Failures of multifunctional bulkhead caused by high gradient of temperature, pressure and speed of rotation

Abstract The multifunctional bulkhead is an assembly which divides the compressor and turbine space (cold and very hot area) in the gas-generator for turbo-jet and turbo-haft engines. The loads of this bulkhead present an interaction of mechanical, thermal, fluid stream and pressure effects which produce extreme operating conditions and specific kinds of failures. Additional unfavorable effects produce a high gradient and a variation of these loads. The article contains a numerical identification of bulkhead operating conditions and an innovative design of the bulkhead for this purpose. Design development is based on the specific failures which are analyzed together with causes and design possibilities for failure prevention. For this purpose, in the existing design approach “Property-based Design”, a specific procedure named Failure-based design – FBD is applied. The paper also includes CFD analysis, numerical analyses of temperature, stress and deflection distribution of the multifunctional bulkhead. The presentation of the test stand and results of gas-generator testing together with the design solution of the multifunctional bulkhead, are also part of the article.