stirling cycle consists of four thermodynamic processes acting on the working fluid:

Isothermal Expansion. The expansion-space and associated heat exchanger are maintained at a constant high temperature, and the gas undergoes near-isothermal expansion absorbing heat from the hot source.

Constant-Volume (known as isovolumetric or isochoric) heat-removal. The gas is passed through the regenerator, where it cools transferring heat to the regenerator for use in the next cycle.

Isothermal Compression. The compression space and associated heat exchanger are maintained at a constant low temperature so the gas undergoes near-isothermal compression rejecting heat to the cold sink

Constant-Volume (known as isovolumetric or isochoric) heat-addition. The gas passes back through the regenerator where it recovers much of the heat transferred in 2 to 3, heating up on its way to the expansion space.

Theoretical thermal efficiency equals that of the hypothetical Carnot cycle – i.e. the highest efficiency attainable by any heat engine. However, though it is useful for illustrating general principles, the text book cycle it is a long way from representing what is actually going on inside a practical Stirling engine and should not be regarded as a basis for analysis. In fact it has been argued that its indiscriminate use in many standard books on engineering thermodynamics has done a disservice to the study of Stirling engines in general.

Other real-world issues reduce the efficiency of actual engines, due to limits of convective heat transfer, and viscous flow (friction). There are also practical mechanical considerations, for instance a simple kinematic linkage may be favoured over a more complex mechanism needed to replicate the idealized cycle, and limitations imposed by available materials such as non-ideal properties of the working gas, thermal conductivity, tensile strength, creep, rupture strength, and melting point.

Operation

Since the Stirling engine is a closed cycle, it contains a fixed mass of gas called the “working fluid”, most commonly air, hydrogen or helium. In normal operation, the engine is sealed and no gas enters or leaves the engine. No valves are required, unlike other types of piston engines. The Stirling engine, like most heat engines, cycles through four main processes: cooling, compression, heating and expansion. This is accomplished by moving the gas back and forth between hot and cold heat exchangers, often with a regenerator between the heater and cooler. The hot heat exchanger is in thermal contact with an external heat source, such as a fuel burner, and the cold heat exchanger being in thermal contact with an external heat sink, such as air fins. A change in gas temperature will cause a corresponding change in gas pressure, while the motion of the piston causes the gas to be alternately expanded and compressed.

The gas follows the behaviour described by the gas laws which describe how a gas’ pressure, temperature and volume are related. When the gas is heated, because it is in a sealed chamber, the pressure rises and this then acts on the power piston to produce a power stroke. When the gas is cooled the pressure drops and this means that less work needs to be done by the piston to compress the gas on the return stroke, thus yielding a net power output.

When one side of the piston is open to the atmosphere, the operation is slightly different. As the sealed volume of working gas comes in contact with the hot side, it expands, doing work on both the piston and on the atmosphere. When the working gas contacts the cold side, its pressure drops below atmospheric pressure and the atmosphere pushes on the piston and does work on the gas.

To summarize, the Stirling engine uses the temperature difference between its hot end and cold end to establish a cycle of a fixed mass of gas, heated and expanded, and cooled and compressed, thus converting thermal energy into mechanical energy. The greater the temperature difference between the hot and cold sources, the greater the thermal efficiency. The maximum theoretical efficiency is equivalent to the Carnot cycle, however the efficiency of real engines is less than this value due to friction and other losses.

Video showing the compressor and displacer of a very small Stirling Engine in action

Very low-power engines have been built which will run on a temperature difference of as little as 0.5 K.

Pressurization

In most high power Stirling engines, both the minimum pressure and mean pressure of the working fluid are above atmospheric pressure. This initial engine pressurization can be realized by a pump, or by filling the engine from a compressed gas tank, or even just by sealing the engine when the mean temperature is lower than the mean operating temperature. All of these methods increase the mass of working fluid in the thermodynamic cycle. All of the heat exchangers must be sized appropriately to supply the necessary heat transfer rates. If the heat exchangers are well designed and can supply the heat flux needed for convective heat transfer, then the engine will in a first approximation produce power in proportion to the mean pressure, as predicted by the West number, and Beale number. In practice, the maximum pressure is also limited to the safe pressure of the pressure vessel. Like most aspects of Stirling engine design, optimization is multivariate, and often has conflicting requirements.

Lubricants and friction

A modern Stirling engine and generator set with 55 kW electrical output, for combined heat and power applications

At high temperatures and pressures, the oxygen in air-pressurized crankcases, or in the working gas of hot air engines, can combine with the engine’s lubricating oil and explode. At least one person has died in such an explosion.

Lubricants can also clog heat exchangers, especially the regenerator. For these reasons, designers prefer non-lubricated, low-coefficient of friction materials (such as rulon or graphite), with low normal forces on the moving parts, especially for sliding seals. Some designs avoid sliding surfaces altogether by using diaphragms for sealed pistons. These are some of the factors that allow Stirling engines to have lower maintenance requirements and longer life than internal-combustion engines.

Analysis

Comparison with internal combustion engines

In contrast to internal combustion engines, Stirling engines have the potential to use renewable heat sources more easily, to be quieter, and to be more reliable with lower maintenance. They are preferred for applications that value these unique advantages, particularly if the cost per unit energy generated ($/kWh) is more important than the capital cost per unit power ($/kW). On this basis, Stirling engines are cost competitive up to about 100 kW.

Compared to an internal combustion engine of the same power rating, Stirling engines currently have a higher capital cost and are usually larger and heavier. However, they are more efficient than most internal combustion engines. Their lower maintenance requirements make the overall energy cost comparable. The thermal efficiency is also comparable (for small engines), ranging from 15% to 30%. For applications such as micro-CHP, a Stirling engine is often preferable to an internal combustion engine. Other applications include water pumping, astronautics, and electrical generation from plentiful energy sources that are incompatible with the internal combustion engine, such as solar energy, and biomass such as agricultural waste and other waste such as domestic refuse. Stirlings have also been used as a marine engine in Swedish Gotland class submarines. However, Stirling engines are generally not price-competitive as an automobile engine, due to high cost per unit power, low power density and high material costs.

Basic analysis is based on the closed-form Schmidt analysis.

Advantages

Stirling engines can run directly on any available heat source, not just one produced by combustion, so they can run on heat from solar, geothermal, biological, nuclear sources or waste heat from industrial processes.

A continuous combustion process can be used to supply heat, so most types of emissions can be reduced.

Most types of Stirling engines have the bearing and seals on the cool side of the engine, and they require less lubricant and last longer than other reciprocating engine types.

The engine mechanisms are in some ways simpler than other reciprocating engine types. No valves are needed, and the burner system can be relatively simple.

A Stirling engine uses a single-phase working fluid which maintains an internal pressure close to the design pressure, and thus for a properly designed system the risk of explosion is low. In comparison, a steam engine uses a two-phase gas/liquid working fluid, so a faulty relief valve can cause an explosion.

In some cases, low operating pressure allows the use of lightweight cylinders.

They can be built to run quietly and without an air supply, for air-independent propulsion use in submarines.

They start easily (albeit slowly, after warmup) and run more efficiently in cold weather, in contrast to the internal combustion which starts quickly in warm weather, but not in cold weather.

A Stirling engine used for pumping water can be configured so that the water cools the compression space. This is most effective when pumping cold water.

They are extremely flexible. They can be used as CHP (combined heat and power) in the winter and as coolers in summer.

Waste heat is easily harvested (compared to waste heat from an internal combustion engine) making Stirling engines useful for dual-output heat and power systems.

Disadvantages

Size and cost issues

Stirling engine designs require heat exchangers for heat input and for heat output, and these must contain the pressure of the working fluid, where the pressure is proportional to the engine power output. In addition, the expansion-side heat exchanger is often at very high temperature, so the materials must resist the corrosive effects of the heat source, and have low creep (deformation). Typically these material requirements substantially increase the cost of the engine. The materials and assembly costs for a high temperature heat exchanger typically accounts for 40% of the total engine cost.

All thermodynamic cycles require large temperature differentials for efficient operation. In an external combustion engine, the heater temperature always equals or exceeds the expansion temperature. This means that the metallurgical requirements for the heater material are very demanding. This is similar to a Gas turbine, but is in contrast to an Otto engine or Diesel engine, where the expansion temperature can far exceed the metallurgical limit of the engine materials, because the input heat source is not conducted through the engine, so engine materials operate closer to the average temperature of the working gas.

Dissipation of waste heat is especially complicated because the coolant temperature is kept as low as possible to maximize thermal efficiency. This increases the size of the radiators, which can make packaging difficult. Along with materials cost, this has been one of the factors limiting the adoption of Stirling engines as automotive prime movers. For other applications such as ship propulsion and stationary microgeneration systems using combined heat and power (CHP) high power density is not required.

Power and torque issues

Stirling engines, especially those that run on small temperature differentials, are quite large for the amount of power that they produce (i.e., they have low specific power). This is primarily due to the heat transfer coefficient of gaseous convection which limits the heat flux that can be attained in a typical cold heat exchanger to about 500 W/(m2K), and in a hot heat exchanger to about 5005000 W/(m2K). Compared with internal combustion engines, this makes it more challenging for the engine designer to transfer heat into and out of the working gas. Increasing the temperature differential and/or pressure allows Stirling engines to produce more power, assuming the heat exchangers are designed for the increased heat load, and can deliver the convected heat flux necessary.

A Stirling engine cannot start instantly; it literally needs to “warm up”. This is true of all external combustion engines, but the warm up time may be longer for Stirlings than for others of this type such as steam engines. Stirling engines are best used as constant speed engines.

Power output of a Stirling tends to be constant and to adjust it can sometimes require careful design and additional mechanisms. Typically, changes in output are achieved by varying the displacement of the engine (often through use of a swashplate crankshaft arrangement), or by changing the quantity of working fluid, or by altering the piston/displacer phase angle, or in some cases simply by altering the engine load. This property is less of a drawback in hybrid electric propulsion or “base load” utility generation where constant power output is actually desirable.

Gas choice issues

The used gas should have a low heat capacity, so that a given amount of transferred heat leads to a large increase in pressure. Considering this issue, helium would be the best gas because of its very low heat capacity. Air is a viable working fluid, but the oxygen in a highly pressurized air engine can cause fatal accidents caused by lubricating oil explosions. Following one such accident Philips pioneered the use of other gases to avoid such risk of explosions.

Hydrogen’s low viscosity and high thermal conductivity make it the most powerful working gas, primarily because the engine can run faster than with other gases. However, due to hydrogen absorption, and given the high diffusion rate associated with this low molecular weight gas, particularly at high temperatures, H2 will leak through the solid metal of the heater. Diffusion through carbon steel is too high to be practical, but may be acceptably low for metals such as aluminum, or even stainless steel. Certain ceramics also greatly reduce diffusion. Hermetic pressure vessel seals are necessary to maintain pressure inside the engine without replacement of lost gas. For HTD engines, auxiliary systems may need to be added to maintain high pressure working fluid. These systems can be a gas storage bottle or a gas generator. Hydrogen can be generated by electrolysis of water, the action of steam on red hot carbon-based fuel, by gasification of hydrocarbon fuel, or by the reaction of acid on metal. Hydrogen can also cause the embrittlement of metals. Hydrogen is a flammable gas, which is a safety concern, although the quantity used is very small, and it is arguably safer than other commonly used flammable gases.

Most technically advanced Stirling engines, like those developed for United States government labs, use helium as the working gas, because it functions close to the efficiency and power density of hydrogen with fewer of the material containment issues. Helium is inert, which removes all risk of flammability, both real and perceived. Helium is relatively expensive, and must be supplied as bottled gas. One test showed hydrogen to be 5% (absolute) more efficient than helium (24% relatively) in the GPU-3 Stirling engine. The researcher Allan Organ demonstrated that a well-designed air engine is theoretically just as efficient as a helium or hydrogen engine, but helium and hydrogen engines are several times more powerful per unit volume.

Some engines use air or nitrogen as the working fluid. These gases have much lower power density (which increases engine costs), but they are more convenient to use and they minimize the problems of gas containment and supply (which decreases costs). The use of compressed air in contact with flammable materials or substances such as lubricating oil, introduces an explosion hazard, because compressed air contains a high partial pressure of oxygen. However, oxygen can be removed from air through an oxidation reaction or bottled nitrogen can be used, which is nearly inert and very safe.

Other possible lighter-than-air gases include: methane, and ammonia.

Applications

It has been suggested that this section be split into a new article titled applications of the Stirling engine. (Discuss)

A desktop alpha Stirling engine. The working fluid in this engine is air. The hot heat exchange is the glass cylinder on the right, and the cold heat exchanger is the finned cylinder on the top. This engine uses a small alcohol burner (bottom right) as a heat source

Heating and cooling

If supplied with mechanical power, a Stirling engine can function in reverse as a heat pump for heating or cooling. Experiments have been performed using wind power driving a Stirling cycle heat pump for domestic heating and air conditioning. In the late 1930s, the Philips Corporation of the Netherlands successfully utilized the Stirling cycle in cryogenic applications.

Combined heat and power

Thermal power stations on the electric grid use fuel to produce electricity, however there are large quantities of waste heat produced which often go unused. In other situations, high-grade fuel is burned at high temperature for a low temperature application. According to the second law of thermodynamics, a heat engine can generate power from this temperature difference. In a CHP system, the high temperature primary heat enters the Stirling engine heater, then some of the energy is converted to mechanical power in the engine, and the rest passes through to the cooler, where it exits at a low temperature. The “waste” heat actually comes from engine’s main cooler, and possibly from other sources such as the exhaust of the burner, if there is one.

In a combined heat and power (CHP) system, mechanical or electrical power is generated in the usual way, however, the waste heat given off by the engine is used to supply a secondary heating application. This can be virtually anything that uses low temperature heat. It is often a pre-existing energy use, such as commercial space heating, residential water heating, or an industrial process.

The power produced by the engine can be used to run an industrial or agricultural process, which in turn creates biomass waste refuse that can be used as free fuel for the engine, thus reducing waste removal costs. The overall process can be efficient and cost effective.

Disenco, a UK based company are going through the final stages of development of their HomePowerPlant. Unlike other m-CHP appliances coming to market the HPP generates 3 kW of electrical and 15 kW of thermal energy, making this appliance suitable for both the domestic and SME markets.

WhisperGen, a New Zealand firm with offices in Christchurch, has developed an “AC Micro Combined Heat and Power” Stirling cycle engine. These microCHP units are gas-fired central heating boilers which sell unused power back into the electricity grid. WhisperGen announced in 2004 that they were producing 80,000 units for the residential market in the United Kingdom. A 20 unit trial in Germany started in 2006.

Solar power generation

Placed at the focus of a parabolic mirror a Stirling engine can convert solar energy to electricity with an efficiency better than non-concentrated photovoltaic cells, and comparable to Concentrated Photo Voltaics. On August 11, 2005, Southern California Edison announced an agreement with Stirling Energy Systems to purchase electricity created using over 30,000 Solar Powered Stirling Engines over a twenty year period sufficient to generate 850 MW of electricity. These systems, on an 8,000 acre (19 km2) solar farm will use mirrors to direct and concentrate sunlight onto the engines which will in turn drive generators. Construction is expected to begin on the farm in 2010, although there are disputes over the project due to concerns of environmental impact on animals living on the site.

Stirling cryocoolers

Any Stirling engine will also work in reverse as a heat pump; when a motion is applied to the shaft, a temperature difference appears between the reservoirs. The essential mechanical components of a Stirling cryocooler are identical to a Stirling engine. In both the engine and the heat pump, heat flows from the expansion space to the compression space; however, input work is required in order for heat to flow against a thermal gradient, specifically when the compression space is hotter than the expansion space. The external side of the expansion-space heat exchanger may be placed inside a thermally insulated compartment such as a vacuum flask. Heat is in effect pumped out of this compartment, through the working gas of the cryocooler and into the compression space. The compression space will be above ambient temperature, and so heat will flow out into the environment.

One of their modern uses is in cryogenics, and to a lesser extent, refrigeration. At typical refrigeration temperatures, Stirling coolers are generally not economically competitive with the less expensive mainstream Rankine cooling systems, even though they are typically 20% more energy efficient. However, below about 40  to 30 C, Rankine cooling is not effective because there are no suitable refrigerants with boiling points this low. Stirling cryocoolers are able to “lift” heat down to 200 C (73 K), which is sufficient to liquefy air (oxygen, nitrogen and argon). They can go as low as 4060 K, depending on the particular design. Cryocoolers for this purpose are more or less competitive with other cryocooler technologies. The coefficient of performance at cryogenic temperatures is typically 0.040.05 (corresponding to a 45% efficiency). Empirically, the devices show a linear trend, where typically the COP = 0.0015 Tc  0.065, where Tc is the cryogenic temperature. At these temperatures, solid materials have lower values for specific heat, so the regenerator must be made out of unexpected materials, such as cotton.[citation needed]

The first Stirling cycle cryocooler was developed at Philips in the 1950s and commercialized in such places as liquid air production plants. The Philips Cryogenics business evolved until it was split off in 1990 to form the Stirling Cryogenics BV, The Netherlands. This company is still active in the development and manufacturing of Stirling cryocoolers and cryogenic cooling systems.

A wide variety of smaller size Stirling cryocoolers are commercially available for tasks such as the cooling of electronic sensors and sometimes microprocessors. For this application, Stirling cryocoolers are the highest performance technology available, due to their ability to lift heat efficiently at very low temperatures. They are silent, vibration-free, and can be scaled down to small sizes, and have very high reliability and low maintenance. As of 2009, cryocoolers are considered to be the only commercially successful Stirling devices.[citation needed]

Heat pump

A Stirling heat pump is very similar to a Stirling cryocooler, the main difference being that it usually operates at room temperature and its principal application to date is to pump heat from the outside of a building to the inside, thus cheaply heating it.

As with any other Stirling device, heat flows from the expansion space to the compression space; however, in contrast to the Stirling engine, the expansion space is at a lower temperature than the compression space, so instead of producing work, an input of mechanical work is required by the system (in order to satisfy the second law of thermodynamics). When the mechanical work for the heat pump is provided by a second Stirling engine, then the overall system is called a “heat-driven heatpump”.

The expansion side of the heat pump is thermally coupled to the heat source, which is often the external environment. The compression side of the Stirling device is placed in the environment to be heated, for example a building, and heat is “pumped” into it. Typically there will be thermal insulation between the two sides so there will be a temperature rise inside the insulated space.

Heat pumps are by far the most energy-efficient types of heating systems. Stirling heat pumps also often have a higher coefficient of performance than conventional heat pumps. To date, these systems have seen limited commercial use; however, use is expected to increase along with market demand for energy conservation, and adoption will likely be accelerated by technological refinements.

Marine engines

The Swedish shipbuilder Kockums has built 8 successful Stirling powered submarines since the late 1980s. They carry compressed oxygen to allow fuel combustion whilst submerged that provides heat for the Stirling engine. They are currently used on submarines of the Gotland and Sdermanland classes. They are the first submarines in the world to feature a Stirling engine air-independent propulsion (AIP) system, which extends their underwater endurance from a few days to two weeks. This capability has previously only been available with nuclear powered submarines.

A similar system also powers the Japanese Sry class submarine.

Nuclear power

There is a potential for nuclear-powered Stirling engines in electric power generation plants. Replacing the steam turbines of nuclear power plants with Stirling engines might simplify the plant, yield greater efficiency, and reduce the radioactive byproducts. A number of breeder reactor designs use liquid sodium as coolant. If the heat is to be employed in a steam plant, a water/sodium heat exchanger is required, which raises some concern as sodium reacts violently with water. A Stirling engine eliminates the need for water anywhere in the cycle.

United States government labs have developed a modern Stirling engine design known as the Stirling Radioisotope Generator for use in space exploration. It is designed to generate electricity for deep space probes on missions lasting decades. The engine uses a single displacer to reduce moving parts and uses high energy acoustics to transfer energy. The heat source is a dry solid nuclear fuel slug and the heat sink is space itself.

Automotive engines

It is often claimed that the Stirling engine has too low a power/weight ratio, too high a cost, and too long a starting time for automotive applications. They also have complex and expensive heat exchangers. A Stirling cooler must reject twice as much heat as an Otto engine or Diesel engine radiator. The heater must be made of stainless steel, exotic alloy or ceramic to support high heater temperatures needed for high power density, and to contain hydrogen gas that is often used in automotive Stirlings to maximize power. The main difficulties involved in using the Stirling engine in an automotive application are startup time, acceleration response, shutdown time, and weight, not all of which have ready-made solutions. However, a modified Stirling engine has been recently introduced that uses concepts taken from a patented internal-combustion engine with a sidewall combustion chamber (U.S. patent 7,387,093) that promises to overcome the deficient power-density and specific-power problems, as well as the slow acceleration-response problem inherent in all Stirling engines. However, it could be possible to use these in co-generation systems that use waste heat from a conventional piston or gas turbine engine’s exhaust and use this either to power the ancillaries (eg: the alternator) or even as a turbo-compound system that adds power and torque to the crankshaft.

At least two automobiles exclusively powered by Stirling engines were developed by NASA, as well as earlier projects by the Ford Motor Company and American Motors Corporation. The NASA vehicles were designed by contractors and designated MOD I and MOD II. The MOD II replaced the normal spark-ignition engine in a 1985 4-door Chevrolet Celebrity Notchback. In the 1986 MOD II Design Report (Appendix A) the results show that highway gas mileage was increased from 40 to 58 mpg and urban mileage from 26 to 33 mpg with no change in vehicle gross weight. Startup time in the NASA vehicle maxed out at 30 seconds,[citation needed] while Ford’s research vehicle used an internal electric heater to jump-start the vehicle, allowing it to start in only a few seconds.

Electric vehicles

Many people believe that Stirling engines as part of a hybrid electric drive system can bypass all of the perceived design challenges or disadvantages of a non-hybrid Stirling automobile.

In November 2007, a prototype hybrid car using solid biofuel and a Stirling engine was announced by the Precer project in Sweden.

The Manchester Union Leader reports that Dean Kamen has developed a series plug-in hybrid car using a Ford Think. DEKA, Kamen’s technology company in the Manchester Millyard, has recently demonstrated an electric car, the DEKA Revolt, that can go approximately 60 miles (97 km) on a single charge of its lithium battery.

Aircraft engines

Stirling engines may hold theoretical promise as aircraft engines, if high power density and low cost can be achieved. They are quieter, less polluting, gain efficiency with altitude due to lower ambient temperatures, are more reliable due to fewer parts and the absence of an ignition system, produce much less vibration (airframes last longer) and safer, less explosive fuels may be used. However, the Stirling engine often has low power density compared to the commonly used Otto engine and Brayton cycle gas turbine. This issue has been a point of contention in automobiles, and this performance characteristic is even more critical in aircraft engines.

Low temperature difference engines

A low temperature difference Stirling Engine shown here running on the heat from a warm hand

A low temperature difference (Low Delta T, or LTD) Stirling engine will run on any low temperature differential, for example the difference between the palm of a hand and room temperature or room temperature and an ice cube. A record of only 0.5 K was achieved in 1990. See which also shows an animated drawing of this type. Usually they are designed in a gamma configuration, for simplicity, and without a regenerator, although some have slits in the displacer typically made of foam, for partial regeneration. They are typically unpressurized, running at pressure close to 1 atmosphere. The power produced is less than 1 W, and they are intended for demonstration purposes only. They are sold as toys and educational models.

Larger (typically 1 m square) low temperature engines have been built for pumping water using direct sunlight with minimal or no magnification.
Other recent applications

Acoustic Stirling Heat Engine

Los Alamos National Laboratory has developed an “Acoustic Stirling Heat Engine” with no moving parts. It converts heat into intense acoustic power which (quoted from given source) “can be used directly in acoustic refrigerators or pulse-tube refrigerators to provide heat-driven refrigeration with no moving parts, or … to generate electricity via a linear alternator or other electro-acoustic power transducer”.

MicroCHP

WhisperGen, a New Zealand based company has developed stirling engines that can be powered by natural gas or diesel. Recently an agreement has been signed with Mondragon Corporacin Cooperativa, a Spanish firm, to produce WhisperGen’s microCHP and make them available for the domestic market in Europe. Some time ago E.ON UK announced a similar initiative for the UK. Stirling engines would supply the client with hot water, space heating and a surplus electric power that could be fed back into the electric grid.

However the preliminary results of an Energy Saving Trust review of the performance of the WhisperGen microCHP units suggested that their advantages were marginal at best in most homes. However another author shows that that Stirling engined microgeneration is the most cost effective of various microgeneration technologies in terms of reducing CO2.

Chip cooling

MSI (Taiwan) recently developed a miniature Stirling engine cooling system for personal computer chips that uses the waste heat from the chip to drive a fan.

Alternatives

Alternative thermal energy harvesting devices include the Thermogenerator. Thermogenerators allow less efficient conversion (5-10%) but may be useful in situations where the end product needs to be electricity and where a small conversion device is a critical factor.

Photo gallery

Preserved examples of antique Rider hot air engines – an alpha configuration Stirling

See also

Thermomechanical generator

Beale Number

West Number

Schmidt number

Fluidyne engine

Stirling radioisotope generator

Relative cost of electricity generated by different sources

Distributed generation

References

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^ http://www.animatedengines.com/ltdstirling.shtml

^ http://www.bsrsolar.com/core1-1.php

^ S. Backhaus; G. Swift (2003)

^ Carbon Trust (2007)

^ MSI (2008) http://www.tweaktown.com/news/9051/msi_employs_stirling_engine_theory/index.html

Bibliography

S.D. Allan (2005). “World’s Largest Solar Installation to use Stirling Engine Technology”. Pure Energy Systems News. http://pesn.com/2005/08/11/9600147_Edison_Stirling_largest_solar/. Retrieved 2009-01-19. 

S. Backhaus; G. Swift (2003). “Acoustic Stirling Heat Engine: More Efficient than Other No-Moving-Parts Heat Engines”. Los Alamos National Laboratory. http://www.lanl.gov/mst/engine/. Retrieved 2009-01-19. 

BBC News (2003-10-31). “Power from the people”. http://news.bbc.co.uk/2/hi/programmes/working_lunch/3231549.stm. Retrieved 2009-01-19. 

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Vw?s Touareg Bluetdi: World?s Cleanest Diesel Engine

Volkswagen’s Touareg has one of the cleanest diesel engines in the world. Its BlueTDI engine with SCR catalytic converter reduces nitrogen dioxide (NOx) emissions by up to 90 percent. Touareg BlueTDI delivers 165kW/225 PS and meets even the strictest “Tier2 Bin5” exhaust emissions standards implemented in the US states particularly in California, Massachusetts, New York, Vermont, and Maine.

In the USA economical turbo-diesels like the V6 BlueTDI more than any present day powertrain technology can help in reducing oil consumption and the generation of climate-impacting greenhouse gases. Volkswagen will offer the Touareg with the SCR catalytic converter starting 2008 first in the US as part of its BlueTec alliance with DaimlerChrysler and Audi. The BlueTec alliance was started by the three carmakers last year.

Volkswagen has also scheduled the launching of a smaller Jetta in America in 2008. It will also be equipped with NOx storage catalytic converter that eliminates up to 90 percent of nitrogen oxides. Both the Touareg BlueTDI and Jetta are scheduled to debut in Europe. The Euro 4 standard currently specifies a NOx limit of 0.25 g/km while the US standard which Volkswagen Touareg BlueTDI satisfies specifies a NOx limit of 0.043 g/km or 0.07 g/mile. Aside from the remarkable NOx catalytic converters that Touareg and Jetta have, they are also equipped with heavy duty VW axles.

It should be noted that the Touareg TDI had successfully towed a Boeing 747 and was made possible by its especially modified a rel=”nofollow” onclick=”javascript:pageTracker._trackPageview(‘/outgoing/article_exit_link’);” href=”http://www.vdubpartsdirect.com/vw_axle.html”title=”VW axle”>VW axle. By towing the 155 ton Boeing 747, Volkswagen Touareg has displayed not only the prowess of its engine but also the durability and power of every component.

The SCR (Selective Catalytic Reduction) Catalytic Converter

SCR is short for “Selective Catalytic Reduction”. Its main function is to selectively convert the nitrogen oxide or NOx exhaust components to nitrogen and water without producing any undesirable byproducts. Volkswagen’s Touareg BlueTDI which will debut at the Geneva Motor show will also feature an oxidation catalytic converter and a diesel particulate filter.

Water-based urea solution like AdBlue is used in converting the nitrogen oxides. The urea solution is stored in an auxiliary tank on the Touareg BlueTDI. It is in the auxiliary tank wherein the 32.5 percent urea is continuously sprayed into the exhaust stream before the SCR catalytic converter. It is measured based on the mass flow of the exhaust. An engine management system after obtaining information from a Nox sensor located after the SCR catalytic converter makes sure that everything is correctly regulated.

The urea solution is atomized into fine spray by a screen and transformed in the hot exhaust has stream upstream of the catalytic converter. It is in the SCR catalytic converter where the nitrogen oxide is split into nitrogen and water. The water-based additive AdBlue is an odorless, non-toxic and biodegradable solution.

The AdBlue is consumed at an average rate of about 0.1 liter per 100 kilometers. The tank and consumption are measured so that the AdBlue supply can last up to the next scheduled service.

Benjamin Hudson works as a supervisor at one of the top engineering firms in the business district of Louisiana. He is also a freelance journalist and has passion for anything automotive.

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