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TO: Bill Tredway (UTRC) FROM: Ara Vartabedian Vimal Pujari Gregg Wayman Norm Paille Subject: UTRC Microturbine Rotor Program Report DATE: 12/7/06 Introduction Silicon nitride offers excellent thermo-mechanical properties such as high strength and creep resistance at elevated temperatures, low co-efficient of thermal expansion and high thermal shock resistance. This makes it a suitable candidate material for high temperature gas turbine components such as integrally bladed rotors (IBR), vanes and combustor liners. At Saint-Gobain in the last two decades, extensive effort was directed towards the development of high temperature silicon nitride based ceramic materials (NT154), net shape forming processes and prototype component field evaluations. Currently, members of the Fine Ceramics R&D team have been involved with improving the NT154 material and forming process. The technology is being used to deliver small quantities of gas turbine components (rotors and vane rings) to customers. Saint-Gobain Advanced Ceramics in East Granby, CT, a manufacturer of silicon nitride bearing balls, was asked to assist in delivering these components by handling the furnacing process steps for the NT154 material. As part of the Microturbine rotor program with United Technologies (UTRC), the manufacturing process, to produce φ3.9” NT154 radial flow rotors (Ingersoll-Rand Design), was explored. The delivery of up to 10 rotors was the goal of the program. The plan is for UTRC to spin test the rotors to evaluate reliability. Radial Flow Rotor Fabrication The NT154 silicon nitride component fabrication process has been developed over the past couple years in the production of radial and axial turbine rotors. The process includes forming the component in the green state. Once formed, the component goes through the typical NT154 furnacing process. Saint-Gobain Advanced Ceramics in East Granby, CT, a manufacturer of silicon nitride bearing balls, has assisted in the furnacing. Depending upon the size and complexity of the component, the process is modified to result in a crack-free, dense part. Portions of the component may then be dense machined (diamond ground). Green Forming Eight rotors were successfully green formed (Figure 1). The dimensional accuracy of the green rotors was measured by CMM and calipers (Table I). Complete dimensional information was collected on only three of the green rotors due to equipment availability. The data that was collected indicates very good part-to-part consistency and accuracy with a maximum deviation from nominal of 0.003”. 118PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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