N093-178 TITLE: Innovative Concepts for Lightweight, Low-Cost, High Temperature Turbine Components

TECHNOLOGY AREAS: Air Platform, Materials/Processes, Space Platforms

ACQUISITION PROGRAM: Joint Strike Fighter, ACAT I

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop innovative concepts for lightweight, low-cost, high temperature turbine components that are of complex shape and capable of surviving 2200 degrees Fahrenheit or greater as required for hot-section non-rotating aero-turbine engine applications.

DESCRIPTION: In order to meet increased mission demand for naval aircraft, gas turbine engines require lighter weight and lower cost components that are durable at high temperatures. To help satisfy this demand, low-cost, high temperature concepts for excellent shape forming capability are needed. Proposed solutions are for application to complex shaped non-rotating (stationary) components in small aero-turbine engines, as utilized in naval aircraft propulsion and power systems. The proposed concepts should exhibit most of the following characteristics:
- Able to replace the superalloys with domestically sourced elements
- Lightweight with densities lower than superalloys
- Easy to fabricate to near-net solid and hollow thin-wall shapes
- Easily machined to complex curvatures and tight tolerances
- Posses fracture toughness sufficient to avoid brittle behavior & excellent impact damage tolerance
- Potential to live in turbine engine environments of 2200 degrees F or greater
- Erosion, corrosion, and oxidation resistance
- Potential for low coefficient of thermal expansion, below superalloy expansion rates
- Sufficiently high thermal conductivity to not be considered an insulator or barrier

The proposed concept are expected to be prototypically proven in hot vanes and outer shrouds, in both cooled (hollow) and un-cooled (solid) configurations. The Navy is seeking novel alternatives to state-of-the-art superalloys and commercial off the shelf CMC's.

Coordination with military turbine engine manufacturers is highly encouraged.

PHASE I: Develop concepts for lightweight, low-cost, high temperature turbine components that are of complex shape and capable of surviving 2200 degrees Fahrenheit or greater as required for hot-section non-rotating aero-turbine engine applications. Demonstrate feasibility of the proposed approach through analysis and/or limited testing.

PHASE II: Fully develop the identified concept from Phase I and produce a prototype component for limited bench type testing.

PHASE III: Fully develop and qualify concepts. Commercially produce lower-cost improved components for turbine engines used by US Navy, DOD, and civil markets.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The technology is directly transferable to current and future, military and commercial, gas turbine engine programs or systems that use superalloys for high-temperature resistance.

REFERENCES:
1. M. Sundberg, G. Malmqvist, A. Magnusson and T. El-Raghy, 2004, Alumina forming high temperature silicides and carbides, Ceramics International, Vol. 30, p. 1899-1904 (http://www.3one2.com/main.html)

2. http://www.materials.drexel.edu/max/MaxPhases.htm

3. Michel W. Barsoum and Tamer El-Raghy, 2001, The MAX Phases: Unique New Carbide and Nitride Materials, pp. 334-343(http://www.3one2.com/AmerSci.pdf)

4. M. W. Barsoum and M. Radovic, 2004, "Mechanical Properties of the MAX Phases", Encyclopedia of Materials: Science and Technology, Elsevier Science, p. 1-16. (Internet accessible at http://hdl.handle.net/1860/1241)

5. http://www.netl.doe.gov/technologies/coalpower/turbines/refshelf/handbook/4.3.pdf

6. http://www.grc.nasa.gov/WWW/K-12/airplane/turbine.html

7. Jack D. Mattingly, Elements of Gas Turbine Propulsion, (AIAA: Reston, VA), 2005.

8. H. Saravanamuttoo, G. Roger, and H. Cohen, Gas Turbine Theory, Fifth Edition, (Prentice Hall: Harlow, England), 2001.

KEYWORDS: Gas Turbine; Materials; Hot Section; Manufacturing; Super Alloys; Ceramics

** TOPIC AUTHOR (TPOC) **

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