Completed funded project

Next generation gas turbines will have to increase efficiency, reduce emissions and lower fuel consumption. The use of metal alloys is technically exhausted with cooling concepts and coatings. Ceramic Matrix Composites (CMC) based on highly rigid SiC ceramic fibres are in principle suitable as alternative construction materials, as they are resistant to high temperatures, light, damage-tolerant and resistant to thermal shock. However, the manufacturing processes for SiC/SiC-CMC are not yet stable and currently expensive, and products are not freely available on the market. For these reasons, the Fraunhofer ADVANCER Alliance is developing an overall process that will lead to reproducible material properties and prototype components.

The main objective was to develop SiC/SiC-CMC for use in gas turbines, thermoprocessing plants and reactor technology with potential for up-scaling the entire production chain. Through the project, Fraunhofer was to achieve a unique position in component and microstructure design and in high-temperature testing.

• Simulation of a low-stress component design for SiC/SiC-CMC by varying the laminate structure
  
• Functional wet chemical fibre coating as BN/SiC double layer leads to fibre pull-out and strength increase of PIP-CMC (Polymere Infiltration Pyrolysis)
  
• Load-compliant fibre preforms in the form of UD prepregs for multilayer construction
  
• High-strength, damage-tolerant PUP-CMC with strength > 400 MPa and elongation > 0,5 %
• Efficient processing technology for PIP-CMC: high quality surfaces and edges as well as excellent shape accuracy
  
• Corrosion-resistant component coating by bond coat based on zirconium titanate and zirconium oxide (ZT-ZO)
  
• Construction of test benches for standard-compliant tensile and bending tests as well as ultrasonic testing by CMC