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using probabilistic CARES/Life analysis; and effects of substrate and EBC properties on thermal stresses in the vanes. Proof testing is a technique where ceramic components are over-stressed prior to use and those that fail or give indication of fracture initiation are discarded. It is an effective method to truncate the component strength distribution at or above the design stress. Solar Turbines, Inc. has a thermal gradient proof test rig to screen out low strength vanes before they are introduced into engine tests. The conditions for vane proof test were derived from Solar Turbines steady state finite element analysis (for additional details on the proof test, see Ref. 13). About 90% of silicon nitride vanes manufactured by Kyocera Ceramics (SN282), NGK Ceramics (SN88), and Honeywell Ceramic Components (AS800) passed the Solar Turbines proof test in the uncoated condition. Two of the SN282 (Kyocera) vanes that passed the proof test were coated with the EBCSiC and subjected to the same test conditions again. The vanes failed the proof test and fractured into two pieces during heat-up prior to reaching the full temperature gradient required by the test. Figure 3 shows the vanes before and after the proof test. The failure appears to be a typical thermal shock failure in fast fracture under high thermal stresses, possibly at the trailing edge. and vanes. The stresses in vanes were then used to predict the probability of failure of the vanes under test conditions. The FEA was performed using ABAQUS Version 6.2 (HKS, Inc.). The solid model of the vane (ProE file) and the thermal boundary conditions; heat transfer coefficients (h) and sink temperatures, (T(sink)), as a function of location on vane were provided by Solar Turbines. The boundary conditions for the thermal shock proof test were provided by Solar Turbines and they closely match the engine conditions. In order to analyze the effect of the EBC on the temperature gradients and stresses, a 15-mil coating solid model was developed by UTRC. The coating solid model was attached to the vane in the EBC- vane analysis using tie constraints. Temperature dependent material data (elastic modulus, thermal expansion, thermal conductivity, and heat capacity) were used for the silicon nitride vanes. The EBC is a 3-layer coating of silicon, mixed oxide layer (Mullite+BSAS), and BSAS layer. Since the thermal conductivity of silicon is much higher than that of mixed oxide and BSAS layers, it would have minimal effect on the thermal gradients. The Si layer may however effect the thermal stresses due to its elastic-plastic response, especially at high temperatures. The properties of Mullite+BSAS and BSAS layers are very similar. Therefore, as a first approximation, the silicon layer is ignored and the 15-mil coating is assumed to be composed of BSAS. Since the properties of plasma-sprayed BSAS were not available, properties of dense BSAS were used in the analysis. The coefficients of thermal expansion (CTE) are likely to have a significant influence on the thermal stresses in the EBC and the vanes. Figure 4 shows the coefficient of thermal expansion (CTE) for SN282, AS800, and the EBC (dense BSAS). Figure 3. EBCSiC coated Solar Turbines vanes before and after the thermal shock proof test. The structural analysis was performed to determine the effect of the EBC on the thermal gradients and the resulting stresses in the EBC 134 Copyright © 2004 by ASMEPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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