Development and Test of Oxide/Oxide CMC Combustor Liner Demonstrators for Aero Engines

2016 ◽  
Author(s):  
Thomas Behrendt ◽  
Stefan Hackemann ◽  
Peter Mechnich ◽  
Yuan Shi ◽  
Sandrine Hönig ◽  
...  
Keyword(s):  
Protective Coating ◽  
Mechanical Design ◽  
Early Stage ◽  
Ceramic Matrix Composites ◽  
Matrix Composites ◽  
Failure Model ◽  
Design Development ◽  
Post Test ◽  
Aero Engines ◽  
Combustor Liner

Ceramic matrix composites (CMC) offer the potential of increased service temperatures and are thus an interesting alternative to conventional combustor alloys. Tubular combustor liner demonstrators made of an oxide/oxide CMC were developed for a lean combustor in a future aero-engine in the medium thrust range and tested at engine conditions. During the design various aspects like protective coating, thermo-mechanical design, development of a failure model for the CMC as well as design and test of an attachment system were taken into account. The tests of the two liners were conducted at conditions up to 80% take-off. A new protective coating was tested successfully with a coating thickness of up to t=1 mm. Different inspection criteria were derived in order to detect crack initiation at an early stage for a validation of the failure model. With the help of detailed pre- and post-test computer tomography scans to account for the micro structure of the CMC the findings of the failure model were in reasonable agreement with the test results.

Development and Test of Oxide/Oxide Ceramic Matrix Composites Combustor Liner Demonstrators for Aero-engines

2016 ◽  
Vol 139 (3) ◽  
Author(s):  
Thomas Behrendt ◽  
Stefan Hackemann ◽  
Peter Mechnich ◽  
Yuan Shi ◽  
Sandrine Hönig ◽  
...  
Keyword(s):  
Protective Coating ◽  
Early Stage ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Oxide Ceramic ◽  
Matrix Composites ◽  
Failure Model ◽  
Post Test ◽  
Aero Engines ◽  
Combustor Liner

Ceramic matrix composites (CMC) offer the potential of increased service temperatures and are thus an interesting alternative to conventional combustor alloys. Tubular combustor liner demonstrators made of an oxide/oxide CMC were developed for a lean combustor in a future aero-engine in the medium thrust range and tested at engine conditions. During the design, various aspects like protective coating, thermomechanical design, and development of a failure model for the CMC as well as design and test of an attachment system were taken into account. The tests of the two liners were conducted at conditions up to 80% take-off. A new protective coating was tested successfully with a coating thickness of up to t = 1 mm. Different inspection criteria were derived in order to detect crack initiation at an early stage for a validation of the failure model. With the help of detailed pre- and post-test computer tomography (CT) scans to account for the microstructure of the CMC, the findings of the failure model were in reasonable agreement with the test results.

scholarly journals Exposure of Ceramics and Ceramic Matrix Composites in Simulated and Actual Combustor Environments

2000 ◽  
Vol 122 (2) ◽  
pp. 212-218 ◽  
Author(s):  
Karren L. More ◽  
Peter F. Tortorelli ◽  
Mattison K. Ferber ◽  
Larry R. Walker ◽  
James R. Keiser ◽  
...  
Keyword(s):  
Ceramic Matrix Composite ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Surface Damage ◽  
Operating Conditions ◽  
Matrix Composites ◽  
Long Term Stability ◽  
Recession Rates ◽  
Combustor Liner

A high-temperature, high-pressure, tube furnace has been used to evaluate the long term stability of different monolithic ceramic and ceramic matrix composite materials in a simulated combustor environment. All of the tests have been run at 150 psia, 1204°C, and 15 percent steam in incremental 500 h runs. The major advantage of this system is the high sample throughput; >20 samples can be exposed in each tube at the same time under similar exposure conditions. Microstructural evaluations of the samples were conducted after each 500 h exposure to characterize the extent of surface damage, to calculate surface recession rates, and to determine degradation mechanisms for the different materials. The validity of this exposure rig for simulating real combustor environments was established by comparing materials exposed in the test rig and combustor liner materials exposed for similar times in an actual gas turbine combustor under commercial operating conditions. [S0742-4795(00)02402-9]

scholarly journals Nondestructive Characterization of Ceramic Composites Used as Combustor Liners in Advanced Gas Turbines

1995 ◽  
Author(s):  
W. A. Ellingson ◽  
S. A. Rothermel ◽  
J. F. Simpson
Keyword(s):  
Gas Turbines ◽  
Thermal Characteristics ◽  
Ceramic Matrix Composites ◽  
Ceramic Composites ◽  
Matrix Composites ◽  
Full Field ◽  
X Ray ◽  
X Ray Imaging ◽  
Combustor Liner ◽  
Nondestructive Characterization

Nondestructive characterization (NDC) methods which can provide full field information about components prior to and during use are critical to the reliable application of continuous fiber ceramic matrix composites in high firing temperature (>1350°C) gas turbines. For combustor liner applications, although nonmechanical load bearing components, thermal characteristics as well as mechanical integrity is vitally important. NDC methods being developed to provide necessary information include x-ray computed tomography (mainly for through-wall density and delamination detection), infrared-based thermal diffusivity imaging, and single-wall through-transmission x-ray imaging (mainly for fiber content and alignment detection). Correlation of the data obtained from NDC methods with subscale combustor liner tests have shown positive results at thermal cycling temperatures from 700°C to 1177°C.

scholarly journals Exposure of Ceramics and Ceramic Matrix Composites in Simulated and Actual Combustor Environments

1999 ◽  
Author(s):  
Karren L. More ◽  
Peter F. Tortorelli ◽  
Mattison K. Ferber ◽  
Larry R. Walker ◽  
James R. Keiser ◽  
...  
Keyword(s):  
Ceramic Matrix Composite ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Surface Damage ◽  
Operating Conditions ◽  
Matrix Composites ◽  
Long Term Stability ◽  
Recession Rates ◽  
Combustor Liner

A high-temperature, high-pressure, tube furnace has been used to evaluate the long term stability of different monolithic ceramic and ceramic matrix composite materials in a simulated combustor environment. All of the tests have been run at 150 psia, 1204°C, and 15% steam in incremental 500 h runs. The major advantage of this system is the high sample throughput; >20 samples can be exposed in each tube at the same time under similar exposure conditions. Microstructural evaluations of the samples were conducted after each 500 h exposure to characterize the extent of surface damage, to calculate surface recession rates, and to determine degradation mechanisms for the different materials. The validity of this exposure rig for simulating real combustor environments was established by comparing materials exposed in the test rig and combustor liner materials exposed for similar times in an actual gas turbine combustor under commercial operating conditions.

Testing Advanced SiC Fiber Tows at Elevated Temperature in Silicic Acid-Saturated Steam

2017 ◽  
Author(s):  
S. J. Robertson ◽  
K. B. Sprinkle ◽  
M. B. Ruggles-Wrenn
Keyword(s):  
Elevated Temperature ◽  
Silicic Acid ◽  
Elevated Temperatures ◽  
Ceramic Matrix Composites ◽  
Saturated Steam ◽  
Test Facility ◽  
Matrix Composites ◽  
Design Development ◽  
Oxidation Rates ◽  
Sic Fiber

Investigating stressed oxidation and scale crystallization kinetics of advanced SiC fibers at elevated temperature in steam is a challenging yet essential undertaking for the assessment of the effects of oxidation on mechanical properties of SiC-SiC ceramic matrix composites (CMCs). Moisture in the oxidizing environment is known to change oxidation rates, reduce scale viscosity and lower temperatures for scale crystallization. In order to study these phenomena, a facility for testing SiC fiber tows in creep at elevated temperatures in air, in steam and in steam saturated with silicic acid was developed. The newly constructed test facility was validated through creep testing of Hi-Nicalon™-S fibers at 800°C in steam saturated with silicic acid. Testing in saturated steam resulted in formation of a uniform oxide scale. Details of the test facility design, development and experimental validation are presented.

Fatigue Characterization of SiC/SiC Ceramic Matrix Composites in Combustion Environment

2020 ◽  
Author(s):  
Ragav P. Panakarajupally ◽  
Joseph Elrassi ◽  
K. Manigandan ◽  
Gregory N. Morscher
Keyword(s):  
Electrical Resistance ◽  
Fatigue Behavior ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Fatigue Tests ◽  
Matrix Composites ◽  
Residual Properties ◽  
Sic Ceramic ◽  
Post Test ◽  
Combustion Environment

Abstract Fatigue behavior of woven melt infiltrated (MI) SiC/SiC ceramic matrix composites (CMCs) was investigated under a tension-tension fatigue condition in a combustion environment. A special experimental facility is designed to subject the CMCs under simultaneous mechanical and combustion conditions which is more representative of some conditions experienced by the hot section components of a jet engine. The MI SiC/SiC ceramic matrix composites considered in this study consists of a SiC matrix densified with liquid Si infiltration, BN interphase and reinforced with two different fibers namely Hi-Nicalon type S and Tyranno SA fibers. A high velocity oxygen fuel (HVOF) gun is used to create the representative combustion condition and a horizontal hydraulic MTS machine to apply the mechanical loading. Several fatigue tests were conducted at different stress levels with a stress ratio of 0.1, frequency of 1 Hz and the specimen surface temperature at 1200 °C. Similar tests were conducted in an isothermal furnace condition at 1200°C for comparison. Electrical resistance (ER) was used to monitor the tests. A reduction in the fatigue life was observed for the two MI systems under combustion conditions in comparison to the isothermal furnace condition at the same applied stress level. This is attributed to the presence of harsh combustion environment present in the burner rig. Electrical resistance showed some promising results in monitoring the temperature and detecting damage in the specimen. Runout condition was set as 24 H (86400 cycles) in burner rig and 100 H (360000 cycles) in furnace environment. Specimens that achieved the runout condition were subsequently tested under monotonic tension testing at room temperature after cooldown to evaluate the residual properties. Residual strength results showed a significant strength reduction in both the furnace and burner rig environments. Post-test microscopy was conducted on the fracture surfaces and longitudinal polished sections of the failed specimens to understand the oxidation behavior and damage mechanisms.

Development and Evaluation of Hybrid Oxide/Oxide Ceramic Matrix Composite Combustor Liners

2005 ◽  
Author(s):  
Andy Szweda ◽  
Steve Butner ◽  
John Ruffoni ◽  
Carlos Bacalski ◽  
Jay Lane ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Ceramic Matrix Composite ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Field Testing ◽  
Oxide Ceramic ◽  
Matrix Composites ◽  
The Us ◽  
Engine Testing ◽  
Combustor Liner

Oxide/Oxide Ceramic Matrix Composites (CMCs) are an attractive class of materials for gas turbine hot section applications. The oxide fiber reinforcement and inherent matrix porosity contributes to favorable fracture toughness and thereby enhanced resistance against impact by foreign objects. Also, the oxide composition ensures superior environmental resistance against accelerated attack by corrosive species in the gas turbine hot section and resulting surface recession typically observed in silicon-based ceramic monolithic and composite materials. Under a program sponsored by the US National Institute of Standards and Technology (NIST) a hybrid oxide/oxide CMC system has been developed with potential application for stationary gas turbine hot section components. COI Ceramics, Inc. has fabricated subscale and full scale combustor liners which have been evaluated in rig and engine testing at Solar, and in field testing in a Solar Centaur® 50S engine at a commercial end user site. Following the conclusion of the NIST program in June 2003 the engine field testing is being continued under a Solar-led program sponsored by the US Dept. of Energy (DOE). As of November 2004, a hybrid oxide/oxide CMC outer combustor liner has accumulated 12,582 field test hours with 63 starts and an extensive material experience base has been developed. The paper will summarize the progress to-date for this hybrid CMC combustor liner development and demonstration, including selected fabrication approach, NDE, and rig/engine test experience.

scholarly journals Fatigue Characterization of SiC/SiC Ceramic Matrix Composites in Combustion Environment

2020 ◽  
Vol 142 (12) ◽  
Author(s):  
Ragav P. Panakarajupally ◽  
Joseph El Rassi ◽  
K. Manigandan ◽  
Gregory N. Morscher
Keyword(s):  
Fatigue Behavior ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Fatigue Tests ◽  
Matrix Composites ◽  
Residual Properties ◽  
Significant Strength ◽  
Sic Ceramic ◽  
Post Test ◽  
Combustion Environment

Abstract Fatigue behavior of woven melt infiltrated (MI) SiC/SiC ceramic matrix composites (CMCs) was investigated under a tension–tension fatigue condition in a combustion environment. A special experimental facility is designed to subject the CMCs under simultaneous mechanical and combustion conditions which is more representative of some conditions experienced by the hot section components of a jet engine. The MI SiC/SiC CMCs considered in this study consists of a SiC matrix densified with liquid Si infiltration, BN interphase, and reinforced with two different fibers, namely, Hi–Nicalon type S and Tyranno SA fibers. A high velocity oxygen fuel (HVOF) gun is used to create the representative combustion condition and a horizontal hydraulic MTS machine to apply the mechanical loading. Several fatigue tests were conducted at different stress levels with a stress ratio of 0.1, frequency of 1 Hz, and the specimen surface temperature at 1200 °C. Similar tests were conducted in an isothermal furnace condition at 1200 °C for comparison. Electrical resistance (ER) was used to monitor the tests. A reduction in the fatigue life was observed for the two MI systems under combustion conditions in comparison to the isothermal furnace condition at the same applied stress level. This is attributed to the presence of harsh combustion environment present in the burner rig. ER showed some promising results in monitoring the temperature and detecting damage in the specimen. Runout condition was set as 24 H (86400 cycles) in burner rig and 100 H (360000 cycles) in furnace environment. Specimens that achieved the runout condition were subsequently tested under monotonic tension testing at room temperature after cooldown to evaluate the residual properties. Residual strength results showed a significant strength reduction in both the furnace and burner rig environments. Post-test microscopy was conducted on the fracture surfaces of the failed specimens to understand the oxidation behavior and damage mechanisms.

Damage Detection and Tensile Performance of Various SiC/SiC Composites Impacted With High Speed Projectile

2013 ◽  
Author(s):  
Gregory N. Morscher ◽  
Christopher Baker ◽  
Andrew Gyekenyesi ◽  
Calvin Faucett ◽  
Sung Choi
Keyword(s):  
High Speed ◽  
Ceramic Matrix Composites ◽  
Impact Behavior ◽  
Matrix Composites ◽  
Tensile Performance ◽  
Post Test ◽  
Ultimate Failure ◽  
Post Impact ◽  
Sic Composites ◽  
Non Destructive

Implementation of ceramic matrix composites (CMCs) in jet engine applications necessitates the understanding of high velocity impact behavior. To this end, various melt-infiltrated SiC/SiC composites were impacted at room temperature at ∼350 m/s with different support systems and tensile tested to failure. Non-Destructive techniques including electrical resistance (ER) and flash thermography were used to examine the specimen pre and post impact. Some specimens were then post-tested in order to assess retained properties. For post tested specimens acoustic emission was used to monitor damage accumulation during the post test and leading up to ultimate failure. Microscopy was performed to correlate damage with impact and post-impact applied stress. The properties of the impacted specimens were assessed based on relevant damage zones. The results are also compared with similar studies performed on similar composites with stress-concentrators such as holes or notches and post-impact specimens tested in bending.

Hybrid Oxide-Based CMCs for Combustion Turbines: How Hybrid Oxide CMC Mitigates the Design Hurdles Typically Seen for Oxide CMC

2007 ◽  
Author(s):  
Jay E. Lane ◽  
Jay A. Morrison ◽  
Bonnie Marini ◽  
Christian X. Campbell
Keyword(s):  
Gas Turbines ◽  
Ceramic Matrix Composites ◽  
Ceramic Matrix ◽  
Turbine Engines ◽  
Material System ◽  
Matrix Composites ◽  
Gas Turbine Engines ◽  
End User ◽  
Life Goal ◽  
Combustor Liner

Ceramic matrix composites (CMCs), in particular oxide-based systems, are of interest for use in combustion turbines. While uncoated oxide CMCs have significant hurdles to implementation in gas turbines, the Siemens hybrid oxide CMC system is able to overcome these challenges. These hybrid oxide CMCs provide distinct advantages over the current non-oxide based systems. The benefits of hybrid oxide-based systems for advanced gas turbines will be discussed. Material system developments will be discussed including those completed by a Siemens Power Generation led team in a recent NIST (National Institute of Standards and Technology) sponsored program to prove the concept of advanced hybrid oxide-oxide CMCs for gas turbine engines. The program fabricated a full scale outer combustor liner that was installed in a Solar Centaur 50S engine at a commercial end user site. In November 2006, this hybrid oxide CMC outer combustor liner met the target life goal of 25,000 hrs with 25,404 hrs of field test experience. The final hurdle for design of hybrid oxide CMC components is the ability to accurately analytically predict behavior. Methods and approaches to address this challenge are discussed as well.

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