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3DCeraTurb: Design and manufacture of CMC stator guide vanes for high-pressure turbines

Süß, Fabia and Friedrich, Lion and Vogel, Felix and Klopsch, Linda and Welter, Michael (2023) 3DCeraTurb: Design and manufacture of CMC stator guide vanes for high-pressure turbines. Deutscher Luft- und Raumfahrtkongress 20233, 2023-09-19 - 2023-09-21, Stuttgart, Deutschland.

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Increasing the performance and efficiency of aero engines is essential for more environmentally friendly air transport. Rising temperatures, especially for combustion section and turbine structures, as well as lower weight of the components are key requirements for new materials. Together with adapted environmental coating systems and cooling features, ceramic composites are good candidates for aircraft applications. They are capable of withstanding high temperatures in an aggressive environment, while the density is two-thirds lower than conventional nickel-based alloys. As part of the DLR project “3DCeraTurb”, the Institute of Structures and Design and the Institute of Materials Research, along with several other DLR institutes, are developing turbine guide vanes made of silicon carbide fibre-reinforced silicon carbide composites (SiC/SiC CMC) and all-oxide CMC, respectively. One aim of 3DCeraTurb is to design and manufacture ceramic stator guide vanes for a high-pressure turbine, to experimentally investigate the vane behaviour in a wind tunnel and to evaluate performance, damage and lifetime for later application in an aircraft engine. The focus is the enhancement of the respective manufacturing processes from plate dimensions to more complex three-dimensional components. A ceramic-based design is the basis for the development and manufacture of a new guide vane geometry, taking into consideration material- and manufacturing-specific constraints. The manufacturing and development processes of the SiC/SiC and oxide CMC components will be presented with a particular focus on SiC/SiC. The SiC/SiC fabrication starts with the draping and CVI fibre coating of woven fabrics, followed by resin infiltration via resin transfer moulding. The final steps involve pyrolysis and liquid silicon infiltration. Surface grinding and laser drilling of cooling holes in the trailing edge are challenging parts during the final machining of the vanes. CFD simulations connected to FEM simulations are carried out accompanying the design and manufacturing process. The safety factors for the wind tunnel and the cruise load case are calculated using the Tsai-Wu criterion.

Item URL in elib:https://elib.dlr.de/199407/
Document Type:Conference or Workshop Item (Speech)
Title:3DCeraTurb: Design and manufacture of CMC stator guide vanes for high-pressure turbines
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Süß, FabiaUNSPECIFIEDhttps://orcid.org/0000-0002-5016-5781UNSPECIFIED
Date:21 September 2023
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Keywords:CMC, SiC/SiC, LSI, nozzle guide vanes
Event Title:Deutscher Luft- und Raumfahrtkongress 20233
Event Location:Stuttgart, Deutschland
Event Type:national Conference
Event Start Date:19 September 2023
Event End Date:21 September 2023
Organizer:Deutsche Gesellschaft für Luft- und Raumfahrt - Lilienthal-Oberth e.V.
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Clean Propulsion
DLR - Research area:Aeronautics
DLR - Program:L CP - Clean Propulsion
DLR - Research theme (Project):L - Advanced Materials and New Manufacturing Technologies
Location: Köln-Porz , Stuttgart
Institutes and Institutions:Institute of Structures and Design > Ceramic Composite Structures
Institute of Materials Research > Structural and Functional ceramics
Deposited By: Süß, Fabia
Deposited On:29 Nov 2023 14:46
Last Modified:24 Apr 2024 20:59

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