Advances in Energy Materials: Ceramic Transactions

157 Pages·2009·4.82 MB·English

Advances in
Energy Materials
Advances in
Energy Materials
Ceramic Transactions, Volume 205
A Collection of Papers Presented at the
2008 Materials Science and Technology
Conference (MSslTO8)
October 5-9, 2008
Pittsburgh, Pennsylvania
Edited by
Fatih Dogan
Navin Manjooran
@WILEY
A John Wiley & Sons, Inc., Publication
Copyright 0 2009 by The American Ceramic Society. All rights reserved.
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ISBN 978-0-470-40843-8
Printed in the United States of America.
1 0 9 8 7 6 5 4 3 2 1
Contents
Preface vii
INDUSTRIAL PERSPECTIVE OVERVIEW
The Role of Materials and Manufacturing Technologies as Enablers 3
in Gas Turbine Cooling for High Performance Engines
Ron S.B unker
ENERGY MATERIALS
Synthesis, Sintering and Dielectric Properties of Nan0 Structured 23
High Purity Titanium Dioxide
Sheng Chao and Fatih Dogan
Sorption/Desorption Properties of MgH,-Oxide Composite Prepared 31
by Ultra High-Energy Planetary Ball Milling
Y. Kodera, N. Yamasaki, J. Miki, M. Ohyanagi, S. Shiozaki, S. Fukui, J. Yin,
and T. Fukui
Ab lnitio Study of the Influence of Pressure on the Hydrogen 41
Diffusion Behavior in Zirconium Hydrogen Solid Solution
Y. Endo, M. Ito, H. Muta, K. Kurosaki, M. Uno, and S. Yamanaka
EBSP Study of Hydride Precipitation Behavior in Zr-Nb Alloys 51
Shunichiro Nishioka, Masato Ito, Hiroaki Muta, Masayoshi Uno, and
ShinsukeYamanaka
FEM Study of Delayed Hydride Cracking in Zirconium Alloy Fuel 59
Claddina
Miayoshi Uno, Masato Ito, Hiroaki Muta, Ken Kurosaki, and Shinsuke Yamanaka
v
The Effect of Manganese Stoichiometry on the Curie Temperature 71
of Lao.67Cao,26Sro,07Mn,+Ux0s3e d in Magnetic Refrigeration
Biering, M. Menon, and N. Pryds
Preparation of ElectrocatalyticallyA ctive RuO,/Ti Electrodes by 77
Pechini Method
0. Kahvecioglu and S. Tirnur
The Myriad Structures of Liquid Water: Introduction to the Essential 87
Materials Science
Rusturn Roy and Manju L. Rao
Preparation of CulnS, Films by Electrodeposition: Effect of Metal 99
Element Addition to Electrolyte Bath
Tomoya Honjo, Masayoshi Uno, and Shinsuke Yarnanaka
Preparation of High-Jc MOD-YBCO Films for Fault Current Limiters 109
M. Sohrna, W. Kondo, K. Tsukada, I. Yarnaguchi, T. Kurnagai, T. Manabe,
K. Arai. and H. Yarnasaki
NANOTECHNOLOGY FOR POWER GENERATION
Modeling of Electromagnetic Wave Propagation of Nano-Structured 11 7
Fibers for Sensor Applications
Neal T. Pfeiffenberger and Gary R. Pickrell
Increased Functionality of Novel Nano-Porous Fiber Optic 123
Structures through Electroless Copper Deposition and Quantum
Dot Solutions
Michael G. Wooddell, Gary Pickrell, and Brian Scott
Thermopower Measurements in 1- D Semiconductor Systems 135
Sezhian Annarnalai, Jugdersuren Battogtokh, Rudra Bhatta, Ian L. Pegg
and Biprodas Dutta
Structural Changes and Stability of Pore Morphologies of a 145
Porous Glass at Elevated Temperatures
Brian Scott and Gary Pickrell
Author Index 159
vi * Advances in Energy Materials
Preface
Increasing awareness of environmental factors and limited energy resources have
led to a profound evolution in the way we view the generation and supply of energy.
Although fossil and nuclear sources will remain the most important energy provider
for many more years, flexible technological solutions that involve alternative means
of energy supply and storage need to be developed urgently.
The search for cleaner, cheaper, smaller and more efficient energy technologies
has been driven by recent technology advancements particularly in the field of ma-
terials science and engineering. This volume documents a special collection of arti-
cles from a select group of invited prominent scientists from academia, national lab-
oratories and industry who presented their work at the symposia on Energy
Materials and Nanotechnology for Power Generation at the 2008 Materials Science
and Technology (MS&T’08) conference held in Pittsburgh, PA, from 5th -9th Oc-
tober These articles represent a summary of the presentations focusing on both the
scientific and technological aspects of energy storage, nuclear materials, nano-
based sensors, catalysts and devices for applications in power generation, solar en-
ergy materials, superconductors and more.
The success of the symposia could not have been possible without the support of
staff at The American Ceramic Society and the other symposia co-organizers Drs.
Masanobu Awano, Wayne Huebner, Dileep Singh, and Gary Pickrell. The organiz-
ers are grateful to all participants and session chairs for their time and effort, to au-
thors for their timely submissions and revisions of the manuscripts, and to review-
ers for their valuable comments and suggestions.
Special thanks to Dr. Ronald Bunker from GE Global Research Center who
kindly provided the introductory article highlighting the industry perspective to-
wards the need for advanced energy materials.
FATIHD OGAN
Missouri University of Science and Technology
NAVINM ANJOORAN
Siemens AG
vii
Advances in Energy Materials
Edited by Fatih Dogan and Navin Manjooran
Copyright C 2009 The American Ceramic Society
Industrial Perspective
Overview
Advances in Energy Materials
Edited by Fatih Dogan and Navin Manjooran
Copyright C 2009 The American Ceramic Society
THE ROLE OF MATERIALS AND MANUFACTURING TECHNOLOGIES AS
ENABLERS IN GAS TURBINE COOLING FOR HIGH PERFORMANCE ENGINES
Ron S. Bunker
GE Global Research Center
Niskayuna, New York, USA
ABSTRACT
Gas turbines contribute a significant portion of the world’s power demand, as well as
the majority of aircraft propulsion needs. Today’s complex cooled gas turbine
components would not be possible without continuous advances in both materials and
manufacturing science and technology. The turbine hot gas path is the most costly
portion of the engine and as a consequence, improvements in materials and
manufacturing, especially those that enable better cooling, carry a high return on
investment. This summary identifies the elements in turbine cooling that can benefit
from materials and manufacturing enabling technologies, as well as many of the
emerging means for making these a reality.
INTRODUCTION
The gas turbine is a specialized engine designed to convert chemical energy into one
or more useful forms of energy, such as thrust, shaft work, and process heat. Gas turbine
engines for aviation and marine propulsion, power generation, and combined heat I power
applications are most commonly in the form of continuously rotating axial
turbomachinery. An overall engine schematic is shown in Figure 1 for the CFM56-5B
commercial aviation gas turbine engine. As a thermodynamic Brayton cycle, the
efficiency of the gas turbine engine can be raised substantially by increasing the firing
temperature of the turbine. Modem gas turbine systems are fired at temperatures far in
excess of the material melting temperature limits. This is made possible by the
aggressive cooling of the hot gas path (HGP) components, the use of advanced materials
for structural components and protective coatings, the application of high efficiency
aerodynamics, the use of prognostic and health monitoring systems, and the continuous
development of improved mechanical stress, lifing, and systems interactions and
behavioral modeling.
The high-pressure turbine (HPT) section of the engine, shown in Figure 2,
encompasses all of these challenges simultaneously. For example, the technology of
cooling gas turbine components via internal convective flows of single-phase gases has
developed over the years from simple smooth cooling passages to very complex
geometries involving many differing surfaces, architectures, and fluid-surface
interactions’. The fundamental aim of this technology area is to obtain the highest
overall cooling effectiveness with the lowest possible penalty on the thermodynamic
cycle performance. Figure 3 provides a generic view of the gross cooling effectiveness
for turbine airfoils with the cooling technologies developed over the years. The use of 20
to 30% of the compressor air to cool the HPT presents a severe penalty on the
thermodynamic efficiency unless the firing temperature is sufficiently high for the gains
to outweigh the losses. In all properly operating cooled turbine systems, the efficiency
gain is significant enough to justify the added complexity and cost of the cooling
3
Role of Materials and Manufacturing Technologies as Enablers in Gas Turbine Cooling
technologies employed. In many respects, the evolution of gas turbine internal cooling
technologies began in parallel with heat exchanger and fluid processing techniques,
“simply” packaged into the constrained designs required of turbine airfoils; ie.
aerodynamics, mechanical strength, vibrational response, etc. Turbine airfoils are after
all merely highly specialized and complex heat exchangers that release the cold side fluid
in a controlled fashion to maximize work extraction. Actively or passively cooled
regions of the hot gas path in both aircraft engine and power generating gas turbines
include the stationary vanes or nozzles, the rotating blades or buckets of the HPT stages,
the shrouds bounding the rotating blades, and the combustor liners and flame holding
segments. Collectively these components are referred to as the hot gas path (HGP). All
such engines additionally cool the interfaces around the immediate HGP, thereby
bringing into consideration the secondary flow circuits of the turbine wheelspaces and the
outer casings that serve as both cooling and positive purge flows. The ever present
constraints common to all components and systems include but are not limited to pressure
losses, material temperatures, component stresses, geometry and volume, aerodynamics,
fouling, and coolant conditions.
Figure 1. High bypass turbofan gas turbine engine
Cooling technology, as applied to gas turbine components such as the high-pressure
turbine vanes and blades, is composed of five main elements that must work in harmony,
(1) internal convective cooling, (2) external surface film cooling, (3) materials selection,
(4) thermal-mechanical design, and (5) selection and/or pre-treatment of the coolant fluid.
The enhancement of internal convective flow surfaces for the augmentation of heat
transfer was initiated through the introduction of turbulators and pin-banks within
investment cast airfoils. These surface enhancement methods continue to play a large
role in today’s turbine cooling designs. With the advancements in materials and
manufacturing technologies of the last decade, a drastically larger realm of surface
enhancement techniques has become cost effective for use in the cooling of turbine
airfoils. The art and science of film cooling concerns the bleeding of internal component
cooling air through the external walls to form a protective layer of cooling between the
4 . Advances in Energy Materials
Role of Materials and Manufacturing Technologies as Enablers in Gas Turbine Cooling
hot gases and the component external surfaces. The application of effective film cooling
techniques provides the first and best line of defense for hot gas path surfaces against the
onslaught of extreme heat fluxes, serving to directly reduce the incident convective heat
flux on the surface. Materials most commonly employed in cooled parts include high-
temperature, high-strength nickel- or cobalt-based superalloys coated with yttria-
stabilized zirconia oxide ceramics (thermal barrier coatings, TBC). The protective
ceramic coatings are today actively used to enhance the cooling capability of the internal
convection mechanisms and to dampen thermal gradients during transient events. The
thermal-mechanical design of the components must marry these first three elements into a
package that has acceptable thermal stresses, coating strains, oxidation limits, creep-
rupture properties, and aero-mechanical response. Under the majority of practical system
constraints, this means the highest achievable internal convective heat transfer
coefficients with the lowest achievable friction coefficient or pressure loss. More often
than not however, the challenge lies in the manufacturing limitations for such thermal-
mechanical designs to be cost effective for the life of the components. The last cooling
design element concerns the correct selection of the cooling fluid to perform the required
function with the least impact on the cycle efficiency. This usually is achieved through
the use of compressor air bled from the most advantageous stage of the compressor, but
can also be done using off-board cooling sources such as closed-circuit steam or air, as
well as intra-cycle and inter-cycle heat exchangers.
Figure 2. Gas turbine hot gas flow path
Advances in Energy Materials 5
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