Ceramic Component Processing Development for Advanced Gas Turbine Engines

1993 ◽  
Vol 115 (1) ◽  
pp. 1-8 ◽  
Author(s):  
B. J. McEntire ◽  
R. R. Hengst ◽  
W. T. Collins ◽  
A. P. Taglialavore ◽  
R. L. Yeckley
Keyword(s):  
Injection Molding ◽  
Room Temperature ◽  
Slip Casting ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Processing Conditions ◽  
Technology Applications ◽  
Ceramic Components ◽  
Manufacturing Technologies ◽  
Engine Components

Norton/TRW Ceramics (NTC) is developing ceramic components as part of the DOE-sponsored Advanced Turbine Technology Applications Project (ATTAP). NTC’s work is directed at developing manufacturing technologies for rotors, stators, vane-seat platforms, and scrolls. The first three components are being produced from a HIPed Si3N4, designated NT154. Scrolls were prepared from a series of siliconized silicon-carbide (Si-SiC) materials designated NT235 and NT230. Efforts during the first three years of this five-year program are reported. Developmental work has been conducted on all aspects of the fabrication process using Taguchi experimental design techniques. Appropriate materials and processing conditions were selected for power beneficiation, densification, and heat-treatment operations. Component forming has been conducted using thermal-plastic-based injection molding (IM), pressure slip-casting (PSC), and Quick-Set™ injection molding.1 An assessment of material properties for various components from each material and process were made. For NT154, characteristic room-temperature strengths and Weibull Moduli were found to range between ≈920 MPa to ≈1 GPa and ≈10 to ≈19, respectively. Process-induced inclusions proved to be the dominant strength-limiting defect regardless of the chosen forming method. Correction of the lower observed values is being addressed through equipment changes and upgrades. For the NT230 and NT235 Si-SiC, characteristic room-temperature strengths and Weibull Moduli ranged from ≈240 to ≈420 MPa, and 8 to 10, respectively. At 1370°C, strength values for both the HIPed Si3N4 and the Si-SiC materials ranged from ≈480 MPa to ≈690 MPa. The durability of these materials as engine components is currently being evaluated.

scholarly journals Ceramic Component Processing Development for Advanced Gas-Turbine Engines

1991 ◽  
Author(s):  
B. J. McEntire ◽  
R. R. Hengst ◽  
W. T. Collins ◽  
A. P. Taglialavore ◽  
R. L. Yeckley ◽  
...  
Keyword(s):  
Injection Molding ◽  
Room Temperature ◽  
Slip Casting ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Ceramic Component ◽  
Component Development ◽  
Technology Applications ◽  
Manufacturing Technologies ◽  
Engine Components

Norton/TRW Ceramics (NTC) is performing ceramic component development as part of the DOE-sponsored Advanced Turbine Technology Applications Project (ATTAP). NTC’s work is directed at developing manufacturing technologies for rotors, stators, vane-seat platforms and scrolls. The first three components are being produced from a HIPed Si3N4, designated NT154. Scrolls were prepared from a series of siliconized silicon-carbide (Si-SiC) materials designated NT235 and NT230. Efforts during the first three years of this five-year program are reported. Developmental work has been conducted on all aspects of the fabrication process using Taguchi experimental design techniques. Appropriate materials and processing conditions were selected for powder beneficiation, densification and heat-treatment operations. Component forming has been conducted using thermal-plastic-based injection molding (IM), pressure slip-casting (PSC), and Quick-Set™ injection molding. An assessment of material properties for various components from each material and process were made. For NT154, characteristic room-temperature strengths and Weibull Moduli were found to be range between ≈920 MPa to ≈1 GPa and ≈10 to ≈19, respectively. Process-induced inclusions proved to be the dominant strength limiting defect regardless of the chosen forming method. Correction of the lower observed values is being addressed through equipment changes and upgrades. For the NT230 and NT235 Si-SiC, characteristic room-temperature strengths and Weibull Moduli ranged from ≈240 to ≈420 MPa, and 8 to 10, respectively. At 1370°C, strength values for both the HIPed Si3N4 and the Si-SiC materials ranged from ≈480 MPa to ≈620 MPa. The durability of these materials as engine components is currently being evaluated.

scholarly journals Development of Silicon Nitride Rotors for the ATTAP Program at Garrett Ceramic Components

1991 ◽  
Author(s):  
B. J. Busovne ◽  
J. P. Pollinger
Keyword(s):  
Silicon Nitride ◽  
High Strength ◽  
Current Status ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Successful Operation ◽  
Technology Applications ◽  
Ceramic Components ◽  
Material Process ◽  
Mechanical Properties Characterization

The development and fabrication of reliable high temperature-high strength silicon nitride rotors by Garrett Ceramic Components (GCC) for the Advanced Turbine Technology Applications Project (ATTAP) is discussed. GCC’s progress will be presented, including mechanical properties characterization, in-process monitoring development, and extensive NDE analysis. The current status of material, process, and part properties of the rotors being developed will be compared to properties required for implementation and successful operation of advanced gas turbine engines at 2500°F.

scholarly journals Experience With the TF40B Engine in the LCAC Fleet

1992 ◽  
Author(s):  
Edward M. House
Keyword(s):  
Gas Turbine ◽  
Hot Corrosion ◽  
Compressor Blade ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Improvement Program ◽  
Air Cushion ◽  
Engine Components ◽  
Carbon Erosion ◽  
The U.S

Four Textron Lycoming TF40B marine gas turbine engines are used to power the U.S. Navy’s Landing Craft Air Cushion (LCAC) vehicle. This is the first hovercraft of this configuration to be put in service for the Navy as a landing craft. The TF40B has experienced compressor blade pitting, carbon erosion of the first turbine blade and hot corrosion of the hot section. Many of these problems were reduced by changing the maintenance and operation of the LCAC. A Component Improvement Program (CIP) is currently investigating compressor and hot section coatings better suited for operation in a harsh marine environment. This program will also improve the performance of some engine components such as the bleed manifold and bearing seals.

scholarly journals Development of 300 kW Class Ceramic Gas Turbine (CGT302)

1995 ◽  
Author(s):  
Kozi Nishio ◽  
Junzo Fujioka ◽  
Tetsuo Tatsumi ◽  
Isashi Takehara
Keyword(s):  
Gas Turbine ◽  
Development Program ◽  
Pollutant Emissions ◽  
Turbine Engines ◽  
Inlet Temperature ◽  
Gas Turbine Engines ◽  
Turbine Inlet Temperature ◽  
Iso Standard ◽  
Current State ◽  
Ceramic Components

With the aim of achieving higher efficiency, lower pollutant emissions, and multi-fuel capability for small to medium-sized gas turbine engines for use in co-generation systems, a ceramic gas turbine (CGT) research and development program is being promoted by the Japanese Ministry of International Trade and Industry (MITI) as a part of its “New Sunshine Project”. Kawasaki Heavy Industries (KHI) is participating in this program and developing a regenerative two-shaft CGT (CGT302). In 1993, KHI conducted the first test run of an engine with full ceramic components. At present, the CGT302 achieves 28.8% thermal efficiency at a turbine inlet temperature (TIT) of 1117°C under ISO standard conditions and an actual TIT of 1250°C has been confirmed at the rated speed of the basic CGT. This paper consists of the current state of development of the CGT302 and how ceramic components are applied.

Impact of Dust Feed on Capture Efficiency and Deposition Patterns in a Double-Walled Liner

2019 ◽  
Author(s):  
Trevor M. Cory ◽  
Karen A. Thole ◽  
Kathryn L. Kirsch ◽  
Ryan Lundgreen ◽  
Robin Prenter ◽  
...  
Keyword(s):  
Room Temperature ◽  
Capture Efficiency ◽  
Test Facility ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Flow Conditions ◽  
Cold Side ◽  
Impingement Plate ◽  
Continuous Feed ◽  
The Difference

Abstract The introduction of particulates into gas turbine engines poses a serious threat to component durability. Particles drawn from the environment, such as ash or sand, can be introduced into the air system used to cool hot section components and drastically diminish cooling performance. In the current study, a dirt-laden coolant stream impinged on a double-walled cooling configuration, which was comprised of an impingement plate followed by an effusion-cooled plate. Experiments were conducted at both room temperature and at temperatures in excess of 750°C; flow conditions were varied to achieve different pressure ratios across the cooling configuration. Dirt particles were introduced into the coolant using two different methods: in discrete bursts, called slugs; or in a continuous feed ensuring a constant stream of particles. This continuous feed mechanism is at the crux of a new test facility created to introduce flexibility and precision in the control of dirt feed rates, particularly for very small (< 50 mg) amounts of dirt. The difference in capture efficiency and in dirt patterns between the two feed methods showed measurably different dirt accumulation levels on the cold side of the effusion plate at the same test conditions. Results show that the slug feed method caused higher capture efficiency and thicker dirt deposition on the effusion plate compared to the continuous feed.

Environmental Barrier Coatings for Monolithic Silicon Nitride: Bond Coat Development

2007 ◽  
Author(s):  
Tania Bhatia ◽  
G. V. Srinivasan ◽  
Sonia V. Tulyani ◽  
Robert A. Barth ◽  
Venkat R. Vedula ◽  
...  
Keyword(s):  
Silicon Nitride ◽  
Bond Coat ◽  
Room Temperature ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Barrier Coatings ◽  
Environmental Barrier Coatings ◽  
Environmental Barrier ◽  
Pressure Steam ◽  
Non Line Of Sight

Environmental barrier coatings (EBCs) are being developed for silicon carbide (SiC) based composites and monolithic silicon nitride (Si3N4) to protect against the accelerated oxidation and subsequent silica volatilization in high temperature high-pressure steam environments encountered in gas turbine engines. It has been found that the application of EBCs developed for SiC-based composites (EBCSiC) to monolithic silicon nitride results in a loss of room temperature mechanical strength of the monolithic substrate. In this paper, we discuss the development of a bond coat system tailored for monolithic silicon nitride that helps retain the strength of the substrate. Some of the unique requirements and challenges associated with the processing of non-line-of-sight EBCs for Si3N4 will also be discussed. Preliminary results from coating of airfoils will be presented.

scholarly journals Ceramic Components for Automotive and Heavy Duty Turbine Engines: CATE and AGT 100

1982 ◽  
Author(s):  
H. E. Helms ◽  
J. A. Byrd
Keyword(s):  
Gas Turbine ◽  
Operating Time ◽  
Ceramic Materials ◽  
Turbine Engines ◽  
Aluminum Silicate ◽  
Lithium Aluminum ◽  
Gas Turbine Engines ◽  
Design Component ◽  
Controllable Factors ◽  
Ceramic Components

Detroit Diesel Allison is actively applying advanced ceramic materials to components in gas turbine engines. Silicon carbide, silicon nitride, aluminum silicate, lithium aluminum silicate, and mullite are materials being used in various components in both the DDA GT 404-4 and AGT 100 engines. Approximately 9400 hr of ceramic component operating time in the GT 404 engine has been accumulated, and design, component processing, proof testing, and engine testing experience have begun to show the applicability of ceramic materials in production engines. Material variability, processing procedures, strength characterization, and nondestructive evaluations are emerging as critical but controllable factors. Ceramic components offer the potential of significant fuel consumption improvements in gas turbine engines for vehicles and other applications.

Development of a Controlled-Expansion Superalloy for Use in Aircraft Gas Turbines

1995 ◽  
Author(s):  
James M. Dahl ◽  
John B. Hansen
Keyword(s):  
Gas Turbines ◽  
Room Temperature ◽  
Coefficient Of Thermal Expansion ◽  
Base Alloy ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Original Design ◽  
Nickel Base ◽  
Potential Customers ◽  
Selection Of

This paper describes the methodology employed to produce a controlled expansion superalloy that has been successfully incorporated in several advanced aircraft gas turbine engines. Objectives of the original R&D study are reviewed in light of requirements given by potential customers. Properties of the alloy are presented and compared to those objectives. It is reported that the alloy has mechanical properties similar to those of the nickel-base alloy 718, and a low coefficient of thermal expansion between room temperature and its Curie temperature of 320°C. It also reported that the alloy has sufficient oxidation resistance so it may be possible to use it uncoated to temperatures approaching 675°C. The selection of the alloy by engine producers is described and the reasons for selecting are noted to be different from the original design criteria.

Development and Investigation of Ceramic Parts for Gas-Turbine Engines

1997 ◽  
Author(s):  
Youry A. Nozhnitsky ◽  
Youlia A. Fedina ◽  
Anatoly D. Rekin ◽  
Nickolai I. Petrov
Keyword(s):  
Gas Turbine ◽  
Ceramic Materials ◽  
Mechanical Tests ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Metallic Materials ◽  
Turbine Engine ◽  
Protective Medium ◽  
Gas Generators ◽  
Engine Components

For years of time there have been conducted the investigations of gas-turbine engine parts made of carbon-carbon and ceramic materials. This paper presents mainly the results of works done to create engine components of ceramic materials. There are given the investigation results on development of equipment and methods intended for use in determining the characteristics of heat-resistant non-metallic materials under ultra high temperature conditions. The unique tooling is developed to be used for conducting mechanical tests in different conditions (vacuum, protective medium, air) at temperatures up to 2200°C. There are considered three possible fields of application of ceramic materials, that are, turbine (1), combustion chamber and other stator components operating at high temperatures (2), bearings (3). Different ceramic elements are designed and manufactured, their structural strength is investigated in the laboratory faculties and also as part of engine gas generators.

A Probabilistic Framework for Risk Prediction of Gas Turbine Engine Components With Inherent or Induced Material Anomalies

2005 ◽  
Author(s):  
Michael P. Enright ◽  
R. Craig McClung ◽  
Luc Huyse
Keyword(s):  
Risk Assessment ◽  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Turbine Engines ◽  
Manufacturing Processes ◽  
Gas Turbine Engines ◽  
Probabilistic Framework ◽  
Turbine Engine ◽  
Risk Of Fracture ◽  
Engine Components

Rare anomalies may be introduced during the metallurgical or manufacturing processes that may lead to uncontained failures of aircraft gas turbine engines. The risk of fracture associated with these anomalies can be quantified using a probabilistic fracture mechanics approach. In this paper, a general probabilistic framework is presented for risk assessment of gas turbine engine components subjected to either inherent or induced material anomalies. A summary of efficient computational methods that are applicable to this problem is also provided.

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