Flex Cycle Combustor Development and Demonstration

An innovative, “flex-cycle” combustion system has been developed for the Garrett Model 400-1 Integrated Power Unit (IPU), a 425 shp (317 kW) gas turbine engine designed for use on future fighter aircraft. Demonstration of this system required real-time transient operation of the combustor in a full-scale test rig. The transient testing was unique, having been performed with an electronic control, which modulated all combustor operating parameters according to programmed engine component maps, drag curves, fuel schedules, and selected ambient test conditions. The axially injected annular combustor is capable of engine starts in two seconds, as well as producing 200 shp (149 kW) for emergency use at all altitudes up to 50,000 ft (15,240 m). The combustion system is capable of switching operation from the emergency power stored energy (SE) mode to the normal-air breathing (NAB) auxiliary power mode without loss of engine power. The flex-cycle combustor supplies emergency power in the SE mode with a temperature rise of 2200°F (1222°C) and in the NAB mode with a temperature rise of 1600°F (889°C). Specific features that make these requirements possible include air-assisted simplex airblast fuel atomizers with integral check valves, and effusion-cooled combustor liner walls. This paper describes the flex-cycle combustion system design, test methods used, and significant test results. Steady-state performance, in both the SE and NAB operating modes, and real-time transient test results are discussed. The transient testing included rapid starts as well as transitions from the SE to NAB operating regimes.