Experimental and Numerical Investigation of Environmental Barrier Coated Ceramic Matrix Composite Turbine Airfoil Erosion

2018 ◽  
Vol 141 (3) ◽  
Author(s):  
Yoji Okita ◽  
Yousuke Mizokami ◽  
Jun Hasegawa
Keyword(s):  
Matrix Composite ◽  
Gas Turbines ◽  
Ceramic Matrix Composite ◽  
Leading Edge ◽  
Ceramic Matrix ◽  
Test Facility ◽  
Surface Erosion ◽  
Erosion Model ◽  
Environmental Barrier ◽  
Higher Temperature

Ceramic matrix composite (CMC) have higher temperature durability and lower density property compared to nickel-based super-alloys which so far have been widely applied to hot section components of aero-engines/gas turbines. One of promising CMC systems, SiC–SiC CMC is able to sustain its mechanical property at higher temperature, though it inherently needs environmental barrier coating (EBC) to avoid oxidation. There are several requirements for EBC. One of such critical requirements is its resistance to particle erosion, whereas this subject has not been well investigated in the past. The present work presents the results of a combined experimental and numerical research to evaluate the erosion characteristics of CMC + EBC material developed by IHI. First, experiments were carried out in an erosion test facility using 50 μm diameter silica as erosion media under typical engine conditions with velocity of 225 m/s, temperature of 1311 K, and impingement angles of 30, 60, and 80 deg. The data displayed brittle erosion mode in that the erosion rate increased with impact angles. Also, it was verified that a typical erosion model, Neilson–Gilchrist model, can reproduce the experimental behavior fairly well if its model constants were properly determined. The numerical method solving particle-laden flow was then applied with the tuned erosion model to compute three dimensional flow field, particle trajectories, and erosion profile around a generic turbine airfoil to assess the erosion characteristics of the proposed CMC + EBC material when applied to airfoil. The trajectories indicated that the particles primarily impacted the airfoil leading edge and the pressure surface. Surface erosion patterns were predicted based on the calculated trajectories and the experimentally based erosion characteristics.

Experimental and Numerical Investigation of Environmental Barrier Coated CMC Turbine Airfoil Erosion

2018 ◽  
Author(s):  
Yoji Okita ◽  
Yousuke Mizokami ◽  
Jun Hasegawa
Keyword(s):  
Numerical Method ◽  
Gas Turbines ◽  
Ceramic Matrix Composite ◽  
Three Dimensional ◽  
Leading Edge ◽  
Test Facility ◽  
Surface Erosion ◽  
Environmental Barrier ◽  
Pressure Surface ◽  
Higher Temperature

Ceramic matrix composite (CMC) have higher temperature durability and lower density property compared to nickel-based super-alloys which so far have been widely applied to hot section components of aero-engines / gas turbines. One of promising CMC systems, SiC-SiC CMC is able to sustain its mechanical property at higher temperature, though it inherently needs environmental barrier coating (EBC) to avoid oxidation. There are several requirements for EBC. One of such critical requirements is its resistance to particle erosion, whereas this subject hasn’t been well investigated in the past. The present work presents the results of a combined experimental and numerical research to evaluate the erosion characteristics of CMC+EBC material developed by IHI. First, experiments were carried out in an erosion test facility using 50 micron diameter silica as erosion media under typical engine conditions with velocity of 225 m/s, temperature of 1311 K, and impingement angles of 30, 60, and 80deg. The data displayed brittle erosion mode in that the erosion rate increased with impact angles. Next, multi-phase flow simulations were carried out for the experimental setup and the predicted erosion rates were compared with the measured data, and consequently, the applied numerical method was verified. The validated numerical method was then applied to compute three dimensional flow field, particle trajectories, and erosion profile around a generic turbine airfoil to assess the erosion characteristics of the proposed CMC+EBC material when applied to airfoil. The trajectories indicated that the particles primarily impacted the airfoil leading edge and the pressure surface. Surface erosion patterns were predicted based on the calculated trajectories and the experimentally-based erosion characteristics.

Effect of a Ceramic Matrix Composite Surface on Film Cooling

2021 ◽  
Author(s):  
Peter H. Wilkins ◽  
Stephen P. Lynch ◽  
Karen A. Thole ◽  
San Quach ◽  
Tyler Vincent ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Matrix Composite ◽  
Film Cooling ◽  
Gas Turbines ◽  
Ceramic Matrix Composite ◽  
Ceramic Matrix ◽  
Composite Surface ◽  
Minimal Impact ◽  
Cooling Hole ◽  
Adiabatic Effectiveness

Abstract Ceramic matrix composite (CMC) parts create the opportunity for increased turbine entry temperatures within gas turbines. To achieve the highest temperatures possible, film cooling will play an important role in allowing turbine entry temperatures to exceed acceptable surface temperatures for CMC components, just as it does for the current generation of gas turbine components. Film cooling over a CMC surface introduces new challenges including roughness features downstream of the cooling holes and changes to the hole exit due to uneven surface topography. To better understand these impacts, this study presents flowfield and adiabatic effectiveness CFD for a 7-7-7 shaped film cooling hole at two CMC weave orientations. The CMC surface selected is a 5 Harness Satin weave pattern that is examined at two different orientations. To understand the ability of steady RANS to predict flow and convective heat transfer over a CMC surface, the weave surface is initially simulated without film and compared to previous experimental results. The simulation of the weave orientation of 0°, with fewer features projecting into the flow, matches fairly well to the experiment, and demonstrates a minimal impact on film cooling leading to only slightly lower adiabatic effectiveness compared to a smooth surface. However, the simulation of the 90° orientation with a large number of protruding features does not match the experimentally observed surface heat transfer. The additional protruding surface produces degraded film cooling performance at low blowing ratios but is less sensitive to blowing ratio, leading to improved relative performance at higher blowing ratios, particularly in regions far downstream of the hole.

Thermo-structural design of a Ceramic Matrix Composite wing leading edge for a re-entry vehicle

2019 ◽  
Vol 207 ◽  
pp. 264-272 ◽  
Author(s):  
Michele Ferraiuolo ◽  
Roberto Scigliano ◽  
Aniello Riccio ◽  
Emanuele Bottone ◽  
Marco Rennella
Keyword(s):  
Matrix Composite ◽  
Structural Design ◽  
Ceramic Matrix Composite ◽  
Leading Edge ◽  
Ceramic Matrix ◽  
Composite Wing

Combustion Test Results of an Uncooled Combustor With Ceramic Matrix Composite Liner

2001 ◽  
Author(s):  
Yasufumi Suzuki ◽  
Toyoichi Satoh ◽  
Manabu Kawano ◽  
Naofumi Akikawa ◽  
Yoshihiro Matsuda
Keyword(s):  
Matrix Composite ◽  
Reverse Flow ◽  
Ceramic Matrix Composite ◽  
Three Dimensional ◽  
Ceramic Matrix ◽  
High Heat ◽  
Combustion Efficiency ◽  
Test Facility ◽  
Annular Combustor ◽  
Release Ratio

A reverse-flow annular combustor with its casing diameter of 400 mm was developed using an uncooled liner made of three-dimensional-woven ceramic-matrix composite. The combustor was tested using the TRDI high-pressure combustor test facility at the combustor maximum inlet and exit temperature of 723K and 1623K respectively. Although both the material and combustion characteristics were evaluated in the test, this report focused on the combustion performance. As the results of the test, the high combustion efficiency and high heat release ratio of 99.9% and 1032 W/m3/Pa were obtained at the design point. The latter figure is approximately twice as high as that of existing reverse–flow annular combustors. Pattern factor was sufficiently low and was less than 0.1. Surface temperatures of the liner wall were confirmed to be higher than the limit of the combustor made of existing heat-resistant metallic materials.

scholarly journals Ceramic Matrix Composite Vane Subelement Burst Testing

2006 ◽  
Author(s):  
David N. Brewer ◽  
Michael Verrilli ◽  
Anthony Calomino
Keyword(s):  
High Pressure ◽  
Matrix Composite ◽  
Ceramic Matrix Composite ◽  
Ceramic Matrix ◽  
Environmental Barrier ◽  
Environmental Barrier Coating ◽  
Barrier Coating

Burst tests were performed on Ceramic Matrix Composite (CMC) vane specimens, manufactured by two vendors, under the Ultra Efficient Engine Technology (UEET) project. Burst specimens were machined from the ends of 76mm long vane sub-elements blanks and from High Pressure Burner Rig (HPBR) tested specimens. The results of burst tests will be used to compare virgin specimens with specimens that have had an Environmental Barrier Coating (EBC) applied, both HPBR tested and untested, as well as a comparison between vendors.

Combustion Test Results of an Uncooled Combustor With Ceramic Matrix Composite Liner

2002 ◽  
Vol 125 (1) ◽  
pp. 28-33 ◽  
Author(s):  
Y. Suzuki ◽  
T. Satoh ◽  
M. Kawano ◽  
N. Akikawa ◽  
Y. Matsuda
Keyword(s):  
Matrix Composite ◽  
Reverse Flow ◽  
Ceramic Matrix Composite ◽  
Three Dimensional ◽  
Ceramic Matrix ◽  
High Heat ◽  
Combustion Efficiency ◽  
Test Facility ◽  
Annular Combustor ◽  
Release Ratio

A reverse-flow annular combustor with its casing diameter of 400 mm was developed using an uncooled liner made of a three-dimensional woven ceramic matrix composite. The combustor was tested using the TRDI high-pressure combustor test facility at the combustor maximum inlet and exit temperature of 723 K and 1623 K, respectively. Although both the material and combustion characteristics were evaluated in the test, this report focused on the combustion performance. As the results of the test, the high combustion efficiency and high heat release ratio of 99.9% and 1032 W/m3/Pa were obtained at the design point. The latter figure is approximately twice as high as that of existing reverse-flow annular combustors. Pattern factor was sufficiently low and was less than 0.1. Surface temperatures of the liner wall were confirmed to be higher than the limit of the combustor made of existing heat-resistant metallic materials.

scholarly journals Investigating the Thermo-Mechanical Behavior of a Ceramic Matrix Composite Wing Leading Edge by Sub-Modeling Based Numerical Analyses

Computation ◽  
2020 ◽  
Vol 8 (2) ◽  
pp. 22 ◽  
Author(s):  
Michele Ferraiuolo ◽  
Concetta Palumbo ◽  
Andrea Sellitto ◽  
Aniello Riccio
Keyword(s):  
Mechanical Behavior ◽  
Matrix Composite ◽  
Thermal Protection ◽  
Ceramic Matrix Composite ◽  
Leading Edge ◽  
Ceramic Matrix ◽  
Thermal Protection Systems ◽  
Protection Systems ◽  
Very High ◽  
Composite Wing

The thermo-structural design of the wing leading edge of hypersonic vehicles is a very challenging task as high gradients in thermal field, and hence high thermal stresses, are expected. Indeed, when employing passive hot structures based thermal protection systems, very high temperatures (e.g., 1400 °C) are expected on the external surface of the wing leading edge, while the internal structural components are required to not exceed a few hundred degrees Celsius (e.g., 400 °C) at the interface with the internal cold structure. Hence, ceramic matrix composites (CMC) are usually adopted for the manufacturing of the external surface of the wing leading edge since they are characterized by good mechanical properties at very high temperatures (up to 1900 °C) together with an excellent thermal shock resistance. Furthermore, the orthotropic behavior of these materials together with the possibility to tailor their lamination sequence to minimize the heat transferred to internal components, make them very attractive for hot structure based thermal protection systems applications. However, the numerical predictions of the thermo-mechanical behavior of such materials, taking into account the influence of each ply (whose thickness generally ranges between 0.2 and 0.3 mm), can be very expensive from a computational point of view. To overcome this limitation, usually, sub-models are adopted, able to focus on specific and critical areas of the structure where very detailed thermo-mechanical analyses can be performed without significantly affecting the computational efficiency of the global model. In the present work, sub-modeling numerical approaches have been adopted for the analysis of the thermo-mechanical behavior of a ceramic matrix composite wing leading edge of a hypersonic vehicle. The main aim is to investigate the feasibility, in terms of computational efficiency and accuracy of results, in using sub-models for dimensioning complex ceramic matrix components. Hence, a comprehensive study on the size of sub-models and on the choice of their boundaries has been carried out in order to assess the advantages and the limitations in approximating the thermo-mechanical behavior of the investigated global ceramic matrix composite component.

Erosion Testing of Environmental Barrier-Coated Ceramic Matrix Composite and Its Behavior on an Aero-Engine Turbine Vane Under Particle-Laden Hot Gas Stream

2020 ◽  
Vol 142 (6) ◽  
Author(s):  
Yoji Okita ◽  
Yosuke Mizokami ◽  
Jun Hasegawa
Keyword(s):  
Matrix Composite ◽  
Ceramic Matrix Composite ◽  
Ceramic Matrix ◽  
Turbine Cascade ◽  
Suction Surface ◽  
Erosion Model ◽  
Pressure Surface ◽  
Hot Gas ◽  
Aero Engine ◽  
Impact Angles

Abstract Ceramic matrix composite (CMC) has better durability at high temperature and lower material density, as compared to nickel-based superalloys which have been the standard material for hot section components of aero-engines. Among the CMC materials, SiC–SiC CMC is especially promising with its superior mechanical property at a higher temperature. It, however, inevitably needs environmental barrier coating (EBC) to protect the substrate against oxidation. The EBC also needs to have other functions and to meet various requirements. One such very critical requirement is the resistance to sand erosion, although the issue has not been investigated well so far. The primary contribution of this work is to reveal the erosion resistance of the CMC + EBC material with wind tunnel test data of good quality and to demonstrate what erosion behavior the material exhibits in a turbine cascade under particle-laden hot gas stream. In the present work, erosion tests were first carried out in a testing facility with an erosion media of 50 μm silica sand. The tests were conducted under a flow velocity of 225 m/s and a temperature of 1311 K to simulate typical aero-engine conditions, and impact angles of 30, 60, and 80 deg were investigated. The obtained data showed a typical brittle erosion mode, where the erosion rate had a positive dependence on the impact angles. A typical erosion model, Neilson–Gilchrist model, was applied to correlate the data, and the model was shown to have a good agreement with the experimental data once it was properly calibrated. Then, the numerical computation solving particle-laden flow was carried out to predict three-dimensional flow field and particle trajectories across the target turbine cascade. The erosion profile along the airfoil was calculated based on the obtained trajectories and the calibrated erosion model. The trajectories showed that the particles mostly impinged the airfoil pressure surface first and then the rebounded particles attacked the opposite suction surface as well. Accordingly, the predicted erosion profile showed a broad erosion band across the pressure surface and also some slight erosion peak at around the mid-chord of the suction surface.

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