Proceedings of GT2005

ASME Turbo Expo 2005: Power for Land, Sea and Air
June 6-9, 2005, Reno-Tahoe, Nevada, USA

GT2005-68781

ENGINE TESTING OF AN ADVANCED ALLOY FOR MICROTURBINE PRIMARY SURFACE

RECUPERATORS

Wendy J. Matthews
Capstone Turbine Corporation
Chatsworth, California

Terry Bartel Dwaine L. Klarstrom Larry R. Walker

Elgiloy Specialty Metals Haynes International Oak Ridge National Laboratory
Elgin, Illinois Kokomo, Indiana Oak Ridge, Tennessee

ABSTRACT become increasingly desirable to extend the life of the

HAYNES ®1 alloy HR-120 ®1 has been identified as a
potential alloy for the manufacture of primary surface
recuperators. Primary surface recuperator components have
been manufactured from HR-120, and actual microturbine
testing is on going. Initial engine test results indicate the
formation of a protective oxide scale that is resistant to both
steady-state and cyclic operation with no evidence of
accelerated attack, and which is likely to meet or exceed the
desired 80,000 hour component life.
Keywords: recuperator, oxidation, microturbine
INTRODUCTION
Microturbine primary surface recuperators are exposed to a
harsh operating environment that combines high temperatures,
water vapor, and other products of combustion with a high gas
velocity. The environment to which the microturbine
recuperator is subjected tends to result in oxidation damage that
is greater than that observed in hot air test rigs, where most of
the long term testing of recuperator alloys has been carried out.
In order to achieve a recuperator life in excess of 80,000 hours
of microturbine operation, it is desirable to manufacture the
primary surface recuperator from an alloy that forms a
protective oxide scale. The presence of such a scale provides
resistance to steady state and cyclic operation, as well as
providing resistance to the accelerated attack that occurs due to
the presence of water vapor in the exhaust gases.
The annular, primary surface recuperator (PSR) used in the
Capstone MicroTurbine ™ is an important contributor to the
thermal efficiency of the microturbine [1]. Recently, it has
1
HAYNES and HR-120 are trademarks of Haynes International, Inc.
recuperator beyond the 40,000 hour life of the microturbine,
with a target life of 80,000 hours of operation for the
recuperator. Recuperator technology at Capstone is well
established using austenitic stainless steels. The austenitic
stainless steels are used to meet the creep strength and
corrosion resistance requirements of the recuperator.
The exhaust gas of the microturbine contains water vapor
as a product of combustion, and recent analyses have
discovered that water vapor can accelerate the rate of oxidation
of stainless steels, leading to increased Cr consumption and Cr
depletion near the surface of the metal [3-7]. While the exact
mechanism has not been defined, it has been shown that an
increase in the Cr and/or Ni content of an alloy will either
prevent accelerated attack or increase the time before it occurs
[5,6,7,13]
Alloys with higher resistance to the harsh oxidizing
environment to which the recuperator is subjected are being
investigated as alternatives to traditional austenitic stainless
steels. The advanced alloys have much greater oxidation
resistance and do not appear to be prone to accelerated attack
(caused by the presence of water vapor in the products of
combustion) that has been observed in the typical stainless steel
alloys [8-11].
HAYNES Alloy HR-120 was chosen by Capstone for in
depth evaluation, as it is a commercially available and well
established alloy. Initial engine testing of HR-120 primary
surface recuperators has been completed and further engine
testing is on-going.
The results of initial engine testing of HR-120 alloy used in
a primary surface recuperator will be presented in this paper.

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 Crushed Region
of Aircell
NOMENCLATURE Fin-folded
Region of
ORNL Oak Ridge National Laboratory
PSR Primary Surface Recuperator
SEI Secondary Electron Imaging
TET Turbine Exit Temperature
µm Micron (micrometer)

EXPERIMENTAL PROCEDURE

Commercially produced HR-120 foil, cold rolled to ~90

µm thick and bright annealed, was obtained from Elgiloy
Specialty Metals for the production of standard primary surface
recuperator aircells. The nominal composition of standard
HAYNES Alloy HR-120, as per the HAYNES International
Alloy Brochure [12], is presented in Table 1.

Fe Ni Co Cr Mo
33a 37 3* 25 2.5*
Figure 1: Recuperator Core with Individual Aircell (inset).
W Nb Mn Si N
2.5* 0.7 0.7 0.6 0.20
The recuperator core was then built into a complete
Al C B *Maximum recuperator assembly and installed on a Capstone C60
a
0.1 0.05 0.004 As Balance microturbine. The engine ran for 1,800 one hour cycles (for a
total of 1,800 hours of operation) at an elevated TET (100°F
above normal operating set-point) with a minimum 900°F cool
Table 1: Nominal Chemical Composition of Standard
down between cycles. The elevated TET and the cyclic nature
HAYNES Alloy HR-120 (Weight Percent).
of the test were chosen to accelerate the rate of oxidation
damage to the recuperator core.
After the completion of the elevated temperature cyclic
The HR-120 foil was processed at the Capstone
test, the recuperator core was removed from the recuperator
Recuperator Manufacturing Facility. The raw foil was
assembly, and aircells were removed for further sectioning.
processed into fin-folded stock, which was subsequently
Samples from HR-120 aircells, in both the crushed and fin-
pressed and trimmed to form individual aircell sheets. The
folded region on the hot gas inlet side of the recuperator core
individual aircells were assembled from two individual sheets
were examined using the electron microprobe at ORNL (JEOL
and various spacer bars, and welded into a recuperator core
JXA-8200 WD/ED Combined Microanalyzer). Samples of the
containing aircells manufactured from both Type 347 Stainless
original HR-120 foil were also examined using the electron
Steel as well as HAYNES Alloy HR-120. Figure 1 shows a
microprobe to provide a baseline for the chemical composition
final recuperator core with an inset showing an individual
of the alloy.
aircell.

RESULTS

BASELINE HR-120 FOIL

Samples of as processed fin-folded and crushed HR-120

foil were examined with the electron microprobe, in order to
establish a baseline element distribution. Figure 2 is an SEI
(Secondary Electron Imaging) micrograph of the original HR-
120 foil, taken with the electron microprobe.

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 In the recuperator, one side of the foil is exposed to air
from the compressor (air side) and the other side is exposed to
the exhaust gas of the Microturbine (gas side). Figure 4 is an
SEI micrograph of an engine tested HR-120 aircell foil cross-
section showing the start and end points of the profile scan.
The left side of the micrograph in Figure 4 is the “air side” of
the foil and the right side is the “gas side” of the foil. The
oxide scale has formed primarily on the “gas side” of the foil.

Air Gas
Side Side

Figure 2: SEI Micrograph of HR-120 Baseline Foil –

Location of Profile Scan.

A profile scan of the baseline foil was made as indicated in

Figure 2. Figure 3 shows electron microprobe element profiles
of Fe, Ni and Cr across the thickness of the foil.

Figure 4: SEI Micrograph of HR-120 Engine Tested Aircell

Foil Cross-section – Location of Profile Scan.

Figure 5 shows electron microprobe element profiles of Fe,

Cr, Ni, and O for the HR-120 cross-section shown in Figure 4.

Figure 3: Electron Microprobe Fe, Ni, and Cr Profiles

Across Baseline HR-120 Foil.

ENGINE TESTED HR-120 FOIL Air Gas

Side Side
Several samples taken from HR-120 aircells around the
circumference of the engine tested recuperator core were Figure 5: Electron Microprobe O, Fe, Cr, and Ni Profiles
examined using the electron microprobe. The following Across HR-120 Foil after Engine Testing.
analysis results are from a section of an HR-120 aircell that was
removed from the fin-folded region, immediately adjacent to
the crushed region, at the hot gas inlet of the recuperator. The profiles in Figure 5 show Cr depletion near the gas
side surface only, with the bulk of the foil retaining the nominal

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 25-26% Cr. Approximately 10% of the total material thickness
has experienced moderate Cr depletion of ~15-30%. It is
estimated that only ~3% of the Cr has been depleted from the
total starting Cr reservoir of the foil.
Figure 6 presents the results of electron probe element
mapping from another location on the same sample. Figure 6a
is a backscattered micrograph of the location chosen for
element mapping. The top of the micrograph is the “gas side”
of the foil, and the bottom is the “air side” of the foil. Again,
oxide scale has formed primarily on the “gas side” of the foil.
Figures 6b-e are element maps, of the engine tested HR-120
foil, showing the distribution of Fe, Ni, Cr, and O.
The element maps of the engine tested HR-120 foil show
that a very thin Chromium oxide layer is present on both the
“air side” and “gas side” of the foil, and that there is a thin
outer layer of Iron oxide on the “gas side” of the foil. The
element maps also show that the Cr depletion is confined to a
region near the surface, and the degree of Cr depletion is
greater on the “gas side” of the foil, as was expected.

Fe Enrichment Ni Enrichment

Cr Depletion

Figure 6: Electron Microprobe Element Maps of HR-120 Engine Tested Aircell Foil Cross-Section - a) Backscattered
Micrograph, b) Fe Map, c) Ni Map, d) Cr Map, and e) O Map.

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 DISCUSSION
The recuperator is a critical component of the Capstone
MicroTurbine system, and the cost can be a significant portion
of the manufacturing cost of the system [Ref. 1]. Increased
oxidation resistance of the recuperator material will result in
greatly extended recuperator life, which can reduce the overall
life cycle cost to the microturbine system.
Capstone experience has shown that the oxidation damage
caused by the 1,800 cyles/1,800 hour elevated TET test is
equivalent to ~15,000 hours of steady-state operation at normal
operating TET [14]. Experience has also shown that ~50% Cr
depletion from the starting Cr reservoir results in reduced
efficiency of the recuperator [14]. The HR-120 engine tested
foil shows ~3% Cr depletion from the starting Cr reservoir.
The low amount of Cr depletion in the foil tested in the
HR-120 engine is very encouraging. These test results would
seem to indicate that a recuperator manufactured from HR-120
foil may exceed the 80,000 hour life target.
Engine testing of the HR-120 foil is continuing at
Capstone, including longer duration cyclic testing and steady-
state endurance testing.
ACKNOWLEDGMENTS
The authors wish to thank K. More and B. Pint of Oak
Ridge National Laboratory for assistance with the analysis.
This work was partially sponsored by the U.S. Department of
Energy, Office of Power Technologies, as part of The
Distributed Energy Program, under Contract DE-AC05-
00OR22725 with UT-Battelle, LLC.
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