U.S. patent application number 15/573928 was filed with the patent office on 2018-10-11 for hybrid component comprising a metal-reinforced ceramic matrix composite material.
The applicant listed for this patent is Siemens Energy, Inc.. Invention is credited to Kimber-Lee Brown, Zachary D. Dyer, Phillip W. Gravett, Jay A. Morrison, Sachin R. Shinde.
Application Number | 20180292090 15/573928 |
Document ID | / |
Family ID | 55315690 |
Filed Date | 2018-10-11 |
United States Patent
Application |
20180292090 |
Kind Code |
A1 |
Dyer; Zachary D. ; et
al. |
October 11, 2018 |
HYBRID COMPONENT COMPRISING A METAL-REINFORCED CERAMIC MATRIX
COMPOSITE MATERIAL
Abstract
A hybrid metal-reinforced ceramic matrix composite (CMC)
material component is provided having a body including a ceramic
matrix composite material and a metal skeleton structure
encompassing at least a portion of the body. A retaining structure
carried by the metal skeleton structure is further included to
induce a compressive force on the body to limit movement of the
body and the metal skeleton structure relative to one another and
enable the metal skeleton structure to carry a greater amount of an
external load than the body.
Inventors: |
Dyer; Zachary D.; (Chuluota,
FL) ; Shinde; Sachin R.; (Oviedo, FL) ;
Gravett; Phillip W.; (Orlando, FL) ; Morrison; Jay
A.; (Mims, FL) ; Brown; Kimber-Lee; (Oviedo,
FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Siemens Energy, Inc. |
Orlando |
FL |
US |
|
|
Family ID: |
55315690 |
Appl. No.: |
15/573928 |
Filed: |
June 30, 2015 |
PCT Filed: |
June 30, 2015 |
PCT NO: |
PCT/US2015/038574 |
371 Date: |
November 14, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F23R 3/60 20130101; F23R
2900/00017 20130101; F23R 3/007 20130101 |
International
Class: |
F23R 3/60 20060101
F23R003/60; F23R 3/00 20060101 F23R003/00 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED DEVELOPMENT
[0001] Development for this invention was supported in part by
Contract No. DE-FE0023955, awarded by the United States Department
of Energy. Accordingly, the United States Government may have
certain rights in this invention.
Claims
1. A hybrid component comprising: a body comprising a ceramic
matrix composite material; a metal skeleton structure encompassing
at least a portion of the body and extending between a base and a
top of the body; and a retaining structure carried by the metal
skeleton structure effective to induce a compressive force on the
body to limit movement of the body and the metal skeleton structure
relative to one another and allow the metal skeleton structure to
carry a greater amount of an external load than the body.
2. The component of claim 1, wherein the metal skeleton structure
comprises an alloy material.
3. The component of claim 2, wherein the alloy material has a
melting point of from 450-600.degree. C.
4. The component of claim 1, wherein the metal skeleton structure
comprises a mating structure such that the component can be
connected to another structure.
5. The component of claim 4, wherein the mating structure comprises
a circumferential flange or tabs for attachment of the component to
another structure.
6. The component of claim 1, wherein the metal skeleton structure
comprises a plurality of ribs extending radially from a base
portion thereof.
7. The component of claim 6, wherein one of the body and the ribs
comprises a plurality of channels configured to receive a portion
of the other of the body and the ribs therein.
8. The component of claim 7, wherein the body comprises a plurality
of channels, and wherein the ribs are configured for slidable
insertion into the plurality of channels.
9. The component of claim 1, wherein the retaining structure
comprises a retaining ring disposed about the metal skeleton
structure and a plurality of fasteners configured to cause the
retaining ring to induce a compressive force on the body upon
tightening of the fasteners.
10. The component of claim 1, wherein the body comprises a
plurality of stacked laminate plates, each plate comprising the
ceramic matrix composite material.
11. A method for forming a hybrid component comprising: mating a
body comprising a ceramic matrix composite material with a metal
skeleton structure such that the metal skeleton structure
encompasses at least a portion of the body and extends between a
base and a top of the body; and supplying a compressive force on
the body via a retaining structure carried by the metal skeleton
structure which limits movement of the body and the metal skeleton
structure relative to one another and allows the metal skeleton
structure to carry a greater amount of an external load than the
body.
12. The method of claim 11, wherein the supplying is done by:
disposing a retaining ring about the metal skeleton structure; and
tightening a plurality of fasteners on the retaining ring to induce
a compressive force on the body.
13. The method of claim 11, wherein the metal skeleton structure
comprises a plurality of ribs, and wherein on of the body and the
ribs comprises a plurality of channels configured to receive a
portion of the other of the body and the ribs therein.
14. The method of claim 13, wherein the body comprises a plurality
of channels, and wherein the method further comprises slidably
inserting the ribs into the channels of the body.
15. The method of claim 11, wherein the metal skeleton structure
comprises an alloy material.
16. The method of claim 11, wherein the alloy material has a
melting point of from 450-600.degree. C.
17. The method of claim 11, wherein the metal skeleton structure
comprises a mating structure such that the component can be
connected to another structure.
18. The method of claim 11, wherein the mating structure comprises
a circumferential flange for attachment of the component to another
structure.
19. The method of claim 11, wherein the body comprises a plurality
of stacked laminate plates, each plate comprising the ceramic
matrix composite material.
Description
FIELD
[0002] The present invention relates to high temperature components
for use in high temperature environments such as gas turbines. More
specifically, aspects of the present invention relate to hybrid
components comprising a metal-reinforced ceramic matrix composite
(CMC) material and methods for manufacturing the same.
BACKGROUND
[0003] Gas turbines comprise a casing or cylinder for housing a
compressor section, a combustion section, and a turbine section. A
supply of air is compressed in the compressor section and directed
into the combustion section. The compressed air enters a combustion
inlet and is mixed with fuel. The air/fuel mixture is then
combusted to produce high temperature and high pressure gas. This
working gas is then ejected past a combustor transition and travels
into the turbine section of the turbine.
[0004] The turbine section comprises rows of vanes which direct the
working gas to the airfoil portions of the turbine blades. As
working gas travels through the turbine section, the gas causes the
turbine blades to rotate, thereby turning the rotor. The rotor is
also attached to the compressor section, thereby turning the
compressor and also an electrical generator for producing
electricity. Hot gas is then exhausted from the system. High
efficiency may be achieved by heating the gas flowing through the
combustion section to as high a temperature as is practical. The
hot gas, however, may degrade various turbine components such as
combustor components, transition ducts, vanes, ring segments,
exhaust components, and turbine blades that the hot gas passes when
flowing through the turbine.
[0005] For this reason, strategies have been developed to protect
such components from extreme temperatures, such as the development
and selection of high temperature materials adapted to withstand
these extreme temperatures, and cooling strategies to keep the
components adequately cooled during operation. For one, ceramic
matrix composite (CMC) materials have been developed that comprise
a ceramic matrix material hosting a plurality of reinforcing fibers
therein. While these CMC materials provide excellent thermal
protection properties, the mechanical strength of CMC materials is
still notably less than that of corresponding high temperature
superalloy materials. Thus, though excellent for resisting thermal
protection in high temperature applications, CMC materials are not
suitable for carrying structural loads. One existing challenge in
the art is thus how to apply CMC materials in regions of the gas
turbine that are structurally loaded in a safe and cost-effective
manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The invention is explained in the following description in
view of the drawings that show:
[0007] FIG. 1 is a perspective view of a component in accordance
with an aspect of the present invention.
[0008] FIG. 2 is a perspective view of a component comprising a CMC
body formed from stacked laminates in accordance with an aspect of
the present invention.
[0009] FIG. 3 illustrates another embodiment of a metal skeleton
structure in accordance with an aspect of the present
invention.
[0010] FIG. 4 illustrates a CMC body being inserted within a metal
skeleton structure in accordance with an aspect of the present
invention.
[0011] FIG. 5 illustrates a CMC body comprising threaded ends
structured to mate with fasteners in accordance with an aspect of
the present invention.
[0012] FIG. 6 illustrates a CMC body having a thermal barrier
coating about an exterior of the CMC body in accordance with an
aspect of the present invention.
DETAILED DESCRIPTION
[0013] The present inventors have developed hybrid components,
which satisfy a need for high temperature components having
increased thermal and corrosion resistance while also having a
desired strength in order to carry structural loads. In one aspect,
the component comprises a CMC material reinforced with a metal
skeleton structure. When employed in a gas turbine, the CMC
material of the component acts as a heat shield between the hot
inner gas flowing through the turbine while the metal skeleton
structure both supports the CMC material and carries structural
loads to a greater extent than the CMC material. In certain
embodiments, the metal skeleton structure may further comprise any
attachment(s) or interface(s) necessary for use of the device in a
gas turbine. In this way, the attachment(s) or interface(s) for the
metal-reinforced CMC components described herein may remain metal
and nearly identical to current configurations where the component
is formed solely from a superalloy, for example.
[0014] In accordance with one aspect, there is provided a hybrid
component including a body comprising a ceramic matrix composite
material and a metal skeleton structure encompassing at least a
portion of the body. The component further comprises a retaining
structure carried by the metal skeleton structure effective to
induce a compressive force on the body to limit movement of the
body and the metal skeleton structure relative to one another and
allow the metal skeleton structure to carry a greater amount of an
external load than the body.
[0015] In accordance with another aspect, there is provided a
method for forming a hybrid component. The method comprises mating
a body comprising a ceramic matrix composite material with a metal
skeleton structure such that the metal skeleton structure
encompasses at least a portion of the body. In addition, the method
comprises supplying a compressive force on the body via a retaining
structure carried by the metal skeleton structure which limits
movement of the body and the metal skeleton structure relative to
one another and allows the metal skeleton structure to carry a
greater amount of an external load than the body.
[0016] Now referring to the figures, there is shown an exemplary
component 10 in accordance with an aspect of the present invention
comprising a body 12 formed at least in part from a ceramic matrix
composite (CMC) material 14. In certain embodiments, the body 12
may define a cavity 15 therein. The body portion 12 (hereinafter
"CMC body 12") is at least partially encompassed about its exterior
16 by a metal skeleton structure 18. In certain embodiments, a
retaining structure 20 is provided which limits or prevents
movement of the CMC body 12 relative to the metal skeleton
structure 18, and vice-versa. In a particular embodiment, the
retaining structure 20 is configured or structured such that it
applies a compressive force to the CMC body 12 in order to maintain
the CMC body 12 in a fixed position while also allowing the metal
skeleton structure 18 to bear further structural loads for the
component 10.
[0017] The CMC body 12 may be of any suitable size and dimension
for its intended application. In addition, the CMC body 12 is at
least partially formed from the CMC material 14. The CMC material
14 may include a ceramic matrix material that hosts a plurality of
reinforcing fibers as is known in the art. In certain embodiments,
the CMC material 14 may be anisotropic, at least in the sense that
it can have different strength characteristics in different
directions. It is appreciated that various factors, including
material selection and fiber orientation, can affect the strength
characteristics of a CMC material. The CMC material 14 may comprise
oxide, as well as non-oxide CMC materials. In an embodiment, the
CMC material 14 may comprise alumina, and the fibers may comprise
an aluminosilicate composition consisting of approximately 70%
alumina; 28% silica; and 2% boron (sold under the name NEXTEL.TM.
312). The fibers may be provided in various forms, such as a woven
fabric, blankets, unidirectional tapes, and mats. A variety of
techniques are known in the art for making a CMC material, and such
techniques can be used in forming the CMC material 14 to be used
herein for the body 12. Exemplary CMC materials 14 for use herein
are described in U.S. Pat. Nos. 8,058,191; 7,745,022; 7,153,096;
7,093,359; and 6,733,907, the entirety of each of which is hereby
incorporated by reference. As mentioned, the selection of materials
is not the only factor which governs the properties of the CMC
material 14 as the fiber direction may also influence the
mechanical strength of the material, for example. As such, the
fibers for the CMC material 14 may have any suitable orientation
such as those described in U.S. Pat. No. 7,153,096.
[0018] In one embodiment, the CMC body 12 comprises a continuous
solid body having as shown in FIG. 1. In another embodiment, as
shown in FIG. 2, the body 12 may comprise a plurality of stacked
laminate plates 22 formed from the CMC material 14. In this
embodiment, each of the stacked laminate plates 22 may be cut to a
desired shape via a laser cutting process and stacked to provide
the desired body 12. In certain embodiments, the stacked laminate
plates 22 may be provided with a support structure, such as a tie
rod, extending through the stacked laminates. The plates may
further include suitable structures, such as retainers, for radial
compression of the plates. Exemplary processes for forming a body
of stacked laminates from a CMC material and associated structures
are set forth in U.S. Pat. Nos. 8,528,339; 7,255,535; 7,402,347;
7,247,002; 7,247,003; 7,198,458; and 7,153,096, for example, the
entirety of each of which is hereby incorporated by reference. Some
advantages a stacked laminate structure include enabling CMC
material to itself bear some structural loading via the individual
plates, as well as increasing a number of possible dimensions and
configurations for an associated component by controlling the
structure of the component on a level-by-level basis.
[0019] The metal skeleton structure 18 may comprise any metal
material which may provide an added strength to the body 12 and may
carry an extent of loading on the component 10. In certain
embodiments, the metal material may comprise an alloy material such
as a Fe-based alloy, a Ni-based alloy, a Co-based alloy as are well
known in the art. In certain embodiments, the alloy may comprise a
superalloy. The term "superalloy" may be understood to refer to a
highly corrosion-resistant and oxidation-resistant alloy that
exhibits excellent mechanical strength and resistance to creep even
at high temperatures. Exemplary superalloy materials are
commercially available and are sold under the trademarks and brand
names Hastelloy, Inconel alloys (e.g., IN 738, IN 792, IN 939),
Rene alloys (e.g. Rene N5, Rene 41, Rene 80, Rene 108, Rene 142,
Rene 220), Haynes alloys, Mar M, CM 247, CM 247 LC, C263, 718,
X-750, ECY 768, 262, X45, PWA 1483 and CMSX (e.g. CMSX-4) single
crystal alloys, GTD 111, GTD 222, MGA 1400, MGA 2400, PSM 116,
CMSX-8, CMSX-10, PWA 1484, IN 713C, Mar-M-200, PWA 1480, IN 100, IN
700, Udimet 600, Udimet 500 and titanium aluminide, for example. In
an embodiment, the metal skeleton structure 18 may be formed from a
metal material having a melting temperature of from 450-600.degree.
C. due to the thermal protection provided by the CMC material
14.
[0020] The metal skeleton structure 18 may comprise any suitable
dimensions, shape, or configuration that extends about at least a
portion of the exterior 16 of the CMC body 12. Referring again to
FIG. 1, in certain embodiments, the metal skeleton structure 18 may
be configured to extend from a base portion 24 of the CMC body 12
to a top portion 26 of the CMC body 12. In the exemplary embodiment
shown in FIG. 1, the metal skeleton structure 18 comprises a
plurality of spaced apart ribs 28 that encompass and provide
structural support to the body 12. The ribs 28 may be of any
suitable number, size, and shape to provide a desired degree of
structural reinforcement to the body 12 and carry a structural load
thereon.
[0021] It is appreciated that the present invention, however, is
not limited to the embodiment of FIG. 1 and that the metal skeleton
structure 18 may alternatively comprise any other suitable
structure which encompasses at least a portion, if not all, of an
exterior 16 of the CMC body 12 and which defines at least a
plurality of openings 25 that allows at least a portion of the
exterior 16 of the body 12 to remain exposed to the surrounding
environment. Without limitation, for example, the metal skeleton
structure 18 may alternatively comprise another structure such as a
grid-like structure 30 as shown in FIG. 3 having a plurality of
intersecting metal members 32 defining openings 34.
[0022] The exposure of the exterior 16 of the CMC body 12 may offer
significant advantages, such as in an environment where the body 12
is exposed to a cooling air flow, such as circulating shell air. In
this way, the CMC body 12 can be passively cooled and the amount of
cooling air utilized for active cooling, which typically travels
through or within the CMC body 12, may be reduced. This not only
allows for material and cost savings, but allows for higher inlet
temperatures which in turn may translate to greater performance and
efficiency. Moreover, in certain embodiments, cooling air reduction
in a combustion system can be either used to: 1) reduce primary
zone temperature (PZT) for a constant rotor inlet temperature (RIT)
operation case, thereby leading to reductions in NOx emissions; or
2) increase RIT (for a constant NOx case), thereby leading to
increase in power output and combined cycle (CC) efficiency.
[0023] In certain embodiments, the metal skeleton structure 18 and
the CMC body 12 comprise an interface which helps prevent rotation
of the body 12 relative to the metal skeleton structure 18, or
vice-versa. For example, in the embodiment shown in FIG. 4, the
body 12 may comprise a plurality of channels 36, each channel 36
having a depth such that at least a portion of a respective rib 28
of a metal skeleton 18 may be received and disposed therein. In a
particular embodiment, the ribs 28 of the metal skeleton 18 may be
slidably inserted within the channels 36 to provide the desired
interface between the CMC body 12 and the metal skeleton 18 for the
component 10. These channels 36 may also be provided in the stacked
laminate structure of FIG. 2. In an alternative embodiment, the
ribs 28 of the metal support structure 18 may instead comprise
channels 36 therein which are configured to receive corresponding
portions of the CMC body 12 therein.
[0024] The retaining structure 20 may be any suitable structure for
at least maintaining contact between the CMC body 12 and the metal
skeleton 18. In certain embodiments, the retaining structure 20 is
further configured to induce a compressive force on the CMC body
12. In this way, the metal skeleton structure 18 may be configured
to receive an external load thereon instead of the structurally
weaker CMC body 12. Referring again to FIG. 1, by way of example
only, the retaining structure 20 may comprise a retaining ring 38
which is configured to engage and fit over an exterior portion 39
the ribs 28 of the metal skeleton 18. The retaining ring 20 may
further include channels or clasps 40 as shown within which the
ribs 28 may be engaged within or otherwise inserted. Although the
retaining ring 38 is shown as fitting over a topmost portion of the
metal skeleton structure 18, it is understood that the present
invention is not so limited. Further, the retaining ring 38 may
comprise one or more additional retaining rings, or alternatively
may comprise any other suitable structure.
[0025] The component 10 and/or retaining structure 20 may include
any further structure(s) effective to at least assist in providing
a compressive force on the CMC material 12. In an embodiment, for
example, as shown in FIG. 5, a plurality of fasteners 42 may be
provided which are configured to mate with threaded ends 44 on the
ribs 28. The retaining ring 38 is omitted from FIG. 5, but
referring again to FIG. 1, it can be appreciated that as fasteners
42 (such as nuts or bolts) are tightened, the fasteners 42 may
increasingly cause the retaining ring 38 and/or metal skeleton
structure 18 to place a greater compressive load or force on the
CMC body 12. This load or force not only maintains the CMC body 12
in a fixed position relative to the metal skeleton structure 18,
but also forces the metal skeleton structure 18 to carry at least
an amount of an external load upon a further application of an
external load to the component 10. In this way, the CMC body 12 may
primarily carry thermal loads while the metal skeleton structure 18
may primarily carry structural loads upon use of the component in
an environment exposing the component 10 to such loads, such as in
a gas turbine environment.
[0026] In accordance with another aspect of the present invention,
the metal skeleton structure 18 may be fabricated so as to be
formed with or otherwise may include any mating parts necessary for
the component 10 to mate with another component. When not integral
components, the mating parts may be joined to the metal support
structure 18 via any suitable method such as welding or soldering.
Referring again to FIG. 1, for example, the component 10 may
include a flange 44 on a base portion 24 thereof for attaching the
component 10 to another component which is configured to mate with
or receive the flange 44. Further, the component 10 may comprise a
plurality of tabs 45 on a top portion 26 thereof for attachment of
the component 10 to a combustor, for example. In an embodiment, the
flange 44, tabs 45, or any other suitable mating structures are
formed from metal. In this way, the mating parts for the component
10 may remain metal and nearly identical to current configurations.
As such, the components described herein can be easily incorporated
into existing turbine systems.
[0027] In accordance with another aspect, to afford greater thermal
protection to the component 10, a thermal barrier coating (TBC) 48
may be applied to an internal surface 50 of the CMC body 12 to
prevent oxidation of or thermal damage to the CMC material since
the internal surface 50 is exposed to high temperatures as shown in
FIG. 6. FIG. 6 is a cross-section taken at line A-A of FIG. 4. In
one embodiment, the thermal barrier coating 48 may comprise a
friable graded insulation (FGI) as is known in the art. See, for
example, U.S. Pat. Nos. 7,563,504; 7,198,462; 6,641,907; 6,676,783;
and 6,235,370, each of which are incorporated by reference herein.
In further embodiments, such thermal barrier coatings may instead
or also be applied to an outer periphery of the CMC body 12.
[0028] In accordance with another aspect of the present invention,
there are provided methods for manufacturing a metal-reinforced CMC
component. In one embodiment, as was shown in FIG. 4, a metal
skeleton structure 18 as described herein may be first fabricated
according to desired specifications, or otherwise provided from a
commercial or suitable source. The metal skeleton structure 18 may
be cast or otherwise formed as a single piece, or may alternatively
require joining of one of more of its components to remaining
portions of the metal skeleton structure 18. Thereafter, the CMC
body 12 as described herein may be provided which may be configured
for slidable insertion into the metal skeleton structure 18 via
aligning the ribs 28 with channels 36 in the CMC body 12 and
sliding the CMC body 12 therein in the direction of arrow B as
shown.
[0029] Thereafter, referring again to FIG. 1, the retaining
structure 20 may be placed on an exterior of the metal skeleton
structure 18 and the retaining structure 20 secured or otherwise
tightened to prevent movement of the CMC body 12 relative to the
metal skeleton structure 18. For example, clasps 40 carried by the
retaining structure 20 may engage ribs 28 therein. Thereafter, as
described previously, fasteners 42 may be tightened on threaded
ends 44 of the ribs 28 such that the retaining structure 20 and/or
metal skeleton structure 18 exerts a compressive load on the CMC
body 12. This compressive load not only keeps the CMC body 12 in
place, but also allows the metal skeleton structure 18 to bear
further external loads.
[0030] While various embodiments of the present invention have been
shown and described herein, it will be obvious that such
embodiments are provided by way of example only. Numerous
variations, changes and substitutions may be made without departing
from the invention herein. Accordingly, it is intended that the
invention be limited only by the spirit and scope of the appended
claims.
* * * * *