STTR Phase I: Additive manufacturing of ceramic composites for next generation gas turbines

STTR 第一阶段：下一代燃气轮机陶瓷复合材料的增材制造

• 批准号: 1549688
• 负责人: Mark Spowart
• 金额: $ 22.5万
• 依托单位: AMERICAN MANUFACTURING, INC.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2016
• 资助国家: 美国
• 起止时间: 2016-01-15 至 2017-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1549688&HistoricalAwards=false
• 关键词: STTR; Phase; Additive; manufacturing; ceramic

The broader impact/commercial potential of this project lies in next generation gas turbines where the heart of the engine, the combustor and the blade, are constructed from ceramic matrix composites (CMCs). These developments will spell a new phase of air transportation beyond the current engines that rely upon nickel-base superalloys, which have reached their maximum capability. The ceramic engines are eventually expected to be 25% more efficient. The CMCs are constructed from fibers of silicon-carbide that are spun into net shape and then infiltrated with an equally robust high temperature matrix, also made from silicon carbide-based ceramics. The fiber composites overcome the inherent brittleness of monolithic ceramics while retaining their mechanical and corrosion resistance in aggressive environments. These composites will have applications beyond gas turbines. They can become the critical breakthrough for the solar collector on Concentrated Solar Power systems, and have the potential to be used as cladding for nuclear fuels for greater safety and accident tolerance. The key innovation in this Phase I project is the development of an additive manufacturing process for creating a dense and defect free matrix from polymer precursors that convert into silicon carbide-based ceramics. This Small Business Technology Transfer Research (STTR) Phase I project employs additive manufacturing to fabricate dense and defect free matrices for ceramic matrix composites (CMCs). These composites are constructed from fibers of silicon carbide (SiC). The innovation in this project lies in constructing the matrix from polymer precursors where nanoscale layers are deposited in quick succession to create the matrix. These silicon-based polymer precursors convert into ceramics when heated to ~800 oC. Nominal processing, also known as polymer-infiltration-and-pyrolysis, produces cracks in the matrix despite 24 hour curing cycles. These cracks degrade the strength of the composite. In this project nanoscale coatings are deposited in the form of thin layers of liquid and then pyrolyzed into the ceramic in just one or two seconds. The coatings are defect free and dense. The short curing time allows rapid deposition of layers. The CMC can be prepared from SiC fiber preforms in about four hours. The feasibility of the process has been demonstrated with carbon fibers under a grant from Ceramics Program at NSF. In this SBIR project, American Manufacturing LLC seeks to demonstrate the fabrication of CMCs made from silicon-carbide fibers, and demonstrate their viability for high temperature applications.

该项目的更广泛的冲击/商业潜力在于下一代燃气轮机，在该燃气涡轮机中，燃烧器和刀片的心脏是由陶瓷基质复合材料（CMC）构建的。这些事态发展将为依赖于镍基超合金团的当前发动机超出目前的发动机的新阶段，这些合金已经达到了最大的能力。最终，陶瓷发动机效率将提高25％。 CMC是由硅胶纤维纤维构成的，这些硅碳化物被纺成净形状，然后用同样强大的高温基质渗入，也由基于碳化硅的陶瓷制成。纤维复合材料克服了整体陶瓷的固有脆性，同时在侵略性环境中保留了机械和腐蚀性。这些复合材料将在燃气轮机以外的应用。它们可以成为太阳能集合太阳能系统的关键突破，并有可能将其用作核燃料的覆层，以提高安全性和意外承受能力。该阶段I项目中的关键创新是开发添加剂制造过程，该过程是从聚合物前体中创建稠密和缺陷的矩阵，这些矩阵转换为基于碳化硅的陶瓷。 这项小型企业技术转移研究（STTR）I阶段项目采用添加剂制造来制造陶瓷基质复合材料（CMC）的无缺陷矩阵。这些复合材料由碳化硅（SIC）的纤维构成。该项目的创新在于从聚合物前体构建矩阵，在这些聚合物前体中，纳米级层迅速沉积以创建矩阵。这些基于硅的聚合物前体加热至〜800 oC时，将其转化为陶瓷。尽管24小时的固化周期，但名义加工，也称为聚合物浸润和透明解析，在基质中产生裂缝。这些裂纹降解了复合材料的强度。在这个项目中，纳米级涂料以薄液层的形式沉积，然后仅在一两秒钟内将其热解入陶瓷中。涂料是无缺陷且致密的。较短的固定时间可以快速沉积层。 CMC可以在大约四个小时内从SIC纤维预形成。根据NSF陶瓷计划的赠款，已经证明了该过程的可行性。在这个SBIR项目中，American Manufacturing LLC试图证明用硅碳化纤维制成的CMC制造，并证明它们对高温应用的生存能力。