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Coatings tailored specifically for Si3N4 are currently being developed by UTRC under programs funded by DOE and ONR. This paper discusses the development of a bond coat system that helps retain the strength of EBC-coated silicon nitride. NOMENCLATURE BSAS Barium Strontium Aluminosilicate CMC Ceramic Matrix Composite CSGT Ceramic Stationary Gas Turbine CTE Coefficient of Thermal Expansion CVD Chemical Vapor Deposition DOE U.S. Department of Energy EBC Environmental Barrier Coating EPM Enabling Propulsion Materials IBR Integrally Bladed Rotor IGT Industrial Gas Turbine NASA National Aeronautics and Space Administration NIST National Institute for Standards and Technology OOF Object Oriented Finite Element Analysis ONR Office of Naval Research SiC/SiC Silicon Carbide Fiber Reinforced Silicon Carbide Matrix CMC Si3N4 Silicon Nitride SN282 Gas turbine grade silicon nitride by Kyocera Industrial Ceramics Corp. Solar Solar Turbines Inc. UTRC United Technologies Research Center EMPHASIS ON THE DEVELOPMENT OF NON-LINE- OF-SIGHT COATINGS In the initial phase of the coating development, the complexity and small size of the monolithic silicon nitride components that needed to be coated were considered. A typical integral vane ring and integrally bladed rotor (IBR) that needs an EBC is shown in figure 1a. Most of the prior experience in EBC development consisted of plasma sprayed coatings and it appeared that existing thermal spray technologies might not be suitable to coat the components of interest. A feasibility study was performed to determine if air plasma spray technique could be used to coat complex shaped engine components such as an integral vane ring. The study was based on a simple analytical approach that considered the ability of a plasma gun to coat “hidden” areas (vanes and platforms) by calculating the angle at which the spray gun approached the component without “gouging” using the ST5+ vane ring design developed under the DOE Advanced Microturbine contract [14]. The quality of coating as a function of gun-angle was independently assessed by thermal spraying a cylinder. The other factors that weighed in on the final feasibility assessment included fixtures, cost, coating uniformity and existing mini-gun technologies. It was established that air plasma spray could not be used to apply environmental barrier coatings (EBCs) of acceptable quality to an integral vane ring assembly. Figure 1b is a pictorial representation of the approach used to assess the relative “accessibility” of the plasma plume to the component. Subsequent coating development for silicon nitride focused on non-line of sight coating methods. The processing routes found most promising were slurry coatings and chemical vapor deposition (CVD). BOND COAT DEVELOPMENT Early work on the development of EBC for silicon nitride (Si3N4) was done under the NASA EPM, DOE CSGT and DOE/ONR funded EBC for Silicon Nitride programs. The EBC developed for silicon carbide (SiC) has been demonstrated to be ineffective for Si3N4 as it caused a debit in room temperature strength of the base material by over 50% [13]. Figure 2 shows the reduction in strength when the 3-layer state-of-the-art EBCSiC is applied to silicon nitride (AS800). A similar strength debit was also seen on other grades of silicon nitride and at elevated temperature the debit in strength was ∼15%. The primary mechanism causing the reduction in the strength of silicon nitride has been identified to be the thermal mismatch between the coating and 145 Copyright © 2007 by ASMEPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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