SBIR-STTR Award

A significant barrier to the insertion of ceramic matrix composite (CMC) materials into advanced aircraft engines is their inherent lack of toughness under erosion and post erosion. Our team will develop and demonstrate a physics-based model for erosion/post erosion of CMCs at room and elevated temperatures (RT/ET). The ICME (Integrated Computational Material Engineering) Physics based Multi Scale Models will predict: a) factors affecting erosion in CMC; b) High temperature erosion; c) thermal history of erodent event; d) mechanical properties at elevated temperature considering effect of defects and f) erosion condition of CMC material and coating. The model will incorporate Erosion Morphology (matrix, tunneling erosion arrests, fiber layers erode), damage and fracture evolution associated with erosion parameters at macro and micro levels for different size and erodent material type and shape as well as particle velocity range. The model will be incorporated into our commercial Multi-scale progressive failure analysis software that integrates commercial FEA and enhances their accuracy limitation. Two different CMC (SiC/SiC, Oxide/Oxide) systems at ET will be rig tested to guide the analysis, supported by Acoustic Emission/Electrical Resistance monitoring and damage assessment and health monitoring. Phase II will perform ET rig test of CMC with EBC and TBC coating.

Benefit:
The application of Ceramic Matrix Composite (CMC) engine parts in advanced aircraft allows engines to operate at higher temperatures and significantly reduces engine weights. Erosion resistant CMC will allow hot section engine life/durability and reliability to increase. The verifiable Physics based analytical/design tool erosion modeling in CMC gas turbine engine development, is significant in terms of reducing concept-to-commercialization time. A novel approach to significantly enhance erosion of CMCs will bring these technologies closer to reality and enable the transition of these advanced material technologies to various military aircraft propulsion systems. Technology usage can include advanced Naval engines, hypersonic, Thermal Protection Systems, and DOD, DOE/NASA sponsored aerospace related engine development programs. It has been demonstrated in prior studies that CMC based material technologies will offer large economic and social benefits, with successful broad-based implementation. Other Industries are land-based or marine gas turbine engine industries, automotive would benefit from successful technology development.

Keywords:
Strength after erosion, Strength after erosion, ceramic matrix composite, Thermal Management, ICME modeling, High temperature CMC mechanical/thermal property predictions, Verification Validation and accreditation (VVA), High Temperature Rig Test, Erosion Particle debris

A significant barrier to the insertion of ceramic matrix composite (CMC) materials into advanced aircraft engines is their inherent degradation under erosion and post erosion. Our team will develop and demonstrate a physics-based model for erosion/post erosion of CMCs at room and elevated temperatures (RT/ET). The ICME (Integrated Computational Material Engineering) Physics based Multi Scale Models will predict: a) factors affecting erosion in CMC; b) Room and High temperature (RT/ET) erosion; c) thermal history of erodent event; d) Retained Strength mechanical properties at RT/ET temperature considering effect of defects, e) Strength A-B Basis allowables, f) fracture allowable. and g) erosion in -Service condition of CMC material. The model will incorporate Erosion Morphology (matrix, tunneling erosion arrests, interphase coating, fiber layers erode), damage and fracture evolution associated with erosion parameters at micro and macro levels for different size and erodent material type and shape as well as particle velocity range. The model will be incorporated into our commercial Multi-scale progressive failure analysis software that integrates commercial FEA and enhances their accuracy limitation. A design of Experiment (DOE) Surrogate Meta modeling and optimization will be performed to generate virtual random particles, to redistribute the deep crater (size, and depth) to several shallow craters size spread on Ceramic surface, that will be driven by Micro crack density phenomenon. Optimization of the CMC system will design for Fiber architecture, layer thickness, fiber orientation considering several particle size, and erodent type. Application will consider erosion design of engine blade, airfoils leading edge, and dome defined by Engine and Airframers. Curved panels and scale up will be considered for Phase II option testing and modeling validation. Two different CMC (SiC/SiC, Oxide/Oxide) systems at RT/ET will be burner rig tested and post erosion retained strength and fatigue tests to establish end of life condition, supported by Acoustic Emission/Electrical Resistance monitoring and damage assessment and health monitoring. Phase II will involve RT/ET Burner rig test of flat plates with two commercially available CMC, and two emerging high potential CMC material system.

Benefit:
The application of Ceramic Matrix Composite (CMC) engine parts in advanced aircraft allows engines to operate at higher temperatures and significantly reduces engine weights. Erosion resistant CMC will allow hot section engine life/durability and reliability to increase. The verifiable Physics based analytical/design tool erosion modeling in CMC gas turbine engine development, is significant in terms of reducing concept-to-commercialization time. A novel approach to significantly enhance erosion of CMCs will bring these technologies closer to reality and enable the transition of these advanced material technologies to various military aircraft propulsion systems. Technology usage can include advanced Naval engines, hypersonic, Thermal Protection Systems, and DOD, DOE/NASA sponsored aerospace related engine development programs. It has been demonstrated in prior studies that CMC based material technologies will offer large economic and social benefits, with successful broad-based implementation. Other Industries are land-based or marine gas turbine engine industries, automotive would benefit from successful technology development. CMC multi-scale erosion modeling will enable its transition to JSF. CMC propulsion applications are ideal fits for platforms such as Variable Cycle Advanced Technology (VCAT), Versatile Affordable Advanced Turbine Engines (VAATE), and other advanced Naval engines. Future use may involve hypersonic aircraft propulsion systems for enhanced life expectancy as well as hypersonic leading-edge programs.

Keywords:
Erosion Particle debris, ICME modeling, Retained Strength after erosion, Verification Validation and Accreditation (VVA), Thermal Management, ceramic matrix composite, High Temperature Rig Test, High temperature CMC mechanical fracture and fatigue properties