Ralf Knoche

Evaluation of Mechanical Properties and Comprehensive Modeling of CMC with Stiff and Weak Matrices

The mechanical properties of ceramic matrix composites (CMC) depend on the individual properties of fibers and matrix, the fiber-matrix interface, the microstructure and the orientation of the fibers. The fiber-matrix interface of ceramics with stiff matrices (e.g. CVI-derived SiC/SiC) must be weak enough to allow crack deflection and debonding in order to achieve excellent strength and strain to failure (weak interface composites WIC). This micromechanical behavior has been intensively investigated during the last 20 years. With the development of CMC with weak matrices (weak matrix composites WMC) as e.g. oxide/oxide composites or polymer derived CMC the mechanical response can not be explained anymore by these models as other microstructural mechanisms occur. If the fibers are oriented in loading direction in a tensile test the WMC behave almost linear elastic up to failure and show a high strength. Under shear mode or if the fibers are oriented off axis a significant quasiplastic stress-strain behavior occurs with high strain to failure and low strength. This complex mechanical behavior of WMC will be explained using a finite element (FE) approach. The micromechanical as well as the FE models will be validated and attributed to the different manufacturing routes.

Improvement of Oxide/Oxide CMC and Development of Combustor and Turbine Components in the HiPOC Program

Three different oxide/oxide ceramic matrix composite (CMC) materials are described. Design concepts for the attachment of the CMC component to the metal structure of the gas turbine are developed in a first work stream focused on the combustion chamber and the turbine seal segment. Issues like environmental barrier coating (EBC)/thermal barrier coatings (TBC), application and volatilization, allowance for the different thermal expansion and the mechanical fixation are addressed. The design work is accompanied by CFD and FEM simulations. A variation of the microstructural design of the three oxide/oxide CMC materials in terms of different fiber architecture and processing of matrix are considered. Also, mechanical properties of these variations are evaluated. The material concepts are developed further in a second work stream. The CMCs are tested in various loading modes (tension, compression, shear, off-axis loading) from room temperature to maximum application temperature focusing on tensile creep behavior. By modification of the matrix and the fiber-matrix interface as well as EBC coatings, the high temperature stability and the insulation performance are enhanced. An outline of the “High Performance Oxide Ceramic”-program HiPOC for the following years is given, including manufacturing of a high-pressure tubular combustor and turbine seal segments from the improved materials as technology samples, for which validation testing up to technology readiness level 4 is scheduled for 2011.Copyright

Development and Validation of Oxide/oxide CMC Combustors within the HiPOC Program

In the framework of the High Performance Oxide Ceramics program (HiPOC), three different oxide/oxide ceramic matrix composite (CMC) materials are studied for a combustion chamber application in continuation of the work reported in Gerendas et al. [1]. A variation in the micro-structural design of the three CMC materials in terms of different fiber architecture and matrix processing are considered in a first work stream. By modification of the matrix and the fiber-matrix interface as well as the application of an environmental barrier coating (EBC), the high temperature stability is enhanced. Furthermore, design concepts for the attachment of the CMC component to the metal structure of the engine are finalized in a second work stream. Issues like sealing of cooling leakage paths, allowance for the different thermal expansion and the mechanical fixation are addressed. An interim standard of the mechanical attachment scheme is studied on a shaker table. Also the friction coefficient between the metallic and ceramic components is analyzed in order to set the proper tightening torque. The manufacturing of the CMC combustor is improved in several iterations in order to achieve a high quality material with optimized fiber architecture. Afterwards, two CMC materials are selected for the combustion testing and the finalized design of the metallic and CMC components is manufactured. A fit check is performed prior to EBC application and laser drilling of the effusion holes in order to evaluate the impact of the manufacturing tolerances on the function of the sealing and attachment scheme and to correct small issues at this stage. First results from the validation testing in a high-pressure tubular combustion rig up to a Technology Readiness Level 4 (TRL4) are reported.Copyright

A Transient Calorimeter Technique for Determining Regional Heat Transfer Coefficients in the Three-Temperature Flowfield at a Turbine Airfoil Leading Edge

In this paper, the authors develop a novel method of obtaining regionally-averaged heat transfer coefficients in flowfields characterized by three temperatures using the well-known transient calorimeter technique. The technique is used to determine heat transfer in aluminum models of idealized turbine blade leading edges cooled through internal surface impingement, film cooling feed passages, and external convective film cooling. The external surface is subject to a stagnating mainstream crossflow. Importantly, the contributions to heating from the external flow and cooling from the internal flow can be separately resolved solely by heating the internal flow. Results for a basic showerhead geometry and an advanced intersecting-passage cooling configuration are presented for a range of internal and external Reynolds numbers. The intersecting-passage model shows little improvement in heat transfer coefficient over the showerhead for the flow conditions tested; however, the total cooling carried out is improved by the increase in exposed surface area. The technique’s uncertainties are fully assessed.Copyright