Ceramic Matrix Composite Combustor Liners: A Summary of Field Evaluations

Abstract

Solar Turbines Incorporated, under U.S. government sponsored programs, has been evaluating ceramic matrix composite combustor liners in test rigs and Solar’s Centaur® 50S gas turbine engines since 1992. The objective is to evaluate and improve the performance and durability of CMCs as high-temperature materials for advanced low emissions combustors. Field testing of CMC combustor liners started in May of 1997 and by the end of 2004, over 67,000 operating hours had been accumulated on SiC∕SiC and oxide∕oxide CMC liners. NOx and CO emissions have been consistently <15ppmv and <10ppmv, respectively. Maximum test durations of 15,144h and 13,937h have been logged for SiC∕SiC liners with protective environmental barrier coatings. An oxide∕oxide CMC liner with a Friable Graded Insulation coating has been tested for 12,582h. EBCs significantly improve SiC∕SiC CMC liner life. The basic three-layer EBC consists of consecutive layers of Si, mullite, and BSAS. The durability of the baseline EBC can be improved by mixing BSAS with mullite in the intermediate coating layer. The efficacy of replacing BSAS with SAS has not been demonstrated yet. Heavy degradation was observed for two-layer Si∕BSAS and Si∕SAS EBCs, indicating that the elimination of the intermediate layer is detrimental to EBC durability. Equivalent performance was observed when the Hi-Nicalon fiber reinforcement was replaced with Tyranno ZM or ZMI fiber. Melt infiltrated SiC∕SiC CMCs have improved durability compared to SiC∕SiC CMCs fabricated by Chemical Vapor Infiltration of the matrix, in the absence of an EBC. However, the presence of an EBC results in roughly equivalent service life for MI and CVI CMCs. Results to date indicate that oxide∕oxide CMCs with protective FGI show minor degradation under Centaur® 50S gas turbine engine operating conditions. The results of, and lessons learned from CMC combustor liner engine field testing, conducted through 2004, have been summarized.