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stress that may built-up between the ceramic combustor can and the metal support under engine operating conditions when both expand thermally, but by different amount. The major concern was that the spring may not be able to maintain the clamping load due to creep, mainly due to high recuperated air temperature (~1130F). To verify the creep strength, wave springs were placed in a furnace and a constant load was applied to simulate service condition. The first set of wave springs were made of INCONEL X750 and they showed substantial creep deformation under load and temperature. A second set of wave springs were made using a more creep resistant Nickel based superalloy (IN718) and tested under same conditions. Unfortunately, the springs showed unacceptable creep deformation again. The springs were then redesigned to reduce stress and more temperature resistance materials were also considered. Ceramic rope seal is another important element of the low stress attachment design. To ensure its integrity under engine conditions, a special testing rig was set up to simulate actual thermal and mechanical loadings. Fatigue tests were run up to 1 million cycles and no visible damage was observed on the seals. The other key element in the use of silicon carbide based materials in the gas turbine environments is the development and use of protective environmental barrier coatings (EBC’s). EBC’s are required because of the accelerated oxidation of SiC and subsequent volatilization of silica in the high temperature high-pressure steam environment. EBC systems for silicon carbide fiber reinforced silicon carbide composites (SiC/SiC CMC’s) were first developed under NASA HSCT Program12. The multi-layer coating system typically consists of a silicon bond layer, a mullite containing intermediate layer and a top layer of a celsian-based complex silicate (such as barium strontium aluminum silicate – BSAS). The effectiveness of such multi-layer coating systems have been demonstrated via > 50,000-hour field tests in industrial gas turbine engines under different DOE programs. Coating trials were performed to apply the multi-layer EBC to the ST5+ combustor liner. The plasma spray parameters were optimised to ensure high quality EBC coatings. Preliminary coating tests showed that a modified EBC process could be applied successfully to the combustor liner. The coating fixtures and parameters that were established during coupon trials were refined. A dense BSAS based coating with desired and uniform thickness was demonstrated on the inner surface of a SiC Hexoloy cylinder with the same ID (circa 6 inches) and similar length (circa 13 inches) as that of the advanced microturbine combustor liner (Figure 4). Figure 5: Cross-section view of EBC on the ID surface of a 6” SiC Hexoloy cylinder SUMMARY Significant progress has been made in designing the ceramic combustor for ST5+ microturbine engine. It is believed that the ceramic combustor can meet the thermal and stress design requirements. The ceramic combustor can was designed with special attention to attachment methods that minimize thermal stresses due to the large difference in thermal expansion coefficients between metallic and ceramic materials. Detailed thermal and stress analyses were performed to that lead to optimal component reliability and manufacturability. ACKNOWLEDGEMENTS The authors would like to thank DOE for its financial support and Debbie Haught of the DOE Office of Power Technologies and Stephen Waslo of the DOE Chicago Operations Office for their programmatic support. They also wish to acknowledge the technical support from their colleagues in Pratt & Whitney Canada. 116PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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