Heat Resistant Fibers
Development of Structure and Fabrication Technology of Heat Resistant Fibrous Composites.
Tech Area / Field
- MAT-SYN/Materials Synthesis and Processing/Materials
8 Project completed
Senior Project Manager
Karabashev S G
Institute of Solid State Physics, Russia, Moscow reg., Chernogolovka
- Institute of Aviation Materials, Russia, Moscow
- University of Delaware / Center for Composites Manufacturing Science and Engineering, USA, DE, Newark\nGKSS-ForschungZentrum Geesthacht, Germany, Geesthacht\nUniversity of Cambridge / Department of Materials Science and Mettalurgy, UK, Cambridge\nEcole Nationale Supérieure des Mines de Paris / Centre des Matériaux, France, Evry
Project summaryObjectives of the project:
The of the project is to develop a technology of producing heat-resistant fibres and composites capable to work at temperatures as high as 1200°C in critical structural elements of gas turbine such as blades, nozzles, etc. This means that the stress which causes rupture at a necessary time base is about 150 MPa (for the material density 8 g/cm3). The material to be developed is a fibrous composite with an oxide fibre and intermetallic alloy matrix. In the Soviet Union, the activity in the metal-matrix-composite field was always conveyed towards a usage of the resulting materials in ballistic and winged missiles as well as in jet engines for military aircraft. The teams of Solid State Physics Institute (SSPI) and Institute of Aviation Materials (VIAM) were heavily involved in the development of metal matrix composites for such purposes. The experience in this field can now be transferred into peaceful areas.
In particular, the experience of the team of SSPI in producing fibres and composites using non-traditional fabrications routes like internal crystallization method and fabrication of continuous fibres based on oxides, and that of VIAM in producing a special structure of heat-resistant alloys based on Ni3А1 intermetallic compound are important as a base to carry out the Project proposed.
The main point of the technical approach to the problem is a fabrication of the fibres. This is based on a technological idea developed in SSPI. It has been already shown that the idea can be used to organize fabrication process for making continuous oxide fibres with a high production rate and, correspondingly, low cost, unlike the well known EFG-method.
Preliminary experiments have shown that the room temperature strength of Al2O3-ZrO2-Y2O3-fibre/intermetallic matrix composites can be higher than 2000 MPa, strength at 1200°C is about 300 MPa. The creep-rupture is determined by the high- strength fibres and the preliminary experimental data together with calculated values show a possibility to reach a creep strength of about 150 MPa on a necessary time base.
To reach a goal, formulated above, it is planned to perform research along the following lines:
1. Investigation of fibre crystallization process, the development of a necessary experimental setup, obtaining a required quantity of fibres, testing them in various matrices, the development of a pilot apparatus to produce the fibres on a semiindustrial scale.
2. Study of an influence of the fibre on the composition' and structure of the matrix, development of a modified composition and technological process of the matrix alloy based on intermetallic compound Ni3Al.
3. Development of a fabrication route of the composite based on casting of a matrix alloy into a mold filled with the fibres.
4. Investigations of the structure and mechanical properties of the composites including long time properties such as creep, creep rupture, fatigue, and so on.
5. Optimization of microstructure of the fibre, matrix, interface, arid composite as a whole.
6. Optimization of fabrication regimes.
A fabrication technology of refractory fibres and heat-resistant composites for a working temperature as high as 1200°C will be developed. The materials can be used in gas turbines of jet engine for civil airplanes, gas pressure stations for gas transportation pipe lines, electricity production facilities, etc., with energy saving up to 5% of fuel.