Status of Silicon Nitride Component Fabrication Processes, Material Properties, and Applications

1997 ◽  
Author(s):  
John P. Pollinger
Keyword(s):  
Power Generation ◽  
Silicon Nitride ◽  
Gas Turbines ◽  
Process Development ◽  
Low Cost ◽  
Turbine Blades ◽  
Hybrid Vehicle ◽  
Thermomechanical Properties ◽  
Commercial Aircraft ◽  
Ceramic Components

Silicon nitride monolithic structural ceramic components have recently been introduced as production parts in commercial aircraft turbomachinery pump and seal applications to take advantage of their unique thermomechanical properties. Additionally, extensive efforts are in progress to develop, evaluate, and productionize silicon nitride components for commercial aircraft turbomachinery hot sections, industrial power generation turbines, and automotive hybrid vehicle turbogenerators. AlliedSignal Ceramic Components has developed a family of in-situ reinforced silicon nitride materials for these applications and is developing and implementing a suite of component fabrication processes to achieve production-viable manufacturing of complex shaped components, including turbine seals, blades, nozzles, wheels, and combustors. A key focus of the manufacturing process development is the need to achieve low cost fabrication of components in order to meet cost targets required for commercial introduction. Finally, the status and plans for a number of aerospace, industrial, and automotive turbomachinery applications are discussed, including commercial aircraft turbomachinery production components (pump and seal parts) and development components (auxiliary power unit turbine blades and nozzles, and propulsion engine wheels and starter wheels), nozzle, blade, wheel and combustor components for automotive hybrid vehicle turbogenerators, and turbine blades and nozzles for industrial power generation gas turbines.

Status of Silicon Nitride Material Properties, Component Fabrication, and Applications for Small Gas Turbines

2000 ◽  
Author(s):  
Danielle D. Newson ◽  
John P. Pollinger ◽  
Douglas J. Twait
Keyword(s):  
Power Generation ◽  
Silicon Nitride ◽  
Gas Turbines ◽  
High Performance ◽  
Solid Freeform Fabrication ◽  
Low Cost ◽  
Field Tests ◽  
Current Status ◽  
Turbine Engine ◽  
The Status

Extensive progress has been made in the development of high performance silicon nitride structural ceramics and component fabrication. This has in turn led to a number of successful applications in small turbines, including commercial aircraft production components and a number of successful tests and continuing field tests in aircraft auxiliary power units, air turbine starters, and stationary power generation engines. The current status, capabilities, limitations, and material refinement efforts for silicon nitride at AlliedSignal Ceramic Components (ASCC) will be presented, including environmental durability and environmental barrier coating investigations. Two key issues in the implementation of silicon nitride turbine components have been the ability to fabricate engine quality hardware, and fabrication at low-enough costs to allow commercialization. The current status of production forming processes will be presented and the development of new low cost forming and advanced technologies including gelcasting and solid freeform fabrication will be discussed, both in regards to component fabrication capability and production cost potential. Finally, the status of a number of commercial and development applications such as propulsion turbine engine seals, APU hot section wheels, blades, and nozzles, industrial turbine nozzles, and power generation microturbine components will be discussed.

scholarly journals Development of Silicon Nitride Engine Components for Advanced Gas Turbine Applications

1989 ◽  
Author(s):  
B. J. Busovne ◽  
J. P. Pollinger
Keyword(s):  
Silicon Nitride ◽  
Gas Turbines ◽  
Process Development ◽  
High Strength ◽  
Current Status ◽  
Successful Operation ◽  
Technology Applications ◽  
Ceramic Components ◽  
Turbine Component ◽  
Mechanical Properties Characterization

The development and fabrication of reliable high temperature-high strength silicon nitride components by Garrett Ceramic Components Division for the Advanced Turbine Technology Applications Project (ATTAP) is discussed. Garrett Ceramic Components’ advanced turbine component process development philosophy and practices will be presented, including implementation of statistically designed experiments, in-process controls, extensive NDE, and mechanical properties characterization. The current status of material, process, and part properties of specific components being developed by Garrett Ceramic Components are compared with the properties required for their implementation and the successful operation of advanced gas turbines with ceramic components at 1370°C.

Development and Fabrication of Silicon Nitride Components for Ceramic Gas Turbine

1997 ◽  
Author(s):  
Keisuke Makino ◽  
Ken-Ichi Mizuno ◽  
Toru Shimamori
Keyword(s):  
High Temperature ◽  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Turbine Blades ◽  
High Strength ◽  
Inlet Temperature ◽  
Turbine Inlet Temperature ◽  
Spark Plug ◽  
Power Turbine

NGK Spark Plug Co., Ltd. has been developing various silicon nitride materials, and the technology for fabricating components for ceramic gas turbines (CGT) using theses materials. We are supplying silicon nitride material components for the project to develop 300 kW class CGT for co-generation in Japan. EC-152 was developed for components that require high strength at high temperature, such as turbine blades and turbine nozzles. In order to adapt the increasing of the turbine inlet temperature (TIT) up to 1,350 °C in accordance with the project goals, we developed two silicon nitride materials with further unproved properties: ST-1 and ST-2. ST-1 has a higher strength than EC-152 and is suitable for first stage turbine blades and power turbine blades. ST-2 has higher oxidation resistance than EC-152 and is suitable for power turbine nozzles. In this paper, we report on the properties of these materials, and present the results of evaluations of these materials when they are actually used for CGT components such as first stage turbine blades and power turbine nozzles.

Development and Evaluation of Silicon Nitride Components for Ceramic Gas Turbine

1998 ◽  
Author(s):  
Yasushi Hara ◽  
Katsura Matsubara ◽  
Ken-ichi Mizuno ◽  
Toru Shimamori ◽  
Hiro Yoshida
Keyword(s):  
Silicon Nitride ◽  
Gas Turbines ◽  
High Speed ◽  
Gas Flow ◽  
Impact Damage ◽  
Turbine Blades ◽  
Impact Testing ◽  
Particle Impact ◽  
Inlet Temperature ◽  
Power Turbine

NGK Spark Plug Co., Ltd. has been developing various silicon nitride materials, and the technology for fabricating components for ceramic gas turbines (CGT) using theses materials. We are supplying silicon nitride material components for the project to develop 300 kW class CGT for co-generation in Japan. EC-152 was developed for components that require high strength at high temperature, such as turbine blades and turbine nozzles. In order to adapt the increasing of the turbine inlet temperature (TIT) up to 1350 °C in accordance with the project goals, we developed two silicon nitride materials with further improved properties: ST-1 and ST-2. ST-1 has a higher strength than EC-152 and is suitable for first stage turbine blades and power turbine blades. ST-2 has higher oxidation resistance than EC-152 and is suitable for power turbine nozzles. On applying these silicon nitride ceramics to CGT engine, we evaluated various properties of silicon nitride materials considering the environment in CGT engine. Particle impact testing is one of those evaluations. Materials used in CGT engine are exposed in high speed gas flow, and impact damage of these materials is considered to be a concern. We tested ST-1 in the particle impact test. In this test, we observed fracture modes, and estimated the critical impact velocity. This paper summarizes the development of silicon nitride components, and the result of evaluations of these silicon nitride materials.

Environmental Characterization of Monolithic Ceramics for Gas Turbine Applications

2005 ◽  
Vol 287 ◽  
pp. 367-380 ◽  
Author(s):  
Mattison K. Ferber ◽  
Hua Tay Lin
Keyword(s):  
Silicon Nitride ◽  
Gas Turbines ◽  
High Performance ◽  
Field Tests ◽  
The United States ◽  
Simple Method ◽  
Ceramic Components ◽  
Carbide Ceramics ◽  
Monolithic Ceramics ◽  
Silicon Carbide Ceramics

Over the last 30 years, a number of programs in Russia, Europe, Japan, and the United States have sought to introduce monolithic ceramic components into gas turbines with the goals of increasing efficiency and lowering emissions. High performance silicon nitride and silicon carbide ceramics typically have been leading candidates for use in these applications. Recent field tests involving silicon nitride vanes and blades have shown that these materials can experience significant recession due to the loss of the normally protective silica scale. This paper first summarizes key findings from these field tests and then describes a relatively simple method for evaluating environmental effects in a laboratory environment.

Advanced Particle Control for Coal-Based Power Generation Systems

1989 ◽  
Author(s):  
Steven J. Bossart
Keyword(s):  
Power Generation ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Speed ◽  
Particle Deposition ◽  
Power Plants ◽  
Turbine Blades ◽  
Combined Cycle ◽  
Department Of Energy ◽  
Power Generation Systems

The Morgantown Energy Technology Center (METC) of the U.S. Department of Energy (DOE) is actively sponsoring research to develop coal-based power generation systems that use coal more efficiently and economically and with lower emissions than conventional pulverized-coal power plants. Some of the more promising of the advanced coal-based power generation systems are shown in Figure 1: pressurized fluidized-bed combustion combined-cycle (PFBC), integrated gasification combined-cycle (IGCC), and direct coal-fueled turbine (DCFT). These systems rely on gas turbines to produce all or a portion of the electrical power generation. An essential feature of each of these systems is the control of particles at high-temperature and high-pressure (HTHP) conditions. Particle control is needed in all advanced power generation systems to meet environmental regulations and to protect the gas turbine and other major system components. Particles can play a significant role in damaging the gas turbine by erosion, deposition, and corrosion. Erosion is caused by the high-speed impaction of particles on the turbine blades. Particle deposition on the turbine blades can impede gas flow and block cooling air. Particle deposition also contributes to corrosive attack when alkali metal compounds adsorbed on the particles react with the gas turbine blades. Incorporation of HTHP particle control technologies into the advanced power generation systems can reduce gas turbine maintenance requirements, increase plant efficiency, reduce plant capital cost, lower the cost of electricity, reduce wastewater treatment requirements, and eliminate the need for post-turbine particle control to meet New Source Performance Standards (NSPS) for particle emissions.

CSGT: Final Design and Test of a Ceramic Hot Section

2003 ◽  
Author(s):  
Oscar Jimenez ◽  
Hamid Bagheri ◽  
John McClain ◽  
Ken Ridler ◽  
Tibor Bornemisza
Keyword(s):  
Silicon Nitride ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
United States Department ◽  
Engine Test ◽  
Metallic Component ◽  
Ceramic Components

The Ceramic Stationary Gas Turbine (CSGT) Development Program was performed under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT). The goal was to improve the performance (fuel efficiency, output power, and exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section metallic components with ceramic components. The team was headed by Solar Turbines Incorporated and supported by ceramic component suppliers and national research institutes. The team performed a detailed engine and component design, fabrication, and field-testing of ceramic components. This program culminated in an engine test at 1121°C (2050°F) TRIT. This was a major challenge in that the engine ran with a continuous fiber reinforced ceramic composite liner (CFCC) and with silicon nitride (Si3N4) stage one ceramic blades and nozzles. The design and testing of all three components will be discussed in this paper, with emphasis on the ceramic nozzles. Another test that will be discussed in this paper is a heavily instrumented engine test that took place prior to the test mentioned above. This instrumented engine test was performed in order to better understand the temperature effects between the ceramic and metallic component interfaces. The results from this were then used to correlate the analytical model with test data. This led to additional design changes to the outer and inner shroud ceramic / metallic interfaces, as well as ceramic nozzles, fabricated from Kyocera SN 282 silicon nitride material. These nozzle changes were then engine tested successfully for a total of 100 hours at full load [1010°C (1850°F) TRIT and 100% speed]. During the engine test, the firing temperature was increased to 1121°C (2050°F) TRIT for an adequate duration to ensure meaningful performance data were gathered.

scholarly journals Ceramic Components for High-Temperature Vehicular Gas Turbines: State of the Art of the German Ceramic Program

1983 ◽  
Author(s):  
K. Hagemeister ◽  
E. Tiefenbacher ◽  
P. Walzer
Keyword(s):  
Silicon Carbide ◽  
High Temperature ◽  
Silicon Nitride ◽  
Combustion Chamber ◽  
Research Program ◽  
Gas Turbines ◽  
State Of The Art ◽  
Development Status ◽  
Research Institutes ◽  
Ceramic Components

In 1974 in Germany a research program was initiated under sponsorship of the Ministry of Research and Technology for developing ceramic components for vehicular gas turbines. Participants were Daimler-Benz, Motoren- and Turbinen-Union and Volkswagen and a number of ceramic companies and research institutes. The paper gives the achieved development-status of the following components: combustion-chamber, nozzles and two types of rotors. Furtheron some results of investigations in regard of durability of silicon nitride and silicon carbide are presented.

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