Oxide Metal Composite Components High Temperature Creep Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-temperature systems, such as power generation and turbine engines, are limited by the mechanical and chemical properties of metallic alloys, which degrade above 600°C, restricting operating temperatures and efficiency.
Innovation Solution
Development of mechanically-robust, thermally-robust, and chemically-robust oxide/metal composite materials using the displacive compensation of porosity (DCP) process, allowing for the creation of components with enhanced creep resistance, thermal conductivity, and corrosion resistance capable of operating above 600°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metallic alloys (stainless steels or Ni-based alloys) are used to form heat exchanger plates, then the components can be manufactured with good mechanical properties, but the operating temperature is limited to below 600°C due to dramatic decreases in mechanical properties at elevated temperatures
Solution Approach 1:
The patent applies composite materials by combining oxide ceramics (such as alumina, magnesia, or zirconia) with metal phases to create oxide/metal composite components. The oxide phase provides high-temperature stability and creep resistance, while the metal phase maintains ductility and toughness. This composite structure enables operation at temperatures above 600°C while retaining adequate mechanical properties, directly resolving the contradiction between temperature capability and mechanical strength.
2Temperature
If metallic alloys are used to form pump components, then the components can be manufactured with adequate mechanical properties, but the operating temperature is limited to below 550°C due to decreases in mechanical properties and corrosion resistance
Solution Approach 1:
The patent uses oxide/metal composite materials for pump components where the oxide phase (such as alumina or magnesia) provides exceptional corrosion resistance in oxidizing environments and reactive liquids at high temperatures, while the metal phase maintains mechanical integrity. This composite approach enables pump operation above 550°C with maintained corrosion resistance, resolving the contradiction between temperature capability and chemical reliability.
3Productivity
If conventional metal alloy-based heat exchangers are used, then the manufacturing process is well-established, but the thermal-to-electrical conversion efficiency is limited due to operating temperature constraints
Solution Approach 1:
The patent changes the fundamental material parameter from conventional metal alloys to oxide/metal composites, which fundamentally alters the operating temperature parameter. This material parameter change enables operation at temperatures above 600°C, which directly increases the thermal-to-electrical conversion efficiency in power generation systems by allowing higher temperature heat sources to be utilized, thereby improving overall system productivity.
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
Enables the operation of high-temperature systems at temperatures exceeding 500°C with improved efficiency, reduced material costs, and increased thermal-to-electrical conversion efficiency, while maintaining mechanical integrity and corrosion resistance.
Implementation Method 1
The at least one displacing metal of the fluid reactant is capable of displacing the at least one displaceable species in the solid oxide reactant to produce at least one solid oxide reaction product
Implementation Method 2
allowing the fluid reactant to infiltrate the porous preform and react with the solid oxide reactant
Implementation Method 3
the pore volume is at least partially filled by the reaction product volume, and the reaction product volume is greater than the solid volume lost by the at least one displaceable species in the solid oxide reactant being displaced
Implementation Method 4
The at least one oxide phase and the at least one metal phase exhibit thermal expansion values within 50% of one another upon heating to a temperature greater than 500° C.
Data Source
AI summary
Methods for producing components for use in high temperature systems that include reacting a fluid reactant and a porous preform that has a pore volume and contains a solid oxide reactant that defines a solid volume of the porous preform. The method includes infiltrating the fluid reactant into the porous preform to react with the solid oxide reactant to produce a oxide/metal composite component, during which a displacing metal replaces a displaceable species of the solid oxide reactant to produce at least one solid oxide reaction product that has a reaction product volume that at least partially fills the pore volume. The oxide/metal composite component includes at least one oxide phase and at least one metal phase. The component is exposed to temperatures greater than 500° C. and the at least one oxide phase and the at least one metal phase exhibit thermal expansion values within 50% of one another.