Melt Infiltrated (MI) SiC/SiC Composites for Gas Turbine Applications

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Shanon Bell
6 years ago
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Luthra GE Corporate Research & Development Schenectady, NY 12301 Talk

1 Melt Infiltrated (MI) SiC/SiC Composites for Gas Turbine Applications Krishan L. Luthra GE Corporate Research & Development Schenectady, NY Talk Presented at DER Peer Review for Microturbine & Industrial Gas Turbines Prorams* on March 14, 2002 *Contract Monitor: Joe Mavec

2 Outline Introduction CMC Opportunities Team Members Applications & Payoff Material System Pathway to Commercialization Current Status & Future Plans Summary 2

3 CMC Opportunity Material Temperature Capability at Product Introduction MI-CMC yrs =400F(Static Parts) Temperature Base 20 yrs =550F Equiaxed DS SX Metals SX+TBC +coolin CMC s represent a ame chanin technoloy DOE had the vision to start the CFCC proram in early nineties 3

4 Collaboration Team Members Prime Contractor: Component Fabrication: GE Global Research Center GE Global Research Center GE Power Systems Composites (GEPSC), formerly Honeywell Advanced Composites, Inc. (HACI) Goodrich Aerospace End User CMC Characterization: GE Power Systems ORNL (Microstructural) Aronne National Lab (NDE) Leverae from other prorams CMC Material Development Environmental Barrier Coatin Component testin HSCT (NASA); Air Force Prorams at GEAE HSCT (NASA) CSGT (DOE) at Solar 4

5 Applications Industrial Gas Turbine Enine Combustion Liner Transition Piece 1st Stae Nozzle 1st Stae Shroud 1st Stae Bucket Stationary components represent the best short-term opportunity 5

6 Payoff & Selected Applications Hiher temperature capability of CMCs allows reduction/elimination of air needed for coolin metallic components Improvement in fuel efficiency Reduction in harmful emissions Hiher output of machines Applicable to all classes of as turbines GE as turbines rane 45 KW to 280,000 KW F-class & H-class machines most advanced Installed base for F-class machines ~36 GW(US) & ~64 GW (worldwide) In 1999 Initial focus on shrouds & combustor liners Technoloy would flow to other stationary components, such as nozzles DOE-CFCC And DOE AMAIGT focused on CMC applications in F-class machines 6

7 Payoff For Stationary Components Up to 1.1% point increase in simple cycle efficiency Increase in 3% output Market rowth of 6%/year and 20% market penetration by 2020 US annual savins of ~290 Billion BTU of enery, equivalent to ~0.29 Billion cubic ft. of natural as at a cost of ~$960 Million (2001 dollars) Annual savins of ~4.3 Million MTCE of CO emissions 2 Annual savins of ~51,000 MT of NO x emissions Extra power eneration worth ~1.3 Billion dollars, further reducin the cost of electricity to customers Use of CMCs offers opportunity for enormous fuel savins, reduction in emissions and reduction in cost of electricity to customers 7

MI-CMCs BSAS Monolithic Ceramics (Si 3 N

8 MI-CMCs BSAS Monolithic Ceramics (Si 3 N 4 ) EBC Mullite + BSAS Silicon layer Stress MI-CMC MI-CMC Strain SiC Fiber (~15 µm) Fiber Coatins(~1 µm) SiC-Si Matrix Fiber Reinforcement Increases Fracture Touhness (Damae Tolerance) Fracture Surface 200 µm 8

254MPa 240MPa ) ap (M ssert S 200 150 100 183MPa

229GPa 216GPa 191GPa Exit 50 0 0.0 0.3 0.6 0.9 1.

9 Hi Nicalon Reinforced M. I. Composites MPa 290MPa Entrance MPa 240MPa ) ap (M ssert S MPa 170MPa 177MPa 160MPa RT 871C 1093C 1204C 225GPa 229GPa 216GPa 191GPa Exit Strain (%) CMCs offer hih temperature strenth alon with damae tolerance NDE 9

Ceramic Matrix Composites - The path into

Qualification Tests 50+ cycles & 300 total

10 Ceramic Matrix Composites - The path into Gas Turbine Enines Stress MI-CFCC HS-188 Strain Lab Tests St. 2 Shroud Combustion Ri Ri Feasibility Tests St. 1 Shroud 200+ cycles & 200 hrs PGT Small Enine Testin New Combustion Ri 80 cycles & 1070 hrs CMC Test Shroud Ri Qualification Tests 50+ cycles & 300 total hours Lare Enine Validation Test 7FA hrs at Customer DOE-CFCC Proram DOE-AMAIGT Proram Proressive testin provides risk Reducin steppin stones to enine test 10

11 Shroud Ri Component Performance Combustors Stainless GE MI CFCC 11

12 Shroud Ri Testin at 1500 C Gas Temperature Failed after 50 cycles HS-188 Survived 200 cycles and 50 hours exposure GE MI-CFCC 12

of ~1875F S1S and S2S Testin: - 1070 hrs - S1S had 46 starts, 24 trips, 1 blade rub - S2S had 61

13 GE2 S2S and S1S Testin at GE Oil & Gas First Stae CMC Shroud 18.5 CMC Second Stae Shroud Rin View aft lookin forward PGT-2 Turbine Cross Section Operated at Gas Temp of ~1875F S1S and S2S Testin: hrs - S1S had 46 starts, 24 trips, 1 blade rub - S2S had 61 starts, 27 trips, plus over 3 blade rubs Blade Rub on Second Stae CMC Shroud Enine Testin of Prepre Processed Shrouds Has Been Very Successful to Date 13

14 Outline Introduction CMC Opportunities Team Members Applications & Payoff Material System Pathway to Commercialization Current Status & Future Plans Summary 14

15 Status & Past Year Accomplishments Unique hih pressure-hih velocity ri desined and bein used for lonterm testin. Needed to evaluate water vapor & velocity effects on CMC materials. Shroud system desin completed. Critical desin features, such as attachment and blade rub tolerance, were evaluated with sub-component tests. Over 30 CMC inner shrouds fabricated for ri and enine testin. EBC deposition process scaled up and CMC shroud coatin optimized. Transient IR thermoraphy demonstrated as useful NDE technique for CMC shroud inspection. A new combustion ri for testin of shroud system was desined, assembled, and its operation verified. Used as short-term validation of shroud system desin before proceedin to enine tests ~200 hours of ri testin completed on two shroud system variations. 15

16 Lon-Term Ri Testin Pressure Vessel Sample retainin rins Test samples Main tube Combustor liner/ Transition piece Fuel nozzle location Exhaust pipe Spacer tubes Hih pressure hih velocity ri Evaluate effects of water vapor and velocity Capabilities Temperature up to 1200 o C + Velocity of 450 ft/sec + 9 atmospheric pressure 1 atmosphere of water vapor Up to 28 tensile test specimens Status ~3000 hours of testin performed Another 2500 hours planned this year Facilities would also be used for microturbine proram Gas inlet Unique material testin facility bein used for lon-term life testin under turbinelike conditions 16

Blade Tip Rub Tolerance Validation Rub specimen Rub tests of prepre and slurry

GTD-111 blades lost mass and substrate ained mass in all tests - indicates

coatin or substantial damae to CMC observed Uncoated Prepre RT Sample TC Rub

17 Blade Tip Rub Tolerance Validation Rub specimen Rub tests of prepre and slurry cast samples, with and without EBC, were done at RT and 1200C Apparatus GTD-111 blades lost mass and substrate ained mass in all tests - indicates wear of blade and deposition of metal onto CMC samples No spallin of EBC coatin or substantial damae to CMC observed Uncoated Prepre RT Sample TC Rub tip Specimen assembly CMC/EBC system very resistant to blade tip rubs EBC coated Prepre 1200C 17

18 EBC Process Scale-Up and Optimization CMC shroud Process successfully scaled up to coat shroud components Quality and thickness control of EBC verified with shroud cut-ups 18

19 NDE by Transient IR Thermoraphy Bad Shroud Good Shroud NDE indications verified as defects by microstructural characterization NDE of CMC Shrouds Demonstrated 19

20 Shroud Test Ri Premix Fuel Coolin Air Coolin Water Primary Air Diffusion Fuel Fuel Nozzle Coolin Air Combustor Transition Piece Shroud Test Section Coolin and leakae flows 20

21 Shroud Test Ri Support Flane Fuel Nozzle Combustor Transition Piece Shroud Test Section Surroate metal shrouds Instrumentation Cast ceramic lower wall (replaced with CMC for durability) 21

22 Future Plans Shrouds Enine test (4000 hours+) at a customer site startin from Fall 02 outae Combustor Liner Combustor preliminary desin completed CY 3Q02 Fabrication of MI-CMC combustor by CY 4Q02 Ri testin of combustor system startin CY 1Q03 Fabrication of final desin and validation ri test by CY 1Q04 Field enine test startin CY 4Q04 22

23 Summary CMCs represent a ame chanin technoloy for industrial as turbines 400 o F improvement over metals CMCs offer opportunities for enormous fuel savins, reduction in emissions, and reduction in cost of electricity to customers DOE s CMC prorams (CFCC & AMAIGT) have taken the lead in CMC material development for their applications in as turbines GE s efforts on CFCC & AMAIGT focused on shroud & combustor liners Field test of first stae shroud in an F-class machine (~150 MW) planned in 2002 at a customer site Combustor liner testin to follow at a customer site in 2004 GE workin with DOE in a risk-reducin, step-wise approach for developin CMCs for Industrial Gas Turbines 23

Continuous-Fiber Ceramic Composites (CFCCs( CFCCs) For Industrial Gas Turbines. Karren L. More and Peter F. Tortorelli

Continuous-Fiber Ceramic Composites (CFCCs( CFCCs) For Industrial Gas Turbines Karren L. More and Peter F. Tortorelli Oak Ridge National Laboratory, Oak Ridge, TN Presented at the DER Materials Peer Review