SiC Fiber Reinforced SiC-Si Matrix Composites Prepared by Melt Infiltration (MI) for Gas Turbine Engine Applications

1999 ◽  
Author(s):  
Gregory S. Corman ◽  
Milivoj K. Brun ◽  
Krishan L. Luthra
Keyword(s):  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Matrix Cracking ◽  
Matrix Composites ◽  
Fiber Reinforced ◽  
Turbine Engine ◽  
Sic Fiber ◽  
Silicon Melt ◽  
Melt Infiltration ◽  
Near Net Shape

General Electric (GE) has developed silicon carbide fiber reinforced SiC-Si matrix composites by silicon melt infiltration (MI) for use in gas turbine engine applications. This paper focuses on a process based on tow prepreging and lamination of unidirectional tapes. Silicon melt infiltration yields a fully dense, near net shape composite with a relatively high thermal conductivity, actually higher than many superalloys at temperatures up to 800°C, and a high proportional limit, or matrix cracking stress. Room and elevated temperature mechanical properties of the composite are presented. Following exposure to various simulated turbine environments this material shows relatively good retention of strength and toughness. The fabrication of turbine shroud and combustor liner components for high pressure combustion rig testing is also described.

Rig and Engine Testing of Melt Infiltrated Ceramic Composites for Combustor and Shroud Applications

2002 ◽  
Vol 124 (3) ◽  
pp. 459-464 ◽  
Author(s):  
G. S. Corman ◽  
A. J. Dean ◽  
S. Brabetz ◽  
M. K. Brun ◽  
K. L. Luthra ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Ceramic Composites ◽  
Gas Turbine Engine ◽  
Matrix Composites ◽  
Turbine Engine ◽  
Sic Fiber ◽  
Silicon Melt ◽  
Melt Infiltration ◽  
Engine Testing ◽  
Observed Damage

General Electric has developed SiC fiber-reinforced SiC-Si matrix composites produced by silicon melt infiltration for use in gas turbine engine applications. High temperature, high-pressure combustion rig testing, and engine testing has been performed on combustor liners and turbine shrouds made from such MI composites. Frame 5 sized combustor liners were rig tested under lean head end diffusion flame conditions for 150 hours, including 20 thermal trip cycles, with no observed damage to the ceramic liners. Similarly, 46-cm diameter, single-piece turbine shroud rings were fabricated and tested in a GE-2 gas turbine engine. The fabrication and testing of both components are described.

Rig and Engine Testing of Melt Infiltrated Ceramic Composites for Combustor and Shroud Applications

2000 ◽  
Author(s):  
Gregory S. Corman ◽  
Anthony J. Dean ◽  
Stephen Brabetz ◽  
Milivoj K. Brun ◽  
Krishan L. Luthra ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Ceramic Composites ◽  
Gas Turbine Engine ◽  
Matrix Composites ◽  
Turbine Engine ◽  
Sic Fiber ◽  
Silicon Melt ◽  
Melt Infiltration ◽  
Engine Testing ◽  
Observed Damage

GE has developed SiC fiber reinforced SiC-Si matrix composites produced by silicon melt infiltration (MI) for use in gas turbine engine applications. High temperature, high pressure combustion rig testing and engine testing has been performed on combustor liners and turbine shrouds made from such MI composites. Frame 5 sized combustor liners were rig tested under LHE diffusion flame conditions for 150 hours, including 20 thermal trip cycles, with no observed damage to the ceramic liners. Similarly, 46 cm diameter, single piece turbine shroud rings were fabricated and tested in a PGT-2 gas turbine engine. The fabrication and testing of both components are described.

scholarly journals Processing of Continuous Fiber Reinforced SI3N4 Matrix Composites for Gas Turbine Engine Components

1994 ◽  
Author(s):  
Misao Iwata ◽  
Takeshi Isoda ◽  
Takuji Itoh
Keyword(s):  
Fracture Toughness ◽  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Matrix Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Turbine Engine ◽  
Helical Angle ◽  
Engine Components ◽  
Si3n4 Matrix

The purpose of this study is to significantly improve the fracture toughness of ceramic materials by incorporating continuous fiber reinforcement, and demonstrate the ability to fabricate gas turbine engine components, such as shrouds and liners. SI3N4, matrix composites were prepared by stacking precursor tapes consisting of carbon fibers coated with a slurry of SI3N4, Al2O3, Y2O3, perhydropolysilazane and xylene. After sintering the continuous fiber reinforced SI3N4-matrix composites had a 4 to 5 times higher fracture toughness of 28.1 MPam1 /2 and a 250 to 300 times higher work-of-fracture of 2.5 × 104 j/m2, than typical monolithic SI3N4 ceramics. In the meantime, the preform tape wound at a helical-angle of 45° was used for forming green bodies of the gas turbine engine components by means of the deep drawing method. In order to sinter these preforms, the preceramic polymer infiltration method (P.C.P.I. method) and pseudo hot isostatic press method were applied for fabricating the shroud and liners, respectively.

Effect of fiber coating on creep behavior of SiC fiber-reinforced titanium aluminide matrix composites

1994 ◽  
Vol 9 (1) ◽  
pp. 198-206 ◽  
Author(s):  
Hsing-Pang Chiu ◽  
J-M. Yang ◽  
J.A. Graves
Keyword(s):  
Creep Behavior ◽  
Matrix Cracking ◽  
Matrix Composites ◽  
Fiber Reinforced ◽  
Transverse Loading ◽  
Damage Mechanisms ◽  
Fiber Coating ◽  
Duplex Coating ◽  
Sic Fiber ◽  
Stress Levels

The effect of fiber coating on the creep behavior and damage mechanisms of unnotched SCS-6 fiber-reinforced Ti3Al matrix composites under longitudinal and transverse loading was investigated at 700 °C. Stresses ranging from 700 to 900 MPa and 200 to 400 MPa were used for longitudinal and transverse loading, respectively. An Ag/Ta duplex layer was coated onto the SCS-6 fiber prior to consolidation via physical vapor deposition. The microstructure of the crept composites was examined to determine the creep deformation mechanisms. The creep cracking behavior of the notched composites was also studied at initial stress intensity factors, Ki, ranging from 15 to 20 MPa-m1/2. Microstructural observation revealed that multiple fiber fracture (at low to medium stress levels), microcracking along the reaction zone/matrix interface (at medium stress levels), and matrix cracking extending from the broken fiber ends (at high stress levels) were the major damage mechanisms during quasi-steady state creep under longitudinal loading. The results show that the Ag/Ta duplex coating significantly improved the creep resistance and flexural strength of the composite under transverse loading. The Ag/Ta duplex coating was also shown to significantly prolong the creep rupture life of SiC fiber-reinforced Ti3Al composites.

Near Net-Shape Forming of Thermal Barrier Coated Components for Gas Turbine Engine Applications

1998 ◽  
Author(s):  
G.E. Kim ◽  
P.G. Tsantrizos ◽  
S. Grenier ◽  
A. Cavasin ◽  
T. Brzezinski
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Gas Turbine ◽  
Bond Coat ◽  
Gas Turbine Engine ◽  
Thermal Barrier ◽  
Forming Process ◽  
Turbine Engine ◽  
Near Net Shape ◽  
Net Shape Forming

Abstract PyroGenesis Inc. has developed a unique Vacuum Plasma Spraying (VPS) near-net-shape forming process for the production of multilayered free-standing components. Initial evaluation on the feasibility of applying this process for the production of gas turbine engine components has been performed. The VPS near-net-shape forming process consists of: selecting an appropriate mold material; preconditioning of mold surface ; depositing metallic, ceramic, or composite layers ; and removing mold from the spray-formed structure. The near-net-shape components are heat treated to improve their mechanical properties. A suitable heat treatment cycle was developed for the VPS-applied superalloy. Much of the recent improvements in gas turbine engine performance has been attributed to the introduction of thermal barrier coatings (TBC) for superalloy components. There exist, however, some limitations in current fabrication methods for closed hot-section components: less than ideal coating quality; welding; limited choice of superalloy material; etc... PyroGenesis has used VPS near-net-shape forming to fabricate closed components with an yttria-stabilized-zirconia inner layer, CoNiCrA1Y bond coat, and IN-738LC outer layer. The results from the initial study demonstrate the feasibility of producing near-net-shape components with good coating structures, superior superalloy materials, and the absence welds. The mold was reusable after minor surface conditioning. The TBC showed uniform thickness and microstructure with a smooth surface finish. The bond coat and structural superalloy layers were very dense with no signs of oxidation at the interface. After heat treatment, the mechanical properties of the IN-738LC compare favourably to cast materials.

Tensile Creep Behavior of Melt-Infiltrated SiC-SiC Composites for Gas Turbine Engine Applications

2007 ◽  
Author(s):  
Vijay V. Pujar ◽  
Gregory N. Morscher
Keyword(s):  
Ceramic Matrix Composites ◽  
Matrix Cracking ◽  
Tensile Creep ◽  
Matrix Composites ◽  
Creep Tests ◽  
Turbine Engine ◽  
Sic Ceramic ◽  
Melt Infiltration ◽  
Sic Composites ◽  
Engine Components

SiC-SiC ceramic matrix composites (CMCs) manufactured by the melt-infiltration (MI) process are considered leading candidates for hot-section turbine engine components. MI composites consisting of different commercially available SiC fibers were fabricated and their room temperature and elevated temperature performance was evaluated. In this paper, results on the performance of composites under tensile creep conditions and the properties of these materials retained after creep are discussed. Specimens were subjected to 100-h creep tests at different stress levels. For samples that did not rupture during creep, retained tensile properties were measured after creep and compared to those on the as-produced samples. Interestingly, the after-creep specimens show higher 0.005% offset stresses (or matrix cracking strengths) relative to those in the as-produced materials, which is attributed to redistribution of stresses among the constituents during the tensile creep test. That is, the results show that the offset stresses in these materials can actually improve with use under tensile creep conditions, which is a desirable attribute for components of these materials for turbine engines.

Rig and Gas Turbine Engine Testing of MI-CMC Combustor and Shroud Components

2001 ◽  
Author(s):  
Gregory Corman ◽  
Anthony Dean ◽  
Stephen Brabetz ◽  
Keith McManus ◽  
Milivoj Brun ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Ceramic Matrix Composites ◽  
Gas Turbine Engine ◽  
Matrix Composites ◽  
Turbine Engine ◽  
Single Piece ◽  
Engine Testing ◽  
Engine Components ◽  
Industrial Gas Turbine

GE is continuing work on the development of Melt-Infiltrated Ceramic Matrix Composites (MI-CMC) for use in industrial gas turbine engine components. Long-term environmental degradation of test samples under realistic engine conditions is being determined using a unique high-pressure combustion rig apparatus. Rig testing is also being used to evaluate an F-class 1st stage shroud system incorporating an MI-CMC inner shroud component. While large, advanced engines, such as the F and H classes, offer the greatest benefits for using MI-CMC components, initial engine tests have been done using a GE-2 (2MW) machine to reduce costs and risk. Long term (1000 hours) engine testing results for single piece GE-2 shrouds are also described.

Application of a Carbon Fiber Reinforced Plastics to Gas Turbine Engine

2016 ◽  
Vol 2016 (0) ◽  
pp. S1910305
Author(s):  
Hironobu MIYOSHI ◽  
Kei-ichi OKUYAMA ◽  
Bianca SZASZ ◽  
Hayato YOSHIO ◽  
Takuya YAMANOUCHI ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Fiber Reinforced ◽  
Turbine Engine ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced
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