Ultrahigh Performance Metallic Turbine Blades for Extreme EnvironmentsULTIMATE Kickoff MeetingMarch 19, 2021

Dr. Ali Yousefiani (PI)Boeing Research & TechnologyDr. David Crudden (Co-PI)AlloyedDr. Ann Bolcavage (Co-PI)Rolls-Royce Corporation

Ultrahigh Performance Extreme Environment Turbine Blades

1100°CSOABase

MetalCapability

TBC/Cooling Technology

Improvements

SOA

TET(1500°C)

1300°CProposed

RCCABase

MetalCapability

T/EBC/Cooling Technology

Improvements

TET(1800°C)

CCA Interlayer Improvements

A thermal barrier coating, made from a ceramic, which provides enough insulation to reduce the temperature experienced by the bulk material to 1300°C, even when the blade is operating at 1800°C

An interlayer, potentially made up of two or more spatially and compositionally graded layers, made from complex concentrated alloys. The principal purposes of these layers is to provide protection from corrosion and oxidation, and to prevent inter-diffusion of elements from the different layers, as well as providing a degree of thermal insulation

A bulk material, made from refractory metal-based complex concentrated alloys, which provide mechanical strength and durability at highly elevated temperatures up to 1300°C

Motivation & Goals of the Project

‣ Materials capability has plateaued and cooling approaches have reached a point where the performance penalty for additional cooling air is just offsetting the cycle efficiency improvement from higher temperatures.

‣ Turbine entry temperature (TET) steady at ~1500°C for decades.

‣ Goal of the project is to design and fabricate a turbine blade component, which will offer drastic improvements in performance compared to the SOA, allowing for engine TET of 1800°C and beyond.

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Technical Approach & Innovations of the Project▸ Integrated

computational approach to developing new alloys and multi-layered turbine blade architecture

▸ Bulk material and interlayers comprised of novel complex concentrated alloys

▸ Powder-based NNS manufacturing enabling breakthrough metallurgy and functionally graded structures

▸ T/EBC system with ‘tunable’ architecture, applied using SPS

2

Huge leap forward in metallic materials solutions for extreme environment applications

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Lead Team Members and Roles

3

The Boeing CompanyBoeing Research & Technology

Team: Dr. Ali Yousefiani (PI)Mr. Austin Mann; Dr. Ryan Glamm; Dr. Timothy Smith (NASA-GRC); Dr. Pei Sun (Univ. of Utah)

➢ Research/development of novel performance enhanced materials and their powder-based methods of processing and production

➢ Predicting behavior of structural materials in extreme environments associated with supersonic/hypersonic flight, atmospheric reentry, rocket/aircraft propulsion, and integrated power/thermal management

➢Maturation of manufacturable, durable, and rapidly deployable multifunctional components for extreme environment applications

Roles:➢ Program management➢ Advanced powder-based bottom-up AM/PM and

hybrid manufacturing developments and complex concentrated alloy feedstock modification efforts

➢ Lead characterization/test/evaluation➢ Lead T2M and TEA activities with focus on

technology transition to supersonic/hypersonic applications

OxMet Technologies Inc.(US Subsidiary of Alloyed Ltd)

Team: Dr. David Crudden (Co-PI)Dr. Sarat Babu; Dr. Rhys Jones; Mr. Will Dick-Cleland

➢ Development/characterization of high-temperature turbomachinery alloys

➢ Pioneered application of electro-thermomechanical testing (ETMT) approach for rapid, small-scale, high-temperature characterization of alloys and microstructures

➢ Development and operation of world-leading ABD® software platform for computational alloy development, as well as Engine and Architect platforms for process and component optimization on LPB fusion

Roles:➢ Design and development of extreme environment

complex concentrated alloys, compatible diffusion layers, and environmental protection layers

➢ Sourcing of powders for use in laser powder-bed fusion and all interlayer alloys

➢ Development of appropriate processing parameters for fabrication of test pieces and demo articles by laser powder-bed fusion

Rolls-Royce North AmericanTechnologies, Inc. – Liberty Works

Team: Dr. Ann Bolcavage (Co-PI)Mr. Robert Proctor; Mr. Timothy White; Mr. Kaare Erickson

➢ Design and manufacture of advanced coating systems for the thermal / environmental protection of high-value turbine section components for Civil and Defense applications

➢ Founding member of CCAM, lead coating process development and improvement through digital systems and intelligence

➢ Design, development, testing and manufacture of novel and complex turbine blade and vane components for advanced demonstrators and engines

Roles:➢ Lead T/EBC system design/process development➢ Develop interlayer and T/EBC application

processes for turbine blade article➢ System level tests to confirm performance targets➢ Define functional requirements for CCA-interlayer-

T/EBC system➢ Support alloy developments, manufacturing

process developments, and T2M/TEA

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Q1 Q2 Q3 Q4 Q5 Q6

M1.1 [Go/No-Go 1]: Refine tasks and milestones (if applicable) – Q1M1.2: Initial T2M Plan submitted and accepted by ARPA-E; initial impact sheet drafted – Q2M1.3: Intermediate T2M Plan submitted for ARPA-E acceptance – Q4M1.4: End of project review – Q6M2.1: Base alloy compositions designed – Q2M2.2: Base alloys produced and evaluated – Q4

M2.3 [Go/No-Go 2]: Base alloys tested and met Phase 1 FOA metrics ➔ Candidate base RCCAs selected – Q6M3.1: Interlayer + TBC/EBC systems designed and produced – Q3M3.2: Interlayer + TBC/EBC systems tested and evaluated – Q5M4.1: Manufacturing approaches selected – Q3M4.2: Optimum manufacturing processes established – Q6

WBS 1. Program Management(1.1) Technical oversight + periodic reviews/reports [BR&T]; (1.2) T2M [RRC/BR&T/Alloyed]; (1.3) Techno-economic analysis (TEA) [BR&T/RRC/Alloyed]

WBS 2. Design/Develop/Downselect Alloys (2.1) Modeling & selection [Alloyed/BR&T]; (2.2) Powder production/enhancement [BR&T/Alloyed]; (2.3) Characterization/test/evaluation [BR&T/Alloyed]; (2.4) Downselect candidate alloys [BR&T/Alloyed]

WBS 3. Design/Develop/Downselect Coating(3.1) Modeling & selection (interlayers/EBC) [Alloyed/BR&T/RRC]; (3.2) Interlayer synthesis & enhancement trials [Alloyed/BR&T]; (3.3) Coating trials [Alloyed/RRC]; (3.4) Characterization/test/evaluation [RRC/Alloyed]; (3.5) Downselect candidate coating systems [RRC/BR&T/Alloyed]

WBS 4. Develop/Downselect Manufacturing Processes(4.1) Laser powder bed fusion AM [Alloyed]; (4.2) Advanced bottom-up PM/AM/HYBRID manufacturing [BR&T]; (4.3) Preliminary blade design & manufacturing plan [RRC/BR&T]; (4.4) Downselect candidate manufacturing processes [BR&T/RRC]

2.1

1.2 1.3 1.4

2.2

3.1 3.2

4.1 4.2

M1.1 G/N

M2.3 G/N

Major Milestones, Tasks & Deliverables

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Key Risks & Mitigations

5

Lik

eli

ho

od

Almost Certain

Likely

Moderate

Unlikely

Rare

Insignificant Minor Moderate Major Catastrophic

Consequences

# Start of project

54 3

2

1

# Risk Mitigation

1Alloy: Base RCCA lacks necessary oxidation resistance and other Phase 1 metrics

Modify and optimize chemistry to improve these characteristics; rely on barrier methods via coatings and/or graded intermediate layers to prevent oxidation of base alloy.

2Alloy: Base RCCA lacksnecessary fabricability / processability

Chemistry modifications to improve volume of ductile phases and emphasis on NNS manufacturing. Utilize SOA hard material machining approaches and optimize parameters as necessary.

3Coating: Coating system (E/TBC) durability is limited at the designated service conditions

Modify and optimize composition, architecture, and coating processing method to address particular shortfall of TBC/EBC (e.g. thermal conductivity, strain tolerance, stability).

4

Manufacturing: Processes unable to meet surface finish and dimensional stability requirements

Optimize process parameters, modify particle size distribution of feedstock, and enhance post processing techniques to meet requirements.

5

Adoption: Cost/availability of materials necessary to operate at desired system conditions is too difficult to overcome

Optimize chemistry with constituent element cost/availability as a key metric to improve characteristics in final compositions and coating system architecture.

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T2M and Aspirational Follow-on Plans

6

Power generation applications

Alloyed

Boeing

Rolls-Royce Corporation

Large primary IGT

Aftermarket, small IGT

License

Manufacture

Supersonic/hypersonic applications

Thermal/power management,EE structures

Jet turbines

License

Launch / satellite

applications

CommercializationFollow-on / Phase 2

▸ Test/Demo coupons ➔ coated test blades, 3”-6”, integrated cooling channels

▸ Interlayer and TBC coating suitable for serial production

▸ Testing against targets

– 1300°C yield strength > 400MPa

– Solidus (base material) > 1500°C

– Fatigue: >1000 cycles to failure at 0.45% strain, 1300°C

– Coating allows 100 hrs at > 1700°C

– Dimensional variability > 1%

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