Overview of the Advanced Ceramics Industry in the United States

Transcription

1 Overview of the Advanced Ceramics Industry in the United States John E. Holowczak Chair, United States Advanced Ceramics Association Associate Director Advanced Materials United Technologies Research Center Glen Mandigo and Doug Freitag, USACA 1020 Nineteenth St. NW Suite 375 Washington, D.C This document does not contain any export controlled technical data.

2 Introduction to USACA Established in 1985 to promote the research, development, and application of advanced ceramics 38 member companies and organizations USACA works to promote advanced ceramic materials, disseminate information about the materials, and interface with the U.S. government on behalf of the industry. Members advise federal agencies through technology roadmaps and conferences. Active technology roadmaps include: Advanced Ceramics Technology Roadmap, 2001 Advanced Ceramics for Distributed Energy, 2004 Ceramic Composites Affordability and Producibility Initiative, 2009 Transparent Ceramic Armor Producibility Roadmap, 2013 Transparent Ceramic Sensor Windows Roadmap, 2017 Ceramic Composites Affordability and Producibility Roadmap update,

3 Lightweight, strong materials capable of performing in extreme environments: What are Advanced Ceramics High Temperature and Pressure High Stiffness and Durability Ultra Hard & Tough Surface Not This! 3

4 Membership Across the Supply Chain Research Design/Stds/ Databases Raw Materials Fabrication Test & Machining QC Integration Evaluation Rutgers UDRI Alfred Johns Hopkins Missouri S&T UDRI SoRI MR&D GE COI Ceramics CeraNova Exothermics Specialty Materials Free Form Fibers Lithoz America MATECH Starfire Harper Advanced Ceramic Fiber Axiom Materials ATC Materials Applied Thin Films GE COI Ceramics CeraNova Boeing Saint Gobain PSI II-VI Composite Horizons NCDMM PSI Bullen CoorsTek MillenniTek Ceramic Tubular Products CoorsTek Lancer Systems Lithoz America Raytheon Rolls Royce United Technologies Westinghouse Kyocera Harper Advanced Thin Films Triton Systems MillenniTek ATC Materials CeraNova UDRI UDRI SoRI Applied Materials GE P&W Rolls Royce Raytheon Boeing Westinghouse 4

5 Comparison of Ceramics Focused and Related Organizations Japan Fine Ceramics Association U.S. Advanced Ceramics Assoc. Promote Fine Ceramics Promote Advanced Ceramics Develop Standards and Research Projects Advise Federal Agencies Cooperate Government & Industry Interface with U.S. Government Ceramic Society of Japan New Energy & Industrial Tech. (METI -> NEDO) Acquisition, Technology & Logistics Agency (ATLA) American Ceramic Society U.S. Dept of Energy U.S. Dept. of Defense 5

6 USACA Leadership John Holowczak, United Technologies, Chair Tom Nixon, Rolls Royce, Vice Chair Craig Iwano, MR&D, Treasurer Andy Thomas, Coorstek, Secretary Glen Mandigo, Executive Director Doug Freitag, Technical Director 1020 Nineteenth St. NW Suite 375 Washington, D.C

7 Primary Activities (Excluding Conference Hosting) Two meetings per year in Washington, DC focused on federal programs of interest to the ceramics industry. Working Groups: Nuclear Materials Working Group Transparent Ceramics Working Group CMC Working Group Workforce Development Working Group Current and planned initiatives: Support DOE Accident Tolerant Fuels program for development and qualification of ceramic cladding Increase federal funding for High Temperature CMCs consistent with recommendations in the USACA CMCs for Advanced Gas Turbines Roadmap for CMC manufacturing Nineteenth St. NW Suite 375 Washington, D.C

8 U.S. Agencies Funding Advanced Ceramics Department of Defense ($3-4 billion) Materials R&D and system development programs under Air Force, Army, Navy, and Defense Wide Department of Energy ($ million) Materials and applications development for nuclear, fuel cell, gas turbine, and renewable energy NASA ($ million) Materials R&D, Aeronautics, Space Exploration FAA ($25-35 million) Databasing (including CMH-17 Handbook development), flight certification, component demonstrations 8

9 USACA Dept. of Defense Priorities Materials in extreme dynamic environments Energy efficient/increased performance gas turbine propulsion technologies High-speed strike weapon technologies Transparent armor for ground, air, sea vehicles Electro-optic/radar transparencies for sensor windows Defense Production Act Title III/ManTech 9

10 USACA NASA Program Priorities Hypersonic Technology Aeronautics Space Exploration SLS and Orion Commercial Space 10

11 USACA Dept. of Energy Program Priorities Accident Tolerant Fuels Advanced Turbines Solid Oxide Fuel Cells Concentrating Solar Harsh and Extreme Environment Materials 11

12 Transparent Ceramics Working Group Developing roadmaps for use by DoD and Industry with the goals of delivering more affordable and capable transparent ceramic armor and sensor windows Participates from throughout the supply chain with leadership from key manufacturers and end users. Technical challenges identified in feedstocks, shape forming, secondary processes, modeling and simulation and materials and component level characterization Electro-Optical Targeting System (EOTS) for F Nineteenth St. NW Suite 375 Washington, D.C Naval Carrier Transparent Armor 12

13 Workforce Development Working Group Focuses on enhancing communication and foster collaboration among industry, academia, and government, supporting recruitment and training efforts in fields enabled by advanced ceramics and composite materials. David Lipke from Missouri S&T, Rich Haber from Rutgers University are Co-Chairs of the working group. Recommends best practices and strategies for increasing quantity and quality of prospective workforce participants Outreach to students via the student page program at the annual Composites, Materials, and Structures Conference. 13

14 Nuclear Materials Working Group Established to work with US Department of Energy and Congress to advance ceramic materials for nuclear energy applications. Ed Lahoda from Westinghouse, and Herb Feinroth from Ceramic Tubular Products are Co-Chairs of the working group. Supporting Department of Energy (DOE) and the nuclear power industry to develop and qualify ceramics for fuel rods and channel boxes as a safer and better performing alternative material to zirconium metal. Activities include advice to DOE on ceramic materials and manufacturing capabilities, and supporting Accident Tolerant Fuels program with the Department of Energy budget. 14

15 CMC Working Group Established to create industry driven roadmaps for use in driving investment by DoD, DOE, NASA and Industry with the goals of delivering more affordable, producible and capable CMCs for use in aeropropulsion, aerostructure and stationary power generation. Participates from throughout the supply chain with leadership from key manufacturers and end users. Common technical challenges identified in raw materials, shape forming, secondary processes, attachments, materials characterization, databases, design tools, and sustainment. Boeing 787 CMC Exhaust Nozzle GE Leap Gas Turbine Shrouds 15

16 CMC Working Group Why the Need for New Materials? Gas-inlet temperature (ºF) Impact of 2700ºF CMC The National Academy of Sciences, Engineering, and Medicine recently completed a study on Commercial Aircraft Propulsion and Energy Systems Research and concluded that additional investment in gas turbine engine materials and coatings should be a high priority. Adapted from a) Nature Materials, V15, 8/16 and b) NAS Commercial Aircraft Propulsion and Energy Systems Research: Reducing Global Carbon Emissions, "2700ºF uncooled materials are required to achieve future targets for gas turbine performance, efficiency and emissions. No comparable study on power gen 16

17 CMC Working Group Industry Contributors Systems Components Materials, Machining, Test, Design, Equipment Research Working group includes OEM s developing new materials for system level cost, performance, and reliability, the supply chain supporting development of new materials, and academia and National Labs creating fundamental knowledge of new material behavior. 17

18 CMC Working Group - Summary Broad government / industry consensus that higher temperature CMCs offer the potential for large capability improvements and economic benefits our immediate challenge is to quantify them. The High Temperature CMC Initiative aggressively attacks the major risk elements needed for successful development, certification, and acquisition. Continued government investment needed to bring higher temperature CMC materials systems to TRL/MRL for affordable, low-risk transition into operational platforms Successful achievement of the identified goals will insure a sustainable high temperature CMC parts production capability in the United States by USACA intends to continue to actively pursuing all available funding avenues and opportunities to make this vital national initiative a reality 18

19 Examples of Recent Work at UTRC in these areas Hybrid monolithic ceramic / CMC development Turbine airfoil applications Armor for soldiers and aircraft Focus on non-oxide monolithics/non-oxide fiber CMCs Polymer derived silicon carbide matrices for Accident Tolerant Nuclear Fuels Performed in support of Westinghouse Potential to reduce cost Enabling reduced nuclear waste Improved ability to withstand reactor malfunctions Retrofit existing reactor fleet Reduce new light water reactor system cost 19

20 Work in Hybrids Extension of FT8 Cooled Ceramic Vane Aeroderivative first stage turbine vanes after 8 hours high pressure sector rig testing DARPA, Navy and U.S. Dept of Energy funded Chart as presented in Hybrid Monolithic Ceramic/Ceramic Matrix Composites; from Turbine Airfoils to Armor, presented by Holowczak et. al. At the 35 Annual International Conference & Exposition on Advanced Ceramics & Composites (ICACC), January 26, 2011, American Ceramic Society Engineered Ceramics Division meeting, Daytona Beach, Fl., Jan

21 How to Use Monolithics for Hi Reliability Applications? Challenge: Harness benefits of ceramics for turbine static structures WITHOUT resorting to all CMC construction Hybrid Ceramic/CMC Concept Monolithic Si 3 N 4 Ceramic Shell Ceramic Matrix Composite Inner Support Structure (Spar) Cooled monolithic ceramic FT8 HPT vane cross section aerothermal analysis Trailing Edge Cooling Slots 21

22 UTRC effort in CMCs for Nuclear Fuel Containment Desire for low cost method of providing a silicon carbide matrix Must withstand high pressure/temperature water Need to withstand irradiation over long periods Focus on polymer infiltration and pyrolysis (PIP) derived silicon carbide matrices PIP SiC matrices were limited in pyrolysis temperature by limit of Hi Nicalon Type S These showed poor resistance to simulated LWR environments (high temperature & pressure water) Use of refractory SiC fibers with greater heat tolerance enabled higher pyrolysis temperatures; yielded much greater resistance to simulated LWR exposure Example of how those studying turbine CMC materials and applications can help developers of accident tolerant nuclear fuel systems Lahoda, Edward J., and Boyan, Frank A. Development of LWR Fuels with Enhanced Accident Tolerance ATF Feasibility Analysis Report Deliverable for the Westinghouse Accident Tolerant Fuel Program. United States: N. p., Web. 22

23 U.S. Advanced Ceramics Association - Summary The Japan Fine Ceramics Association and U.S. Advanced Ceramics Association share common interests and goals One important difference lies in USACA s lobbying efforts with U.S. Congress for further research and development and manufacturing scale up funding There are synergies between CMC development for turbine engines, and for accident tolerant nuclear fuel encapsulation Groups involved in these separate applications should work together to accelerate development Greater international cooperation needed USACA intends to continue to actively pursuing all available funding avenues and opportunities to make new applications of ceramics and CMC s a reality 23