LI Longbiao. Research progress on application and airworthiness compliance validation of ceramic-matrix composites in aeroengines[J]. Acta Materiae Compositae Sinica, 2025, 42(1): 54-87. DOI: 10.13801/j.cnki.fhclxb.20240623.002
Citation: LI Longbiao. Research progress on application and airworthiness compliance validation of ceramic-matrix composites in aeroengines[J]. Acta Materiae Compositae Sinica, 2025, 42(1): 54-87. DOI: 10.13801/j.cnki.fhclxb.20240623.002

Research progress on application and airworthiness compliance validation of ceramic-matrix composites in aeroengines

More Information
  • Received Date: April 29, 2024
  • Revised Date: June 08, 2024
  • Accepted Date: June 17, 2024
  • Available Online: June 23, 2024
  • Published Date: June 23, 2024
  • Ceramic-matrix composites (CMCs) inherit the advantages of high temperature resistance and corrosion resistance, overcome the brittleness of monolithic ceramic, and possess lower density, better high-temperature durability strength and better designability compared with the superalloys, and are 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 CMCs 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 CMCs in the hot-section components of aeroengines combustion chambers, turbines, and exhaust systems, and establishes the relationships between the CMCs 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 CMCs components are also given. Case studies were also conducted for the CMCs mixer and center body of SAFRAN (France) and the CMCs turbine shroud of GE (USA).

  • Objectives 

    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. 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).

    Methods 

    The application of CMC hot-section components in aeroengines covers intermediate-temperature (700~1000C) intermediate-load (<120 MPa) static components (e.g., nozzle seal/regulator, mixer/center body, etc.), high-temperature (1000~1300C) intermediate-load (<120 MPa) static components (e.g., combustor liner, flame stabilizer, turbine shroud, turbine guide vane, etc.), high-temperature and high-load (σ ≈ 300 MPa) rotor parts (e.g., turbine blade, turbine blisk, etc.). The CMC regulator/seal, turbine shroud, mixer/center body, etc. have completed full life-cycle validation and entered into operation and batch production; the CMC combustor liner, turbine guide vane, etc. are undergoing full life-cycle validation and are expected to enter into the operation; while the CMC turbine blade and turbine disk, etc. have entered into field testing.

    Results 

    CMC components follow the "process-property-structure-component" integrated design idea. Changes in the parameters of the CMC fabrication process will have an impact on its mechanical properties, which in turn affects the strength and stiffness of the CMC structure, as well as the reliability and durability of the components during operation. According to the airworthiness documents, different methods are acceptable as long as the structural compliance verification requirements are met. The airworthiness compliance verification method for a specific CMC component depends on the structural characteristics of the actual component, available databases, and experience with similar structures that have been adopted. In the field of airworthiness compliance verification of CMC components, SAFRAN (France) and GE (USA) have rich experience in airworthiness verification and have formed mature and standardized airworthiness compliance verification ideas, processes, models, methods, tools and technology systems.Conclusions:After forty years of development, CMC has shown great performance advantages. After millions of hours of testing, examination and verification, it has been proved that the revolutionary era of CMC replacing high-temperature alloys has come. The gap between China and developed countries such as Europe and the United States is obvious in terms of the application scope of CMC hot-section components in aeroengines, integrated design of "process-performance-structure-component", assessment system, cumulative assessment time, and airworthiness compliance verification, etc. It is suggested that the design, assessment and application of CMC hot-section components in aeroengines need to pay attention to: ① Establish the integrated design method of CMC "process-performance-structure-component", shorten the development cycle of CMC engineering application, and accelerate the application of CMC hot-section components in aeroengines. ② Establish the airworthiness design of CMC hot-section components for different applications (e.g., combustion chamber, turbine and exhaust system, etc.) and the building-block airworthiness verification approach, and establish the theory and approach system for the design, preparation, evaluation and verification of CMC aeroengine hot-section components. ③ Propose a set of airworthiness compliance verification process and method for CMC hot-section components.

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