Experimental study on high temperature performances of silica-based ceramic core for single crystal turbine blades

Silica-based ceramic cores are widely utilized for shaping the internal cooling canals of single crystal superalloy turbine blades. The thermal expansion behavior, creep resistance, and high temperature flexural strength are critical for the quality of turbine blades. In this study, the influence of zircon, particle size distribution, and sintering temperature on the high-temperature performance of silica-based ceramic cores were investigated. The results show that zircon is beneficial for narrowing the contraction temperature range and reducing the shrinkage, improving the creep resistance and high-temperature flexural strength significantly. Mixing coarse, medium and fine fused silica powders in a ratio of 5:3:2, not only reduced high temperature contraction, but effectively improved the creep resistance. Properly increasing the sintering temperature can slightly reduce the thermal deformation and improve the high-temperature flexural strength of the silica-based core, but excessively high sintering temperature negatively impacts the creep resistance and high-temperature flexural strength.     

Creep behaviour of an Al–Si–Al2O3 composite based on phase evolution at 1300oC

An Al–Si–Al₂O₃ composite was prepared with corundum, aluminium powder and silicon powder. A creep test was carried out at 1300°C under 0.2 MPa for 50 h in air. The results show that the Al–Si–Al₂O₃ composite performs a low constant creep rate and remain until the end of the 50-h test. This is attributed to the in-situ formation of the tough non-oxide reinforcements, whisker-like (AlN)_x(Al₂OC)_1-x solid solution and granular β-SiC, by reactions of Al and Si during creep test. The whisker-like (AlN)_x(Al₂OC)_1-x solid solution and granular β-SiC reinforcements are evenly filled in the pores, which play the role of bridging and pinning reinforcement, forming a strong network structure with corundum aggregates. Moreover, these non-oxide phases are not wetted by the liquid phases, which impel the liquid phase shrinks in the network structure in isolation during creep test. Thus, the adverse effect of the liquid phase on the high-temperature strength of the composites is eliminated, so the composites with strong network structure quickly get a stationary low-creep state. A creep mechanism model is established.     

Multiphysics phase-field modeling of quasi-static cracking in urania ceramic nuclear fuel

This work presents phase-field modeling of quasi-static cracking in urania (UO₂) ceramic nuclear fuel under neutron radiation at high temperatures. Considering the tightly coupled multi-physics processes within the fuel during reactor power operation, a diffusion model including Fickian and Soret effects is used to describe the oxygen hyper-stoichiometry (x in UO_2+x), and the temperature field is given by a thermal model involving non-uniform fission-generated heat source and heat flow across fuel pellet, pellet-cladding gap and cladding to the outside heat sink. Both temperature and irradiation effects are taken into account for the basic thermo-mechanical properties and irradiation behaviors of the nuclear fuel. Especially, the acceleration of fuel thermal creep by oxygen hyper-stoichiometry is included. The fracture due to the above physical processes is approximated by a scalar phase-field variable based upon a cohesive phase-field fracture method. A granite fracture experiment is simulated to validate the thermo-fracture coupling approach. For the first time, the diffusion-thermo-mechanical-fracture coupling model is applied to UO₂ fuel pellet cracking during reactor startup, power ramp and reactor shutdown. UO₂ creep is found to play an important role on the fuel pellet fragmentation. The developed capability supports interpretation of experimental data and can guide material design of ceramic nuclear fuels.     

Densification mechanisms and microstructural evolution during spark plasma sintering of boron carbide powders

Micron-sized boron carbide (B₄C) powders were subjected to spark plasma sintering (SPS) under temperature ranging from 1700 °C to 2100 °C for a soaking time of 5, 10 and 20 min and their densification kinetics was determined using a creep deformation model. The densification mechanism was interpreted on the basis of the stress exponent n and the apparent activation energy Q_d from Harrenius plots. Results showed that within the temperature range 1700–2000 °C, creep deformation which was controlled by grain-boundary sliding or by interface reaction contributed to the densification mechanism at low effective stress regime (n = 2,Q_d = 459.36 kJ/mol). While at temperature higher than 2000 °C or at high stress regime, the dominant mechanism appears to be the dislocation climb (n = 6.11).     

CMC jackets for metallic pipes – A novel approach to prevent the creep deformation of thermo-mechanically loaded metals

Steel materials suffer extensive creep by the application at temperatures of about 700?°C and pressures about 350?bar in a power plant environment. The presented concept overwraps a steel pipe with a ceramic matrix composite (CMC) jacket in order to support the steel pipe and provide high temperature strength. Finite Element simulations show the influence of the wall thickness of CMC jacket and the coefficient of thermal expansion (CTE) on circumferential stresses within the hybrid metal ceramic pipe. Suitable fiber and matrix materials were studied, composites fabricated and mechanical properties determined. Finally, a prototype was designed in order to confirm the feasibility of the concept. The lifetime of a pure steel pipe was increased by more than four-fold by the additional CMC jacket.     

Model for prediction of simultaneous time-dependent damage evolution in multiple plies of multidirectional polymer composite laminates and its influence on creep

A model to predict time-dependent evolution of simultaneous transverse cracking developed in multiple plies during creep loading and its effects on creep of multidirectional polymer matrix composite laminates is presented. The stress states in the intact regions of the plies are determined using the lamination theory during an incremental change in time. The stored elastic energy, determined using this stress state, is compared with a critical stored elastic energy value for damage to determine if a ply would fracture after the increment. If fracture is predicted, variational analysis is used to determine the perturbation in ply stresses due to cracking. This procedure is repeated to determine the crack evolution and creep strain. Model predictions compared well with experimental results for a [±θ_m/90_n]_s laminate.     

Three stage creep behavior of MgO containing ordinary refractories in tension and compression

In service tensile and compressive stresses occur in refractory linings, these stresses lead to creep of refractories. Ordinary refractories experience creep of the primary stage and may further proceed to the secondary and tertiary creep stage. For the development of advanced material models for finite element simulations it is necessary to investigate the creep behavior in all three creep stages under tensile and compressive loads. Hence, two advanced high temperature uniaxial creep testing devices, applying a wide range of tensile and compressive loads, were used to determine the three creep stages in a reasonable time under service related loading conditions. The Norton–Bailey creep equations and an inverse identification procedure were applied for the evaluation of the experimental results. A magnesia refractory was studied at elevated temperatures and its respective creep parameters for each stage were determined. The stress dependency on the creep behavior can be seen clearly on the creep curves and the corresponding creep parameters. Furthermore, a comparative study of creep parameters and creep rates was performed between the magnesia refractory and a magnesia-chromite refractory. The results demonstrate the significant asymmetrical creep behavior in tension and compression for both materials. The creep investigation in this paper favors the requirement for consideration of the three stage creep behavior and the asymmetrical creep behavior in thermomechanical modelling activities of industrial vessels.     

Short-term creep behavior of a biodegradable polymer reinforced with wood-fibers

The short-time creep behavior at tensile and single cantilever mode of deformation for a series of biodegradable composites was thoroughly studied. The composites were based on a biodegradable polymer matrix consisted a blend of poly(butylene adipate-terephthalate) (PBAT) copolyester, produced by non-renewable resources, and Polylactic acid (PLA). The matrix was reinforced with three different wood fiber types, at 20 and 30 wt%. The experimental data were analyzed in terms of Findley's and Burger's viscoelastic models. The effect of stress and temperature and wood fiber type on the material's creep response was analytically studied, while the Burger's model parameters were related to the composites morphology. In all cases, the wood fibers improved the creep resistance of the composites.     

The dynamic creep rupture of a secondary superheater tube in a 43 MW coal-fired boiler by the decarburization and multilayer oxide scale buildup on both sides

A dynamic creep mechanism has been proposed and verified through a case study. A secondary superheater tube burst occurred in a 43 MW coal-fired boiler. Microstructural examination indicates that the overheating temperatures reached 900 °C (above Ac3). The overheating duration was estimated to be 3 h by calculating with LMP formula. The 710 μm steam-side scale and 960 μm fireside scale built-up in the short time of overheating. The burst scenario was a short-term severe overheating on the basis of the long-term creep. The multilayer oxide scales on both sides have been studied with ESEM/EDS, indicating FeO. At 900 °C, full decarburization had gone throughout the tube. As the strength reduced due to the decarburization, the creep mechanism transformed from long-term intergranular creep to short-term transgranular rupture. The two types of dimples on the fractograph and two types of cracks in the microstructures confirmed the mechanism transformation. The overheating, the scale buildup and the decarburization constituted the full picture of the dynamic creep rupture.     

Field trial of a reinforced landfill cover system: performance and failure

The geotechnical stability of an inclined multilayer capping depends on the shear strength available along the various interfaces. If the slope is very steep an additional reinforcing geosynthetic may be used to obtain a safer condition. Full-scale field trials can provide better resolution data on the reinforcement behaviour than conventional calculation methods based only on laboratory tests. The paper deals with a field trial carried out on multilayer capping, reinforced with a geogrid, in an Italian landfill. The geogrid behaviour was monitored for a month using displacement sensors and pressure cells located along the slope and in the anchor trench. Subsequently, the cover system was led to collapse by cutting the reinforcement and an analysis of the reinforcement behaviour and its relevance in the system stability were studied. This paper discusses in detail the setup of the field trial and the experimental data recorded during installation, monitoring, and failure phases of the system. The deformation behaviour of the geogrid during the entire test was recorded and analysed. The resulting data highlight the effects of the construction process on the geogrid behaviour including the contribution of geogrid creep characteristics until the failure.