Research progress on application and airworthiness compliance validation of ceramic-matrix composites in aeroengines
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摘要: 陶瓷基复合材料(Ceramic-Matrix Composite, CMC)继承了陶瓷材料耐高温、抗腐蚀等优点,克服了陶瓷材料的脆性,相较于高温合金密度更低、高温持久强度更优、可设计性更强,是新一代航空发动机热结构的理想材料。欧美等发达国家自20世纪80年代,经过上百万小时的测试、考核与验证,已经证明CMC代替高温合金的革命性改变已经到来。本文系统分析了CMC多种制备工艺及物理/力学性能,CMC在航空发动机燃烧室、涡轮、排气系统热端部件的结构设计、部件考核以及工程应用等,建立了CMC制备工艺、材料性能、部件设计与工程应用之间的关联关系。从适航角度出发,给出了CMC部件的适航认证要求、适航性设计及符合性验证方法等,并针对法国SAFRAN公司的CMC混合器和中心体、美国GE公司的CMC涡轮外环等进行了案例分析。Abstract: Ceramic-matrix composite (CMC) inherits the advantages of high temperature resistance and corrosion resistance, overcomes the brittleness of monolithic ceramic, and possesses lower density, better high-temperature durability strength and better designability compared with the superalloys, and is the ideal material for the new generation of aeroengine thermal structures. Since the 1980s, Europe and the United States and other developed countries after millions of hours of testing, assessment, and validation, has proved that revolutionary change as substituting a CMC in place of a superalloy has come. This paper systematically analyzes different preparation processes and physical/mechanical properties of CMCs, the structural design, component assessment and engineering applications of CMC in the hot-section components of aeroengines combustion chambers, turbines, and exhaust systems, and establishes the relationships between the CMC preparation process, mechanical properties, component design and engineering applications. From the airworthiness point of view, the airworthiness certification requirements, airworthiness design and compliance validation methods of CMC components are also given. Case studies were also conducted for the CMC mixer and center body of SAFRAN (France) and the CMC turbine shroud of GE (USA).
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Key words:
- Ceramic-matrix composites (CMCs) /
- Aeroengines /
- Combustor chamber /
- Turbine /
- Exhaust system /
- Airworthiness /
- Compliance validation.
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图 7 (a)Solar Centaur 50 S燃气轮机及燃烧室构型;(b)CG NicalonTM SiC/SiC火焰筒;(c)覆盖环境障涂层的Hi-NicalonTM SiC/SiC火焰筒;(d)燃气轮机测试后的Hi-NicalonTM SiC/SiC火焰筒;(e)覆盖FGI的NextelTM 720/alumina火焰筒[13]
Figure 7. (a) Solar Centaur 50 S gas turbine and the configuration of the combustor; (b) CG NicalonTM SiC/SiC liner; (c) Hi-NicalonTM SiC/SiC liner with EBCs; (d) Hi-NicalonTM SiC/SiC liner after gas turbine testing; (e) NextelTM 720/alumina outer liner with FGI surface coating[13]
图 8 (a)SiC/SiC外火焰筒;(b)SiC/SiC内火焰筒;(c)安装在HPBR的外火焰筒;(d)安装在HPBR的内火焰筒;(e)NASA格林研究中心的HPRB;(f)试验后的SiC/SiC内火焰筒[14]
Figure 8. (a) SiC/SiC outer combustor liner; (b) SiC/SiC inner combustor liner; (c) The outer combustor liner installed on HPBR; (d) The inner combustor liner installed on HPBR; (e) HPBR in NASA GRC; (f) The SiC/SiC inner combustor liner after testing [14]
图 10 (a) GE 7 FA燃气轮机SiC/SiC燃烧室火焰筒[16];(b) GE与Allison研制的SiC/SiC燃烧室火焰筒[17];(c) GE公司研制的用于CFM56发动机的多斜孔冷却SiC/SiC燃烧室火焰筒[18];(d) GE为NASA先进亚音速燃烧装置研制的SiC/SiC燃烧室火焰筒[19]
Figure 10. (a) SiC/SiC combustor liner of GE 7 FA gas turbine[16]; (b) SiC/SiC combustor liner developed by GE and Allison[17]; (c) Low emission SiC/SiC combustor liner for CFM 56 engine developed by GE[18]; (d) SiC/SiC combustor sector rig for the NASA ASCR developed by GE[19]
图 16 (a) F7-10涡扇发动机及涡轮外环使用环境;(b) SiC/SiC涡轮外环几何形状、温度场及应力场分析;(c) SiC/SiC涡轮外环支撑结构强度试验及热疲劳试验;(d) SiC/SiC涡轮外环发动机地面测试[26]
Figure 16. (a) F7-10 turbofan engine and operating environment of turbine shroud; (b) Geometry, temperature field, and stress field of SiC/SiC turbine shroud; (c) Hook strength test and thermal fatigue test of SiC/SiC turbine shroud; (d) Ground engine testing of SiC/SiC turbine shroud [26]
图 18 (a)SiC/SiC涡导叶片示意图;(b)MI/CVI SiC/SiC涡导叶片截面CT扫描图;(c)SiC/SiC涡导叶片几何尺寸;(d)NASA GRC 模拟涡轮环境测试台;(e)CVI-SiC/SiC涡导叶片在1371℃模拟涡轮环境测试31小时后表面形貌;(f)MI-SiC/SiC涡导叶片在1371℃模拟涡轮环境测试21小时后表面形貌;(g)MI-SiC/SiC涡导叶片在1371℃模拟涡轮环境测试75小时后表面形貌[29][30][31]
Figure 18. (a) Schematic of SiC/SiC turbine guide vane; (b) CT scan of the cross-section of MI/CVI SiC/SiC turbine guide vanes; (c) Dimensions of SiC/SiC turbine guide vane; (d) Rig testing at NASA GRC; (e) Surface morphology of CVI-SiC/SiC turbine guide vane after 31 h test at 1371℃; (f) Surface morphology of MI-SiC/SiC turbine guide vane after 21 h test at 1371℃; (g) Surface morphology of MI-SiC/SiC turbine guide vane after 75 h test at 1371℃ [29][30][31]
图 21 NASA GRC研制和测试了CMC/陶瓷涡轮导向叶片(a)涡导叶片构型及金属涡导叶片;(b)涡导叶片结构及组成;(c)涡导叶片CMC叶身及内部陶瓷冷却通道;(d)涡导叶片内部冷却孔分布;(e)涡导叶片有限元应力分析;(f)涡导叶片叶身及内部冷却结构;(g)制备成型的涡导叶身;(h)涡导叶片开展燃烧环境测试[34]
Figure 21. CMC/Ceramic turbine guide vane developed and tested by NASA GRC (a) Configuration of turbine guide vane and the metal vane used in the engine; (b) Components of the guide turbine vane; (c) The CMC airfoil and ceramic cooling channel of the guide vane; (d) The distribution of the cooling holes inside of the vane; (e) The stress analysis of the guide vane; (f) The airfoil and inner cooling structure of the guide vane; (g) The airfoil of the guide vane after fabrication; (h) The combustion environment testing of the guide vane [34]
图 24 IHI公司制备并测试了空心SiC/SiC涡导叶片(a)涡导叶片织物结构;(b)制备成型的涡导叶片;(c)加工成型的涡导叶片;(d)涡导叶片CT扫描成像;(e)涡导叶片热循环测试;(f)涡导叶片热冲击测试;(g)IHI公司的IM270燃气轮机;(h)涡导叶片发动机测试[37]
Figure 24. IHI fabricated and tested hollow SiC/SiC turbine guide vane (a) fabric arrangement of the guide vane; (b) the guide vane after molded; (c) the guide vane after machining; (d) CT diagram of the guide vane; (e) Thermal cyclic test of the guide vane; (f) thermal shock of the guide vane; (g) IM270 gas turbine engine; (h) engine testing of the guide vane [37]
图 25 IHI公司设计、制备并测试了实心SiC/SiC涡导叶片(a)涡导叶片三维几何设计图;(b)制备加工成型的涡导叶片;(c)第一次400小时发动机测试、测试后涡导叶片及CT扫描图;(d)第二次862小时发动机测试、测试后涡导叶片及CT扫描图[38]
Figure 25. Solid SiC/SiC turbine guide vane designed, fabricated and tested by IHI (a) 3D geometry diagram of guide vane; (b) Guide vane after fabrication and machining; (c) Guide vane and CT scanning after the 1st engine testing; (d) Guide vane and CT scanning after the 2nd engine testing [38]
图 26 通用电气燃机公司设计与制备的金属/CMC涡导叶片(a)涡导叶片的组成结构;(b)铺层工艺;(c)SiC基体沉积过程;(d)制备加工过程;(e)加工成型并沉积EBC后的涡导叶片[39]
Figure 26. Metal/CMC turbine guide vane developed by GE gas power (a) Component and assembly of guide turbine vane; (b) Ply lamination of guide vane; (c) Densification of SiC matrix; (d) Fabrication and processing of guide vane; (e) Guide turbine vane with EBC after machining [39]
图 27 西北工业大学制备与测试SiC/SiC双联涡导叶片(a)制备加工后的涡导叶片;(b)CT扫描图;(c)热冲击试验;(d)1400℃热冲击试验及试验后涡导叶片形貌;(e)1480℃热冲击试验及试验后涡导叶片形貌[40]
Figure 27. SiC/SiC twin turbine guide vane fabricated by Northwestern Polytechnical University (a) Twin guide vane after fabrication and machining; (b) CT scanning diagram of the guide vane; (c) Cyclic thermal shock testing of the guide vane; (d) Surface morphology of the guide vane after 1400 ℃ cyclic thermal shock testing; (e) Surface morphology of the guide vane after 1480 ℃ cyclic thermal shock testing [40]
图 28 (a)SiC/SiC低压涡轮导叶;(b)涡轮导叶的热疲劳试验;(c)温度载荷谱;(d)试验后导叶表面出现基体凹坑;(e)凹坑附近扫描电镜分析图;(f)裸露的SiC纤维发生氧化[41]
Figure 28. (a) SiC/SiC low pressure turbine guide vane; (b) Thermal fatigue experiments of turbine guide vane; (c) Temperature load spectrum;(d) Matrix pits occurred on the vane surface after thermal fatigue experiments; (e) Scanning electronic microscopy photo of the damage region around the matrix pits; (f) Oxidation of exposed SiC fibers [41]
图 29 (a)无冷却MI-SiC/SiC涡轮转子叶片(淡黄色叶片是有涂层;灰色叶片无涂层);(b)低压涡轮SiC/SiC涡轮转子叶片在F414发动机进行测试(淡黄色叶片是有涂层;灰色叶片无涂层);(c)在巴黎航展展示的涡轮转子叶片[42]
Figure 29. (a) Uncooled MI-SiC/SiC turbine blade (yellowish blades are EBC-coated, and gray blades are uncoated); (b) Full stage SiC/SiC blades installed on F414 engine for testing (yellowish blades are EBC-coated, and gray blades are uncoated); (c) SiC/SiC turbine blade presented by GE at the Paris Air Show in[42]
图 31 NASA GRC与GE公司研制的带冷却涡轮转子叶片(a)叶片内部双腔冷却结构;(b)叶片榫头拔出试验试样;(c)叶片榫头拔出破坏模式1;(d)叶片榫头拔出破坏模式2[44]
Figure 31. Cooled turbine blade developed by NASA GRC and GE (a) Airfoil cross-section with double cavity; (b) Flat airfoil with dovetail for pull testing; (c) Damage mode 1 for the blade pull testing; (d) Damage mode 2 for the blade pull testing [44]
图 32 (a)低压涡轮转子叶片构型;(b)三种榫头设计方案;(c)两种叶身设计方案;(d)叶冠的旋转测试;(e)SiC/SiC低压涡轮转子叶片;(f)转子叶片旋转测试;(g)转子叶片振动疲劳测试[45]
Figure 32. (a) Configuration of low pressure turbine blade; (b) Three types of dovetail; (c) Two types of airfoil; (d) Spin test of tip shroud; (e) SiC/SiC low pressure turbine blade; (f) Spin test of blade; (g) Vibration fatigue test of blade[45]
图 34 (a) C/SiC轮盘CT扫描图;(b) C/SiC叶盘CT扫描图;(c) C/SiC叶盘表面形貌;(d)极向叶盘试验后形貌;(e)准各向同性叶盘试验后形貌;(f)叶根处出现裂纹[47]
Figure 34. (a) CT scanning of C/SiC disk; (b) CT scanning of C/SiC blisk; (c) Surface morphology of C/SiC blisk; (d) Surface morphology of polar blisk after testing; (e) Surface morphology of quasi-isotropic blisk after testing; Cracks at blade [47]
图 38 (a) SiC/SiC涡轮叶盘制备(a-1:SiC/SiC涡轮叶盘SiC纤维预制体设计方案;a-2:SiC纤维预制体SiC基体致密化;a-3和a-4:SiC/SiC涡轮叶盘在线加工成型过程);(b) SiC/SiC涡轮叶盘室温超转试验(b-1: 超转破坏后的残骸;b-2:碎块体视镜照片);(c) SiC/SiC涡轮叶盘发动机台架试验考核(c-1:安装在发动机内的SiC/SiC涡轮叶盘;c-2:N=994次n=60000 r/min试验后的轮盘表面状态;c-3: 表面氧化形貌; c-4: 叶盘CT扫描图)[51]
Figure 38. (a) Fabrication of SiC/SiC turbine blisk (a-1: Design of SiC fiber preform in SiC/SiC turbine blisk; a-2 SiC matrix densification on the SiC fiber preform; a-3 and a-4: On-line machining process of SiC/SiC turbine blisk); (b) Overspeed rotation testing of SiC/SiC turbine blisk (b-1: Fragments after over rotation damage; b-2: Fragment stereoscopic photo); (c) Engine bench testing of SiC/SiC turbine blisk (c-1: SiC/SiC turbine blisk installed in the test engine; c-2: Surface morphology of SiC/SiC turbine blisk after N=994 tests at n=60000 r/min; c-3: Surface oxidation morphology; c-4: CT scanning of blisk after testing) [51]
图 40 CERASEP® A410和SEPCARBINOX® A500 密封片地面发动机试验与飞行试验 (a) CMCs密封片安装在F100-PW-229发动机上进行地面测试[57];(b) CMCs密封片经过发动机地面测试后表面形貌及热成像图[57];(c) CMCs密封片发动机地面测试后剩余强度试验[57];(d) SEPCARBINOX® A500密封片首次在F16战斗机上进行了测试[58];(e) SEPCARBINOX® A500密封片在F15战斗机上进行了飞行测试[58];(f) SEPCARBINOX® A500密封片表面光学观察[58];(g) SEPCARBINOX® A500密封片热成像观察[58];(h)剩余强度测试11个试样的拉伸应力应变曲线[58];(i) 试样拉伸断口显微形貌[58]
Figure 40. Ground engine testing and flight testing of CERASEP® A410 and SEPCARBINOX® A500 seals (a) Ground F100-PW-229 engine testing of CMCs seals[57]; (b) Surface morphology and thermography image of CMCs seals after engine testing[57]; (c) Residual strength testing of CMCs seals after engine testing[57]; (d) First flight testing of SEPCARBINOX® A500 seals on F16 fighter aircraft[58]; (e) Flight testing of SEPCARBINOX® A500 seals on F15 fighter aircraft[58]; (f) Optical photograph of SEPCARBINOX® A500 seal[58]; (g) Thermography image of SEPCARBINOX® A500 seal[58]; (h) Tensile stress-strain curves of 11 samples for residual strength testing[58]; (i) Microstructure morphology of fracture tensile specimen[58]
图 41 (a) F414-GE-400发动机尾喷口调整片与密封片工作示意图;(b) F414-GE-400发动机尾喷口安装SiC/C调节片与密封片;(c) F414-GE-400发动机安装GE公司的氧化物/氧化物密封片与调节片[53]
Figure 41. (a) Schematic of nozzle flap and seal on F414-GE-400; (b) SiC/C flaps and seals installed on F414-GE-400; and (c) Oxide/Oxide flaps and seals installed on F414-GE-400[53]
图 42 (a) CERASEP® A40 C混合器;(b) CERASEP® A40 C混合器在CFM56-5 C发动机上进行地面测试;(c) CERASEP® A40 C中心体;(d)CERASEP® A40 C中心体在A320飞机进行飞行验证[43][59]
Figure 42. (a) CERASEP® A40 C mixer; (b) Ground testing of CERASEP® A40 C mixer on CFM56-5 C engine; (c) CERASEP® A40 C centerbody; (d) Flight demonstration of CERASEP® A40 C centerbody on A320[43][59]
图 43 (a)氧化物/氧化物中心体;(b)氧化物/氧化物外环;(c)组装后的排气系统;(d)Trent 1000发动机地面试车台;(e)氧化物/氧化物排气系统在Trent 1000发动机开展地面测试;(f)氧化物/氧化物排气系统在B787飞机进行飞行测试[60][61]
Figure 43. (a) Oxide/Oxide centerbody; (b) Oxide/Oxide outer ring; (c) Oxide/Oxide exhaust system assembly; (d) Trent 1000 ground engine bench; (e) Ground testing of Oxide/Oxide exhaust system on Trent 1000; (f) Flight testing of Oxide/Oxide exhaust system on B787[60][61]
图 45 (a)采用氧化物/氧化物排气系统的Passport 20发动机及环球7500和8000公务机;(b)金属模具经过特殊脱模处理后,按照指定的铺层要求铺放在混合器模具上;(c)将铺设好的叠层抽真空,转移到热压罐中,在高温高压下固化;(d)固化后,取出真空袋,将零件脱模,然后转移到烧结炉;(e)将零件从烧结炉中取出并冷却,在五轴数控铣床上进行加工;(f)对零件进行表面测量等质量控制;(g)对零件进行无损检测;(h)在固化、加工、检查后,将金属零件与CMC部件连接起来;(i)氧化物/氧化物排气系统安装在Passport 20发动机上[63]
Figure 45. (a) The Passport 20 engine adopting Oxide/Oxide exhaust system powering Global 7500 and 8000 business jet; (b) After the metal molds are treated with a special mold release, the cut patterns are hand-laid on the mixer molds in the specified ply schedule; (c) The finished layups are vacuum bagged and transferred to an autoclave for cure under high heat and pressure; (d) After cure, the vacuum bag is removed, the parts are de-molded and then transferred to the sintering oven; (e) After the parts are removed from the sintering furnace and cooled, they are machined on this 5-axis CNC milling machine; (f) Quality control inspection includes surface measurements on the parts; (g) Nondestructive inspection on the parts; (h) Following cure, machining and inspection, metal details and ceramic components are joined; (i) Oxide/Oxide exhaust system is installed on the Passport 20 engine [63]
表 1 陶瓷基复合材料(CMC)在航空发动机热端部件的应用以及采用的制备工艺
Table 1. Application of Ceramic-Matrix Composite (CMC) in hot-section components of aero engines and related fabrication process
Year Country Programs Institute & Company CMCs Fabrication Engines Components TRL 1989 France ‒ Société Européenne de Propulsion (SEP) CERASEP® A373 NicalonTM SiC/[Si-B-C] Chemical Vapor Infiltration (CVI) M53-2 Nozzle Inner Flap 8 1990 USA HSCT NASA Gleen Research Center (GRC),
P&W, Honeywell2 D SylramicTM SiC/SiC Slurry Cast- Melt Infiltration (MI) ‒ Combustor Liner, Heatshield, Sidewall 4 1992-2004 USA CSGT DoE, Solar Turbines, B.F. Goodrich Aerospace (BFG), Dupont Lanxide Composites, Inc. (DLC), UTRC, AlliedSignal Composites, Inc. (ACI), Honeywell Advanced Composites, Inc. (HACI), ACK-COCI 2 D CG NicalonTM SiC/SiC
2 D Hi-NicalonTM SiC/SiC 2 D
2 D NextelTM 720/AluminaCVI
Slurry Cast MI, Slurry InfiltrationSolar Centaur 50 s Combustor Liner 5 1994 Japan ‒ Research Institute of Advanced Material Gas-Generator Co., Ltd TyrannoTM SiC/SiC CVI+PIP (polymer infiltration and pyrolysis) ‒ Turbine Blisk 4 1996 France ‒ SEP SEPCARBINOX® A262 C/SiC CVI M88-2 Nozzle Outer Flap 9 1998-1999 USA ‒ GE SiC/SiC Prepreg-MI GE 7 FA Combustor Liner 5 1999 Japan ‒ Ishikawajima-Harima Heavy Industries (IHI) 3D Si-Ti-C-O TyrannoTM SiC/SiC CVI+PIP ‒ Turbine Blisk 4 2000 USA IHPTET GE, Allison SiC/SiC Prepreg-MI XTC76/3 Combustor Liner 4 2000 USA ‒ NASA GRC,
NASA Marshall Space Flight Center (MSFC)C/SiC CVI ‒ Turbine Blisk 4 2001 Japan ‒ Japan Defense Agency - Propulsion Division
Kawasaki Heavy Industries Ltd.3D TyrannoTM ZMI SiC/SiC PIP 50 kN-thrust class augmented turbofan engine Reverse-flow annular combustor liner 4 2001 Japan ‒ Japan Aerospace Exploration Agency (JAXA) 3D C/C CVI+PIP ‒ Turbine Blisk 4 2003 USA UEET
TECH56GE HyperComp® SiC/SiC Slurry Cast-MI CFM56 Combustor liner 5 2004-2006 USA UEET NASA GRC, GE, Goodrich Y-woven SylramicTM SiC/SiC Slurry Cast-MI ‒ Turbine Guide Vane 5 2005 USA UEET P&W,
United Technologies Research Center (UTRC)Y-woven SylramicTM SiC/SiC Slurry Cast-MI FT8 Turbine Guide Vnae (Hollow) 5 2005 France ‒ Snecma Propulsion Solide (SPS) SEPCARBINOX® A500 C/[Si-B-C] CVI F100-PW-229 Nozzle Flap 8 2005-2015 France ‒ SAFRAN CERASEP® A40 C SiC/SiC CVI CFM56 Mixer & Centebody 9 2007 France ‒ SAFRAN CERASEP® A410 Hi-NicalonTM SiC/[Si-B-C] CVI ‒ Flame holder in Afterburner 5 2008-2010 France ‒ SAFRAN CERASEP® A40 C SiC/SiC CVI CFM56-5 B LPT blade 6 2008-2015 USA ‒ GE, US Army Aviation Applied Technology Directorate (AATD) SiC/SiC Prepreg-MI F414 LPT blade 5 2009 France TECH56 SAFRAN CERASEP®A410 CVI CFM56 Combustor Liner 6 2009 Germany HiPOC Rolls-Royce Germany
EADS Innovation Works
ASTRIUM Space Transportation
German Aerospace Center, DLRWHIPOX(Wound Highly Porous Oxide Matrix CMC)
UMOXTM
OXIPOL®(Oxide CMC based on Polymers)Slurry Infiltration MI
PIP‒ Tubular Combustor Liner 4 2010 USA EPR NASA GRC, GE, P&W HiPerCompTM Gen-II 2 D Hi-NicalonTM Type S SiC/SiC Prepreg-MI ‒ Outer and Inner Combustor Liners 4 2010 USA ‒ UTRC, P&W Canada 2 D TyrannoTM SA SiC/SiC Slurry-Cast MI PW 206 Combustor Dome, Large Entry Duct (LED), Small Entry Duct (SED) 4 2010 USA ERA NASA GRC, GE, Hypertherm Hi-NicalonTM Type S SiC/SiC Prepreg-MI
CVI‒ HPT Guide Vane 5 2010 USA ERA NASA GRC, Rolls-Royce LibertyWorks®(RRLW)
AFRL, ATK-COIC, Support Service LLC2 D NextelTM 610/AS Slurry Infiltration ‒ Mixer 6 2010-2012 Japan ‒ IHI 2 D/3D TyrannoTM ZMI SiC/SiC CVI+SPI(solid phase infiltration)+PIP IM270 Turbine Guide Vane (Hollow) 5 2011 USA ‒ GE 2 D NextelTM 720/Alumina Slurry Infiltration F414 Nozzle Seals 9 2014 USA T3 NASA GRC SylramicTM-iBN/SiC CVI+PIP ‒ Turbine Guide Vane (Hollow) 5 2014 USA CLEEN Boeing, ATK-COIC, Albany Engineered Composites (AEC), Rolls-Royce 2 D NextelTM 610/AS Slurry Infiltration Trent 1000 Nozzle & Centerbody 7 2015 USA ‒ GE HyperComp® SiC/SiC Prepreg-MI LEAP-1 A Turbine Shroud 9 2015-2019 China ‒ AECC Commercial Aircraft Engine Co., Ltd SiC/SiC CVI ‒ HPT Guide Vane 3 2015-2021 Japan ‒ IHI, JAXA Hi-NicalonTM Type S SiC/SiC CVI+MI F7-10 Turbine Shroud 5 2015 Japan ‒ IHI 3D TyrannoTM ZMI SiC/SiC CVI+SPI+PIP IM270 Turbine Guide Vane (Solid) 5 2015 USA A Fully NonmetallicGas Turbine Engine Enabled by Additive Manufacturing NASA GRC SiC/SiC Binder Jet Process ‒ Single/Twin-aligned/Four aligned HPT Guide Vane 3 2016 USA ‒ GE HyperComp® SiC/SiC Prepreg-MI LEAP-1 B Turbine Shroud 9 2016 Japan ‒ IHI TyrannoTM ZMI SiC/SiC CVI+SPI+PIP ‒ LPT blade 4 2016
2018USA ‒ GE 2 D NextelTM 720/Alumina Slurry Infiltration Passport 20 Mixer, Centerbody, Cowling 9 2018 USA ‒ Raytheon Technologies Research Center (RTRC) SiC/SiC ‒ FT4000 Turbine Guide Vane (Hollow) 4 2018 USA ‒ GE HyperComp® SiC/SiC Prepreg-MI GE-9 X Inner and Outer Combustor Liner, Turbine Shroud 9 2020 China ‒ Beihang University (BUAA) 2 D plain-woven SiC/SiC CVI ‒ LPT Guide Vane 3 2021 USA ‒ GE Gas Power SiC/SiC Prepreg-MI HA Turbine Guide Vane (Hollow) 3 2021 China ‒ Northwestern Polytechnical University (NPU)
AECC Hunan Aviation Powerplant Research Institute
Nanjing University of Aeronautics and Astronautics (NUAA)
Xiangtan University
Nanchang Hangkong University2 D plain-woven Amosic-3TM SiC/SiC CVI ‒ Twin-aligned HPT Turbine Guide Vane (Hollow) 4 2022 China ‒ Northwestern Polytechnical University (NPU)
AECC Hunan Aviation Powerplant Research Institute
Nanjing University of Aeronautics and Astronautics (NUAA)
Wuhan University of Technology
Nanchang Hangkong UniversitySpider Web Structure (SWS) SiC/SiC CVI ‒ Turbine Blisk 7 2023 China ‒ Beihang University (BUAA) SiC/SiC CVI ‒ LPT blade 4 表 2 典型CVI/PIP/MI SiC/SiC物理和力学属性
Table 2. Physical and mechanical properties of CVI/PIP/MI SiC/SiC
Parameters CERASEP®A400 CERASEP®A410 CERASEP®A415 CERASEP®A416 N22® N24® N26® HiperComp®/
Slurry CastHiperComp®/
PrepregAS-720 N Fiber NicalonTM Hi-NicalonTM Hi-NicalonTM Hi-NicalonTM S Sylramic Sylramic-iBN Sylramic-iBN Hi-Nicalon Hi-Nicalon Nextel 720 Matrix Si-B-C Si-B-C Si-B-C Si-B-C SiC SiC SiC SiC SiC AS Fiber volume fraction/(%) 35 35 40 40 36 36 36 35-38 22-24 44 Density/(g/cm3) 2.2-2.3 2.2-2.3 2.4-2.5 2.4-2.5 2.85 2.76 2.52 2.70
2.66(1200℃)2.80
2.76(1200℃)2.73 Porosity/(%) 12-14 12-14 5-7 5-7 2 2 14 6 <2 48 Elastic Modulus /(GPa) 180(RT) 220(RT)
210(873 K)
205(1473 K)230(RT) 240(RT) 250(RT) 220(RT) 200(RT) 196(RT)
144(1200℃)285(RT)
243(1200℃)76(RT) Ultimate Tensile Strength/(MPa) 300(RT) 315(RT)
320(873 K)
325(1473 K)370(RT) 360(RT) 400(RT) 310(RT) 330(RT) 358(RT)
271(1200℃)321(RT)
224(1200℃)195(RT) Fracture strain/(%) 0.5(RT) 0.5(RT)
0.6(873 K)
0.6(1473 K)0.6(RT) 0.52(RT) 0.35(RT) 0.30(RT) 0.40(RT) 0.74(RT)
0.52(1200℃)0.89(RT)
0.31(1200℃)‒ Interlaminar Shear Strength/(MPa) ‒ 30 ± 5 ‒ ‒ 70(RT) ‒ ‒ ‒ 135(RT)
124(1200℃)‒ Thermal Expansion Coefficient
(//)/(10-6/K)4.5(RT) 4.5(RT) 4.5(RT) 4.5(RT) ‒ ‒ ‒ 4.34(RT) 3.73(RT) 6.3(RT) Thermal Conductivity Coefficient (//) /(W/m.K) 7(1000℃) 7(1000℃) 8(1000℃) 9(1000℃) ‒ ‒ ‒ 30.8(RT)
14.8(1200℃)33.8(RT)
14.7(1200℃)2.0(RT) Thermal Conductivity Coefficient (⊥)/(W/m.K) 2(1000℃) 2(1000℃) 5(1000℃) 6(1000℃) 24(204℃)
15(1204℃)41(204℃)
17(1204℃)26(204℃)
10(1204℃)22.5(RT)
11.8(1200℃)24.7(RT)
11.7(1200℃)2.0(RT) 表 3 陶瓷基复合材料适航规章、咨询通告、工业手册/技术出版物与力学/物理性能测试标准
Table 3. Airworthiness Regulations, Advisory Circular, Industry Specifications and Technical Reports, and Mechanical Physical Properties Testing Standards for CMCs
Airworthiness Regulations CFR 33.15[67] Materials CFR 33.19[67] Durability CFR 33.27[67] Turbine, compressor, fan and turbosupercharger rotor overspeed CFR 33.62[67] Stress analysis CFR 33.70[67] Engine life – limited parts CFR 33.75[67] Safety analysis Advisory Circular AC 20-107 B[68] Composite Aircraft Structure AC 21-26 A[69] Quality Control for the Manufacture of Composite Structures AC 25.571-1 D[70] Damage Tolerance and Fatigue Evaluation of Structure AC 25.1309-1 A[71] System Design and Analysis Industry Specifications and Technical Reports CMH−17 Vol. 5[7] Ceramic Matrix Composites ARP 5150 A [72] Safety Assessment of Transport Airplanes in Commercial Service PS-ANM-25-05[73] Transport Airplane Risk Assessment Methodology Handbook Mechanical Testing Standards ASTM C1275-18[74] Standard Test Method for Monotonic Tensile Behavior of Continuous Fiber-Reinforced Advanced Ceramics with Solid Rectangular Cross-Section Test Specimens at Ambient Temperature ASTM C1359-13[75] Standard Test Method for Monotonic Tensile Strength Testing of Continuous Fiber-Reinforced Advanced Ceramics with Solid Rectangular Cross-Section Test Specimens at Elevated Temperatures ASTM C1468-19 a[76] Standard Test Method for Transthickness Tensile Strength of Continuous Fiber-Reinforced Advanced Ceramics at Ambient Temperature ASTM C1292-22[77] Standard Test Method for Shear Strength of Continuous Fiber-Reinforced Advanced Ceramics at Ambient Temperatures ASTM C1425-19[78] Standard Test Method for Interlaminar Shear Strength of 1 D and 2 D Continuous Fiber-Reinforced Advanced Ceramics at Elevated Temperatures ASTM C1292-22[79] Standard Test Method for Shear Strength of Continuous Fiber-Reinforced Advanced Ceramics at Ambient Temperatures ASTM C1358-18[80] Standard Test Method for Monotonic Compressive Strength Testing of Continuous Fiber-Reinforced Advanced Ceramics with Solid Rectangular Cross Section Test Specimens at Ambient Temperatures ASTM C1341-13[81] Standard Test Method for Flexural Properties of Continuous Fiber-Reinforced Advanced Ceramic Composites Physical Properties Testing Standards CEN ENV 1159-1[82] Advanced technical ceramics - Ceramic composites - Thermophysical properties - Part 1: Determination of thermal expansion CEN ENV 1159-2[83] Advanced technical ceramics - Ceramic composites - Thermophysical properties - Part 2: Determination of thermal diffusivity CEN ENV 1159-3[84] Advanced Technical Ceramics - Ceramic Composites, Thermophysical Properties - Part 3: Determination of Specific Heat Capacity -
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