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The likelihood of failure of the SN282 vanes was calculated using as-processed properties obtained from Kyocera [RT Strength: 634 MPa/92 ksi, Weibull modulus m=10 and 1400°C (2552°F) Strength: 468 MPa/68 ksi, m=10]. The overall probability of failure of the vane was calculated using the CARES/Life code from NASA Glenn Research Center. The vanes were assumed to fail due to volume flaws in fast-fracture and Weibull principal of independent action (PIA) was selected as the fracture criterion. The probability of failure was calculated using the as- processed strength of SN282, assuming that the EBC does not lead to any substrate strength debit. The failure probability was found to increase from 3.1E-04 to 7.3E-03 using RT strength values and from 6.3E-03 to 1.4E-01 using 2552°F strength data, for without and with the EBC respectively. The failure of the coated SN282 vanes prompted UTRC and Oak Ridge National Laboratory (ORNL) to evaluate the effect of the EBC on substrate strength (see next sections). In one early study, the room temperature 4-point bend strength of the coated SN282 samples was found to be only 130 MPa (19 ksi) indicating a significant debit in strength (~80%) due to the EBC. (However later work at ORNL indicated greater RT strengths, see Fig. 10.) For a 130 MPa (19 ksi) RT strength, the CARES/Life analysis predicts the probability of failure of coated vanes to be 1.0 (Table 2). At elevated temperature the probability will be between 0.14 and 1.0 depending on the extent of strength debit. Figure 7. Maximum principal stress (psi) in coated SN282 vane at steady state condition. Table 2. Failure probability of vanes with and without the EBC Strength (ksi) RT 92 92 19 2552 F 68 68 Not Available 37..8 37.8 B Max. Stress (ksi) 35.5 Weibull Modulus (estimate) RT/2552 F 10 10 10 137 Copyright © 2004 by ASME As-processed SN282 Material/ Property SN282 with E No-EBC Nozzle Nozzle with EBC Over-all Vane Failure RT 3.10E-04 7.30E-03 1.00E+00 Probability 2552 F 6.30E-03 1.40E-01 ----- Source: As-processed SN282 Strength from Kyocera Industrial Ceramics Corp. SN282 with EBC strength data from ORNL The above analysis used hot-pressed BSAS properties for the EBC. In reality, the plasma- sprayed EBC will be porous and will have lower conductivity and elastic modulus. In order to determine the effect of the EBC properties on thermal stresses in the vane, the analysis was repeated with half the thermal conductivity and half the stiffness of hot pressed BSAS values. Half values correspond to ~30% porosity uniformly distributed in the coating. The remaining properties of the substrate and boundary conditions were the same as before. Table 3 shows the effects of properties of the EBC on the stresses. The stress drop in the EBC is expected since the stiffness is half that of the substrate, the stressesPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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