Silicon Carbide Fiber and Its Application to Ceramic Matrix Composites

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1 Silicon Carbide Fiber and Its Application to Ceramic Matrix Composites Michio TAKEDA NGS Advanced Fibers Co.,Ltd. Ceramics Expo May 1 st, 2018

2 Company Profile of NGS Advanced Fibers Head Office 1-1 Takauchi, Toyama, JAPAN Representative Michio Takeda Established April, 2012 Capital 1.15 Bil. JPY Shareholders NCK(50%)/ GE(25%)/ Safran(25%) Employees 70 Product Silicon Carbide Fibers, NICALON Certification JIS Q9100 (January, 2017) NGS Advanced Fibers Tokyo NGS is the strategic joint venture of Nippon Carbon and leading aviation companies in US, Europe. Nippon Carbon GE Aviation Safran (Fiber Technology) (CMC application) Of course, NGS is willing to supply SiC fibers to all customers. 2

3 Classification of Different Fiber Types

4 Production and Compositional Details for Commercially Available SiC-Based Fibers Four companies produce SiC fibers commercially.

5 Invention of SiC fiber from Organosilicon Polymer Prof. Yajima (Tohoku University) invented the method to convert organosilicon polymer into SiC fiber in Thermal decomposition Polycarbosilane Silicon Carbide Industrialization of SiC fiber from polycarbosilane was carried out. Nippon Carbon made Nicalon in 1983 Ube Industry made Tyranno in

6 Feature of SiC Fibers As fine, flexible continuous fiber, it can be made various woven fabrics. Light weight, high strength and high modulus Good thermal and oxidation resistance at high temperature Good chemical resistance Suitable for a reinforcement of composite materials 6

7 Durability Test under a load at high temperature (Temperature: 1200, Atmosphere: oxidative flame) Silicon Carbide Fiber No Failure for > 7 hrs. (Load: 307g) Carbon Fiber 24 sec. (Load: 307g) Alumina Fiber 10 sec. (Load: 12g) Aluminosilicate Fiber 1.5 sec. (Load: 12g) Time to Failure (sec.) Durability test of ceramic fibers under a load at high temperature SiC fiber shows much better durability compared with other ceramic fibers. 7

8 Production Process of SiC Fibers High modulus Creep resistant (2002~) High heat resistant (1995~) Standard grade (since 1983)

9 Irradiation-Curing SiC Fiber (O: 0.4 %) Thermal Exposure Test of SiC Fibers Treating Temperature Oxidation-Curing SiC Fiber (O: 11.2 %) Low-oxygen SiC fiber showed much improved thermal stability compared to that by oxidation-curing. 9

10 Creep Strain vs. Time Curve for Some SiC Fibers Handbook of Ceramic Composites (Springer US,2005) Some SiC fibers show improved creep resistance under stress in 1400 C.

11 Advantage of Ceramic Matrix Composite (CMC) CMC is non-brittle (ductile) material and available above 1000 ⁰ C 11

12 CMC Component Technology Development Improved CMC process has required higher performance SiC fiber. Our SiC fibers have always caught up successfully with such needs. 12

13 Replace Metal Parts to CMC Ceramic Matrix Composites (CMC) is: Lighter weight, more heat resistant than metal. CMC enables the engine with better fuel efficiency. Metal CMC 1/3 Weight 200 C UP Heat Resistance

14 First CMC Application in Commercial Engine LEAP Engine (CFM International) CMC shroud for High pressure turbine (GE) LEAP engine, which uses CMC shroud reinforced by SiC fiber, is in service from

15 A320NEO & 737MAX powered by LEAP in Service First CFM LEAP-1A-powered Airbus A320neo delivered to Pegasus Air. Jul 21, 2016 May 17, 2017 Boeing completes its first 737 MAX delivery to Malindo Air. 15

16 Market Limitation of SiC Fibers Market Volume and Applications for Carbon-F vs. SiC-F PMCs for Aerospace: Aircraft, Satellite Sports: Golf, Tennis racket, Fishing rod, Bike Industrial: Automobile, Wind turbine, Pressure vessel C/C Composites for Brake, Rocket nozzle Carbon Fiber 100,000 ton/year Silicon Carbide Fiber 10 ton/year CMCs for Jet engine

17 Prospect for SiC Fiber Market Comparison of three fiber types Properties Strong Moderate Weak Thermal stability Carbon, SiC Oxide Oxidation Oxide SiC Carbon Creep SiC, Carbon Oxide Price Carbon Oxide SiC SiC fiber is more expensive and has limited market at present. But it shows strong presence under the conditions of High temperature AND Oxidative environment AND Under stress, suitable for reinforcement of CMCs. 17

18 Current and Future Applications of SiC fiber Burner Spacecraft Nuclear Application Fuel cladding, Channel box, etc. Aircraft Engines Expanding to other part and other maker s one. Turbine for Power Generation 18

19 SiC fiber is key material for innovation. Thank you for your attention. 19