Main Article Content
Abstract
The High Pressure Turbine (HPT) blades of a turbo-engine, whether used in land-based power- generating equipment or in aircraft propulsion systems, are among the most severely loaded engineering components; they operate at very high temperatures, they are subjected to very high centrifugal stresses, they are susceptible to creep and fatigue damage and they are also exposed to adverse conditions such as corrosion, oxidation, sulphidation, foreign object damage, etc. Nickel-based super alloys were used to make turbine blades in the 1940s and the Turbine Inlet Temperature (TIT) has been steadily increased over the years due to material innovations such as improved alloy chemistry and protective coatings, processing innovations such as directional solidification and single crystal blade fabrication and design innovations such as complex internal cooling channels that enable the blades to operate at temperatures beyond their melting point. With the improvements attainable with the super alloys reaching the limit, efforts are underway to reduce the weight of the blades by making them out of lower density materials such as intermetallic compounds of titanium and aluminum. With the reduction in the centrifugal forces, the weight of the supporting structures such as the bearings can also be reduced, resulting in gains in fuel consumption and reduction in the generation of exhaust gases. Intermetallic compounds such as titanium aluminides and nickel aluminides, composites using such intermetallics as matrices, and ceramic matrix composites with silicon carbide fibers in a silicon carbide matrix, are being introduced in a phased manner; some of these materials have already shown their potential in the Low Pressure Turbine (LPT) stages and are advancing through the higher temperature parts of the turbo-engine with the ultimate goal of replacing the heavier super alloys. These new materials are difficult to fabricate and innovative methods based on centrifugal casting, forging and additive manufacturing from powders are being developed. This paper describes some of these important innovative developments.
Keywords
Article Details
References
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- Trimble, S., "General Electric Primes CMC for Turbine Blades", Flight Global, 17 November 2010.
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- http://what-when-how.com/materialsparts-and finishes/aluminides/.
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- Ward-Close, C., Minor, R. and Doorbar, P., "InterMetallic Composites - A Review", Intermetallics, Vol.4, 1996, pp.217-229.
- Deevi, S., C. and Zhang, W. J., "Intermetallics: Applications", Encyclopedia of Materials, Science and Technology, Elsevier Science Ltd. ISBN: 0-080431526, pp.4165-4173.
- Jozwik, P., Polkowski, W. and Bojar, Z., "Applications of Ni3Al Based Intermetallic Alloys-Current Stage and Potential Perceptivities", Materials, Vol. 8, 2015, pp. 2537-2568.
- Aoki, K. and Izumi, O., "Improvement in Room Temperature Ductility of the Intermetallic Compound Ni3Al by Boron Addition", Journal of Japan Institute of Metals, Vol.43, 1979, pp.358-359.
- Deevi, S., C. and Sikka, V. K., "Exo-MeltTM Process for Melting and Casting Intermetallics", Intermetallics, Elsevier, Vol.5, 1997, pp.17-27.
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- Comie, J. A., Suplinskas, R., J. and DeBolt, H., "Surface Enhancement of Silicon Carbide Filament for Metal Matrix Composites", Summary Report for ONR Contract N00014-79-C-0691, Dept. of Navy, Arlington, VA, 1981.
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- Cui, S., Cui, C., Xie, J., Liu, S. and Shi, J., "Carbon Fibers Coated with Graphene Reinforced TiAl Alloy
- Composite with High Strength and Toughness", Scientific Reports, 20018, pp.1-8.www.nature.com/
- scientificreports.
- Liu, W. and DuPont, J., "Fabrication of Titanium Aluminide Matrix Composites by Laser Engineered
- Net Shaping", Report of PECASE Award, Grant No. DMI 9983968, Division of Manufacturing and Industrial Innovation of NSF.
- Noebe, R. D., Bowman, R. R. and Nathal, M. V., "Review of the Physical and Mechanical Properties
- of the B2 Compound NiAl", Inter. Mater. Rev., Vol.38, No.4, 1993, pp.193-232.
- Whittenberger, J. D., "Characteristics of an Elevated Temperature AlN Particulate Reinforced NiAl",
- Structural Intermetallics, Edited by Darolia, R., et al, TMS, 1993, pp.819-828.
- Burkovskaya, N. P., Yefimochkin, I., Yu., Sevostyanov, N. V. and Rodionov, A. I., "A Composite
- Material Based on Al2O3 Dispersion-Strengthened Nickel Aluminide", Inorganic Materials: Applied
- Research, Vol.7, No.1, 2016, pp.91-96.
- Raj, S.V., Singh, M. and Bhatt, R. T., "High Temperature Lightweight Self-Healing Ceramic Composites for Aircraft Engine Applications", NASA/TM 2014-218352, Glenn Research Center, October 2014.
- Garvie, R. C., Hannink, R. H. J. and Pascoe, R.T., "Ceramic Steel?", Nature (London), Vol.258, 1975,
- pp.703-704.
- Klocke, F., Klink, F., Veselovac, D., Aspinwall, D. K., Soo, S. L., Schmidt, M., Schilp, J., Levy, G. and
- Kruth, J. P., "Turbomachinery Component Manufacture by Application of Electro-Chemical, ElectroPhysical and Photonic Processes", CIRP Annals, Vol.63, Issue 2, 2014, pp.703-726.
- Gardiner, G., "The Next Generation of Ceramic Matrix Composites", Blog Post: 4/11/2017, Composites
- World.
- Zhao, H., Fengling, Yu., Bennett, T. D. and Wadley, H. N. G., "Morphology and Thermal Conductivity of
- Yttria Stabilized Zirconia Coatings", Acta Materialia, Vol.54, 2006, pp.5195-5207.
- Trimble, S., "General Electric Primes CMC for Turbine Blades", Flight International, 17 November 2010.
- Levy, D., "Ceramic Matrix Composites Take Flight in LEAP Jet Engine", Chemistry/Materials Science,
- January 2017. https://phys.org/print402738384. html
- Yajima, S., "Development of Ceramics, Especially Silicon Carbide Fibres, from Organosilicon Polymers by Heat Treatment", Philosophical Transactions of the Royal Society of London, Series A,
- Vol.294, 1980, pp.419-426.
- Uesaka, Y., "SiC Fibres See Increasing Use in High Temperature Applications", Nikkei Asian Review,
- March 25, 2017.
- "Future is Hot for Ceramic Matrix Composites in Engines", SAE International, 17 March 2009,
- http://articles.sae.org/6112/
- Flores, O., Bordia, R. K., Nestler, D., Krenkel, W. and Motz, G., "Ceramic Fibers Based on SiC and
- SiCN Systems: Current Research, Development, and Commercial Status", Advanced Engineering Materials, Vol.16, No.6, 2014, pp.621-636.
- Murata, H., Nakamura, T. and Tanaka, Y., "Development of New CMC Manufacturing Process for Aerospace Structural Parts", Engineering Review, Vol.46, No.3, 2006, pp.101-108.
- Simos, N., "Composite Materials under Extreme Radiation and Temperature Environments of the Next
- Generation Nuclear Reactors", Chapter 28 , pp.571- 586, in Metal, Ceramic and Polymeric Composites
- for Various Uses, Edited by Cuppoletti, J., 2011.
- Hart, A. H. C., Koizumi, R., Hamel, J., Owuor, P. S., Ito, Y., Ozden, S., Bhowmick, S., Amanulla, S. A.S.,
- Tsafack, T., Keyshar, K., Mital, R., Hurst, J., Vajtai, R., Tiwary, C. S. and Ajayan, P. M., "Velcro_Inspired SiC Fuzzy Fibers for Aerospace Applications", ACS Appl. Mater. Interfaces, Vol.9, No.15, 2017, pp.13742-13750.
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- pp.291-301.
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- Thermal Barrier Coatings", Surface and Coatings Technology, Vol.204, 2010, pp.2432-2441.
- Arthur, E. K., Ampaw, E., Azeko, S. T., Danyuo, Y., Agyei-Tuffour, B., Kan-Dapaah, K. and Obayemi, J.
- D., "Design of Thermally Reliable Environmental Barrier Coating for a SiC/SiC Ceramic Matrix Composites", International Journal of Composite Materials, Vol.3, No.6, 2013, pp.191-197.
- Zok, F.W., "Ceramic-Matrix Composites Enable Revolutionary Gains in Turbine Engine Efficiency",
- American Ceramic Society Bulletin, Vol.95, No.5, 2016, pp.22-28.
- Estrada, C. M., "New Technology Used in Gas Turbine Blade Materials", Scientia Technica Ano,
- Vol.13, No.36, 2007, pp.297-301.
References
Prabhakaran, R., "The High Pressure Gas Turbine Blades of Jet Engines", Journal of Aerospace Sciences and Technologies, Vol.69, No.2, May 2017, pp.261- 285.
Trimble, S., "General Electric Primes CMC for Turbine Blades", Flight Global, 17 November 2010.
Cervenka, M., "The Rolls Royce Trent Engine", Power Point Presentation, 5 October 2000.
Mouritz, A. P. (Editor)., "Introduction to Aerospace Materials", ISBN 978-1-85573-946-8,Woodhead Publishing Ltd, Elsevier, 2012.
Iqbal, F., "Fracture Mechanisms of Gamma-TiAl Alloys Investigated by In-Situ Experiments in a Scanning Electron and Atomic Force Microscope", Ph.D Thesis, University of Erlangen-Nurnberg, 2012.
Chestnutt, J. C., "Titanium Aluminides for Aerospace Applications", The Minerals, Metals and Materials Society, 1992.
Dimiduk, D. M., "Gamma Titanium Aluminide Alloys-an Assessment Within the Competition of Aerospace Structural Materials", Materials Science and Engineering A, Vol.263, No.2, 1999, pp.281-288.
Austin, C. M., "Gas Turbine Engine Implementation of Gamma Titanium Aluminide", Superalloys 1996, Edited by Kissinger, R. D., Deye, D. J., Anton, D. L., Cetel, A. D., Nathal, M. V., Pollock, T. M. and Woodford, D. A., The Minerals, Metals and Materials Society, 1996.
Yanqing, S., Tong, L., Xinzhong, l., Ruirun, C., Hongsheng, D., Jingjie, G. and Hengzhi, F., "Lamellar Orientation Control in Directionally Solidified TiAl Intermetallics", Special Report, China Foundry, Vol.11, No.4, July 2014, pp.219-231.
Lapin, J., "TiAl-Based Alloys: Present Status and Future Perspectives", Metal, January 2009, pp.1-12.
Leyens, C., Braun, R., Frohlich, M. and Hovsepian, P. EH., "Recent Progress in the Coating Protection of Gamma Titanium-Aluminides", JOM, Vol.58, No.1, 2006, pp.17-21.
Kablov, E.N., Lomberg, B.S., Buntushkin, V.P., Golubovskii, E. P. and Muboyaadzhyan, S. A., "Intermetallic Ni3Al Base Alloy: A Promising Material for Turbine Blades", Metal Science and Heat Treatment, Vol.44, Nos.7-8, 2002, pp.284-287.
Darolia, R., Walston, W. S.and Nathal, M.V., "NiAl Alloys for Turbine Airfoils", Superalloys 1996, The Minerals, Metals and Materials Society, 1996.
http://what-when-how.com/materialsparts-and finishes/aluminides/.
Darolia, R., Lahrman, D. and Field, R., "The Effect of Iron, Gallium and Molybdenum on the Room Temperature Tensile Ductility of NiAl", Scr. Met., Vol.26, 1992, pp.1007-1012.
Ward-Close, C., Minor, R. and Doorbar, P., "InterMetallic Composites - A Review", Intermetallics, Vol.4, 1996, pp.217-229.
Deevi, S., C. and Zhang, W. J., "Intermetallics: Applications", Encyclopedia of Materials, Science and Technology, Elsevier Science Ltd. ISBN: 0-080431526, pp.4165-4173.
Jozwik, P., Polkowski, W. and Bojar, Z., "Applications of Ni3Al Based Intermetallic Alloys-Current Stage and Potential Perceptivities", Materials, Vol. 8, 2015, pp. 2537-2568.
Aoki, K. and Izumi, O., "Improvement in Room Temperature Ductility of the Intermetallic Compound Ni3Al by Boron Addition", Journal of Japan Institute of Metals, Vol.43, 1979, pp.358-359.
Deevi, S., C. and Sikka, V. K., "Exo-MeltTM Process for Melting and Casting Intermetallics", Intermetallics, Elsevier, Vol.5, 1997, pp.17-27.
Christoph, K., "Development of Oxide Dispersion Strengthened Titanium Aluminides for Additive Manufacturing", Doctoral Thesis, ETH (Eidgenossische Technische Hochschule) Zurich, 2016.
Singerman, S. A. and Jackson, J. J., "Titanium Metal Matrix composites for Aerospace Applications", Superalloys 1996, The Minerals, Metals and Materials Society, 1996, pp.579-586.
Comie, J. A., Suplinskas, R., J. and DeBolt, H., "Surface Enhancement of Silicon Carbide Filament for Metal Matrix Composites", Summary Report for ONR Contract N00014-79-C-0691, Dept. of Navy, Arlington, VA, 1981.
Kampe, S., Bryant, and Christodoulou., Creep Deformation of TiB2-Reinforced Near-gamma Titanium Aluminides", Metallurgical Transactions, Vol.A22, 1991, pp.447-454.
Soboyejo, W. O. and Sastry, S. M. L., An Investigation of the Effects of Ductile Phase Reinforcement on the Mechanical Behavior of Advanced High Temperature Intermetallics", Materials Science and Engineering A, Vol.171, 1993, pp.95-104.
Zhang, K., Fen, W., Zhu, J. and Wu, H., Mechanical Properties and Microstructure of Al2O3 /TiAl In Situ Composites Doped with Cr and V2O5", Science of Sintering, Vol.44, 2012, pp.73-80.
Cui, S., Cui, C., Xie, J., Liu, S. and Shi, J., "Carbon Fibers Coated with Graphene Reinforced TiAl Alloy
Composite with High Strength and Toughness", Scientific Reports, 20018, pp.1-8.www.nature.com/
scientificreports.
Liu, W. and DuPont, J., "Fabrication of Titanium Aluminide Matrix Composites by Laser Engineered
Net Shaping", Report of PECASE Award, Grant No. DMI 9983968, Division of Manufacturing and Industrial Innovation of NSF.
Noebe, R. D., Bowman, R. R. and Nathal, M. V., "Review of the Physical and Mechanical Properties
of the B2 Compound NiAl", Inter. Mater. Rev., Vol.38, No.4, 1993, pp.193-232.
Whittenberger, J. D., "Characteristics of an Elevated Temperature AlN Particulate Reinforced NiAl",
Structural Intermetallics, Edited by Darolia, R., et al, TMS, 1993, pp.819-828.
Burkovskaya, N. P., Yefimochkin, I., Yu., Sevostyanov, N. V. and Rodionov, A. I., "A Composite
Material Based on Al2O3 Dispersion-Strengthened Nickel Aluminide", Inorganic Materials: Applied
Research, Vol.7, No.1, 2016, pp.91-96.
Raj, S.V., Singh, M. and Bhatt, R. T., "High Temperature Lightweight Self-Healing Ceramic Composites for Aircraft Engine Applications", NASA/TM 2014-218352, Glenn Research Center, October 2014.
Garvie, R. C., Hannink, R. H. J. and Pascoe, R.T., "Ceramic Steel?", Nature (London), Vol.258, 1975,
pp.703-704.
Klocke, F., Klink, F., Veselovac, D., Aspinwall, D. K., Soo, S. L., Schmidt, M., Schilp, J., Levy, G. and
Kruth, J. P., "Turbomachinery Component Manufacture by Application of Electro-Chemical, ElectroPhysical and Photonic Processes", CIRP Annals, Vol.63, Issue 2, 2014, pp.703-726.
Gardiner, G., "The Next Generation of Ceramic Matrix Composites", Blog Post: 4/11/2017, Composites
World.
Zhao, H., Fengling, Yu., Bennett, T. D. and Wadley, H. N. G., "Morphology and Thermal Conductivity of
Yttria Stabilized Zirconia Coatings", Acta Materialia, Vol.54, 2006, pp.5195-5207.
Trimble, S., "General Electric Primes CMC for Turbine Blades", Flight International, 17 November 2010.
Levy, D., "Ceramic Matrix Composites Take Flight in LEAP Jet Engine", Chemistry/Materials Science,
January 2017. https://phys.org/print402738384. html
Yajima, S., "Development of Ceramics, Especially Silicon Carbide Fibres, from Organosilicon Polymers by Heat Treatment", Philosophical Transactions of the Royal Society of London, Series A,
Vol.294, 1980, pp.419-426.
Uesaka, Y., "SiC Fibres See Increasing Use in High Temperature Applications", Nikkei Asian Review,
March 25, 2017.
"Future is Hot for Ceramic Matrix Composites in Engines", SAE International, 17 March 2009,
Flores, O., Bordia, R. K., Nestler, D., Krenkel, W. and Motz, G., "Ceramic Fibers Based on SiC and
SiCN Systems: Current Research, Development, and Commercial Status", Advanced Engineering Materials, Vol.16, No.6, 2014, pp.621-636.
Murata, H., Nakamura, T. and Tanaka, Y., "Development of New CMC Manufacturing Process for Aerospace Structural Parts", Engineering Review, Vol.46, No.3, 2006, pp.101-108.
Simos, N., "Composite Materials under Extreme Radiation and Temperature Environments of the Next
Generation Nuclear Reactors", Chapter 28 , pp.571- 586, in Metal, Ceramic and Polymeric Composites
for Various Uses, Edited by Cuppoletti, J., 2011.
Hart, A. H. C., Koizumi, R., Hamel, J., Owuor, P. S., Ito, Y., Ozden, S., Bhowmick, S., Amanulla, S. A.S.,
Tsafack, T., Keyshar, K., Mital, R., Hurst, J., Vajtai, R., Tiwary, C. S. and Ajayan, P. M., "Velcro_Inspired SiC Fuzzy Fibers for Aerospace Applications", ACS Appl. Mater. Interfaces, Vol.9, No.15, 2017, pp.13742-13750.
Spitsberg, I. and Steibel, J., "Thermal and Environmental Barrier Coatings for SiC/SiC CMCs in Aircraft Engine Applications", International Journal of Applied Ceramic Technology, Vol.1, No.4, 2004,
pp.291-301.
Katz, A., "SiC/SiC Ceramic Matrix Composites (CMC) for Jet Engine Applications: State of the Art",
th Israeli Symposium on Jet Engines and Gas Turbines, Technion, Haifa, Israel, November 17, 2016.
Eaton, H. et al., "Article Having Silicon-Containing Substrate and Barrier Layer and Production
Thereof", US Patent No. 6,387,456, 2001.
Zhao, H., Yu, Z. and Wadley, H. N. G., "The Influence of Coating Compliance on the Delamination of
Thermal Barrier Coatings", Surface and Coatings Technology, Vol.204, 2010, pp.2432-2441.
Arthur, E. K., Ampaw, E., Azeko, S. T., Danyuo, Y., Agyei-Tuffour, B., Kan-Dapaah, K. and Obayemi, J.
D., "Design of Thermally Reliable Environmental Barrier Coating for a SiC/SiC Ceramic Matrix Composites", International Journal of Composite Materials, Vol.3, No.6, 2013, pp.191-197.
Zok, F.W., "Ceramic-Matrix Composites Enable Revolutionary Gains in Turbine Engine Efficiency",
American Ceramic Society Bulletin, Vol.95, No.5, 2016, pp.22-28.
Estrada, C. M., "New Technology Used in Gas Turbine Blade Materials", Scientia Technica Ano,
Vol.13, No.36, 2007, pp.297-301.