Session: Poster Session

Paper Number: 159433

Development of All-Oxide Cmc With 3d Braided Fiber Reinforcements for Hot Gas Components 

The ongoing search for advanced materials capable of withstanding the harsh conditions of gas turbine operation has led to interest in all-oxide ceramic matrix composites (CMCs) as a possible high-temperature, high-strength material due to their exceptional oxidation stability and corrosion resistance. These properties are critical to improving the combustion of both conventional and synthetic fuels, thereby increasing plant efficiency and reducing emissions. This poster will present the status of a pressure slip casting process tailored to produce 3D braided fiber reinforced CMCs specifically designed for the challenging environmental conditions found in the hot gas sections of modern turbines.

In contrast to conventional manufacturing processes, which often limit the scalability and design flexibility of CMCs, the newly developed process at RWTH Aachen University's  Institute of Textile Technology (ITA) integrates the use of 3D braids with automatized pressure slip casting. This innovative approach enables the production of near-net-shape components, which significantly reduces the amount of post-processing required and enables the complex geometries of modern turbine designs. The process uses a matrix system of Al2O3-YSZ-RBAO reinforced with 3M Nextel 610 alumina fibers, which significantly increases the damage tolerance and service life of the composite material. A comprehensive thermomechanical model has been developed to demonstrate the effectiveness of this process. These simulations are essential to evaluate the performance of the material under the extreme conditions typical of turbine applications, focusing on the response of the structure to thermal and mechanical loading.

The final outcome of this project, described in the poster, is the fabrication of a demonstrator component - a solid oxide CMC stator blade and turbine nozzle. This demonstrator not only demonstrates the practical application of the materials and processes developed, but also serves as an important benchmark for evaluating the impact of these new turbine materials on the overall performance of the turbine.

Presenting Author: Jonathan Wüllner Institut fuer Textiltechnik of RWTH Aachen University

Presenting Author Biography: Jonathan Wüllner is a mechanical engineering student at RWTH Aachen University, where he also works as a student assistant at the Institute of Textile Technology. His research focuses on the development of new tools and equipment for the pressure slip casting of fiber-reinforced ceramics. In particular, Jonathan is involved in adapting process technologies to enable the production of ceramic matrix composite (CMC) components for energy-related applications. His efforts are contributing to the advancement of manufacturing capabilities in high performance ceramic engineering with the goal of improving the efficiency and effectiveness of materials used in energy systems.

Authors:

Fabian Jung Institut für Textiltechnik of RWTH Aachen University
Jonathan Wüllner Institut fuer Textiltechnik of RWTH Aachen University