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Section 4.0 Ceramic Turbine Technology Development Task 6 – Ceramic Turbine Technology The benefits of ceramic turbines have been discussed in sections 1 and 2. Critical risk reduction on ceramic turbine technologies was added as Task 6 to the AMS contract in 2005. The aim was to enable the implementation of uncooled EBC-coated ceramic turbine components capable of 2100F T4 operation within integrated CHP systems in order to maximize fuel utilization and energy cost savings, improving electrical efficiency by 5 points, increasing power by 50%, and reducing the effective cost of electricity ($/kW) by 15%. The critical risk reduction for ceramic component design in preparation for feasibility demonstration of ceramic turbine components in a C60 was planned but could not be completed because of strategic differences with Capstone. UTRC focused its activities on EBC design, composition and process development and scale-up. 4.1 Ceramic Component Design. Current design practice for silicon nitride ceramic components involves manual transfer between various codes and only allows for the uncertainty in the strength of the silicon nitride material. An effort was initiated to enhance the current design methodology, focusing on the integration of the FEA code (ANSYS) and the ceramic reliability code (CARES) with an advanced probabilistic code (UNIPASS) to provide for the ability to incorporate additional uncertainties in the design process and to more fully automate the entire process and remove sources of error associated with manual transfer of results between the ANSYS and CARES codes. Integration with UNIPASS allows for the effects of additional uncertainties such as dimensional variation and heat transfer coefficients to be factored into the overall component reliability. The capability of this enhanced approach was demonstrated using a simple component geometry representative of a turbine shroud. It was demonstrated that the enhanced capability reduced the time required to reach an optimized survival probability and also showed the sensitivity of the design reliability to uncertainties other than material strength (e.g. dimensional variation stemming from manufacturing tolerances, heat transfer coefficient used in thermal analysis). Future work will consider integration with the CAD model to allow for automated design revisions for optimized reliability as well as demonstrations on more complex turbine component geometries. This enhanced design methodology should reduce the time required for design of ceramic components while at the same time providing a more accurate prediction of reliability. A paper that has been accepted for publication at the IGTI-ASME Turboexpo 2007 is included in the appendix (GT2007- 27935). This paper describes the methodology developed in much greater detail. 4.2 Development of Environmental Barrier Coatings for Silicon Nitride The poor steam stability of Si-based ceramics has been well documented in recent literature and the development of environmental barrier coatings are key to ensuring the 82PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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