MAX Phase Metal Composite Gas Turbine Rotor
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Solution Overview
Problem
High-density materials used in gas turbines result in significant centrifugal forces on rotor parts, limiting the size of gas turbines, and existing materials lack the necessary mechanical strength and low density for efficient operation at high temperatures.
Innovation Solution
The use of MAX phases, a type of ternary ceramic, combined with metal alloys in a composite structure, where the MAX phase is infiltrated into hollow metal structures or coated on bulk metal parts, and processed using powder technology and heat treatment to reduce density and enhance mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-density nickel super alloys are used for gas turbine rotor parts, then mechanical strength and thermal resistance are improved, but centrifugal forces increase significantly, limiting the size of gas turbines
Solution Approach 1:
The patent applies composite materials by combining MAX phase ceramics (Ti2AlC, Ti3SiC2) with metal matrices (nickel super alloys, cobalt-based alloys, or iron-based alloys). This creates a composite structure where the ceramic phase provides low density (4 g/cm³) and thermal resistance, while the metal phase provides mechanical strength and toughness. The composite structure resolves the contradiction by achieving both low density and high strength simultaneously, enabling larger gas turbine sizes without excessive centrifugal forces.
Solution Approach 2:
The patent utilizes porous materials by creating a hierarchical pore structure in the MAX phase ceramic matrix. The porous structure reduces the overall density of the composite material while maintaining structural integrity through the metal phase reinforcement. The pore architecture allows for weight reduction without compromising mechanical properties, directly addressing the density-strength contradiction.
2Weight of moving object
If MAX phase ceramics are used to reduce density, then centrifugal forces are reduced, but mechanical strength and thermal resistance at high temperatures are insufficient
Solution Approach 1:
The patent combines MAX phase ceramics with metal matrices to create a composite material system. The MAX phase provides low density and thermal resistance, while the metal matrix (nickel super alloy, cobalt-based alloy, or iron-based alloy) provides mechanical strength, toughness, and high-temperature capability. This composite approach resolves the contradiction by leveraging the complementary properties of both material classes.
Solution Approach 2:
The patent applies parameter changes by controlling the composition ratios of the composite material. Specifically, it optimizes the content of MAX phase (40-80 wt%), metal matrix (20-60 wt%), and reinforcement particles (0-20 wt%) to achieve the desired balance between density, strength, and thermal resistance. By adjusting these parameters, the material properties can be tailored to meet specific performance requirements.
3Weight of moving object
If MAX phase is infiltrated into hollow metal structures or coated on bulk metal parts, then density is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming hollow metal structures or coating metal parts with MAX phase powder before final assembly. The hollow structures are prepared in advance with controlled geometry and surface area, and the MAX phase coating is applied prior to infiltration or assembly operations. This sequencing simplifies the overall manufacturing process by breaking down complex operations into manageable preliminary steps.
Solution Approach 2:
The patent utilizes porous materials by employing MAX phase with controlled porosity as an infiltration material. The porous structure of the MAX phase allows it to be infiltrated into hollow metal structures through simple processes like vacuum impregnation or pressure infiltration, without requiring complex manufacturing steps. This approach reduces density while maintaining manufacturing feasibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the construction of large gas turbines without changing rotor materials, reducing centrifugal forces and improving mechanical strength and thermal resistance, enabling efficient operation at high temperatures.
Implementation Method 1
combining said metal and said MAX phase by powder technology processes and/or spray methods to build said gas turbine part up
Implementation Method 2
Said HIP or heat treatment process may be done at a temperature less than the melting point of said metal and MAX phase for densification and/or stress relaxation at high temperature
Implementation Method 3
Said HIP or heat treatment process may be done at a temperature less than the melting point of said metal and MAX phase for densification and/or stress relaxation at high temperature
Data Source
AI summary
The present disclosure relates to building very large gas turbines without changing rotor materials. The gas turbine part can include a structure composed of a metal and a ternary ceramic called MAX phase, having a formula Mn+1AXn, where n=1, 2, or 3, M is an early transition metal such as Ti, V, Cr, Zr, Nb, Mo, Hf, Sc, Ta, and A is an A-group element such as Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl, Pb, and X is C and/or N.