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bearing contribution. At 1204°C (2200°F) and at a load rate of 0.003MPa/s (4.4E-04 ksi/s) the debit is ~30% implying sensitivity to the atmosphere in comparison to the 30 MPa/s (4.4 ksi/s) load rate. Both conditions, however, show less debit than at RT (60% to 70 % debit). Figure 9. EBCSiC coated Solar Turbines vane post proof test showing mid-span failure. The following conclusions were made based on the structural analysis and life prediction of Solar Turbines vanes and mechanical characterization at ORNL: 1. The thermal stresses are strongly dependent on CTE mismatch between the EBC and substrate and weakly dependent on elastic modulus mismatch. 2. The maximum stress location for both steady state and transient condition is vane trailing edge (mid-span). 3. Transient stresses during heating are ~35% higher than the steady state stresses in the vanes. The time at which the transient stress peaks (~15 secs) matches with the experimental observation of vane failure during heat-up. 4. The thermal stress increases by 6 to 48%, depending on the residual stress relaxation, when the EBCSiC is applied to silicon nitride vanes. 5. The probability of failure of coated SN282 vanes is 100% due to significant strength debit of the substrate by the coating process. STRENGTH DEBIT IN EBCSiC COATED SILICON NITRIDE In an attempt to further our understanding of the apparent debit observed in the strength of the EBCSiC coated Solar Turbines vanes, UTRC studied the flexure strength behavior of AS800 silicon nitride at room temperature under several conditions. Test coupons of nominal size 8 x 0.4 x 0.3 cm were made from AS800 and tested in four-point bending. The mechanical behavior was characterized by varying the following parameters: 1. Material surface: As-processed and machined surfaces 2. Grit blast conditions 3. Effects of heat treatment and heat treat atmosphere 4. Effects of individual EBC layers: Bond coat, bond coat plus intermediate coat, and three layer-coated surfaces. Strength (MPa) 139 Copyright © 2004 by ASME 800 700 600 500 400 300 200 100 0 Shroud Bulk w/ EBC w/o EBC SN282 Rod Figure 10. ORNL RT strength testing of EBCSiC coated Solar Turbines SN282 vanes (red = vane #9, and blue = vane #11) post proof test failure. “w/EBC” and “w/oEBC” refer to strength calculation including or not thickness of coating – both conditions have EBC coating on silicon nitride. Strength measurements of the as-processed and as-machined (no subsequent heat treatment) surfaces of the AS800 bend bars showed RTPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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