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Application of Oxide Dispersion Strengthening Coatings for Improved Transpiration Cooling

National Energy Technology Laboratory

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Technology Marketing Summary

Research is active on the development and incorporation of oxide dispersion strengthening (ODS) coatings for use in gas turbine component cooling applications. This invention is available for licensing and/or further collaborative research from the U.S. Department of Energy’s National Energy Technology Laboratory.

Description

Specifications for current 7FA-05 land-based gas turbine engines require inlet operating temperatures to be maintained at ∼1,360 °C. However, to improve overall power generation efficiency, turbine engines are being designed to operate at greater temperatures: ∼1,485 °C for the H-engine, ∼1,620 °C for the J-engine, and ∼1,700 °C for future engines. To achieve these goals, high-efficiency, near-zero emission turbine power systems depend on the advancement of thermal protection of hot sections, such as the first and second stage rotating and stationary airfoils and control of secondary flows. Current technology for protecting turbine airfoils primarily relies on the combined effects of a thermal barrier coating and convective cooling. However, simply focusing on the development of thermal barrier coatings materials and cooling technologies is insufficient to meet the thermal-mechanical demands imposed by the hot gas future with elevated turbine-inlet-temperatures. Significant advances in turbine cooling effectiveness, as well as thermal barrier coating performance and durability are required to accelerate development of advanced energy systems.

This invention describes a method and apparatus for generating transpiration cooling using a porous ODS high temperature alloy layer in conjunction with near surface embedded microchannel (NSEMC) architectures and film cooling configurations. The transpiration cooling process reduces superalloy substrate airfoil temperature, resulting in improved turbine component durability.

Benefits

· Provides a fabrication process for porous ODS coatings

· Porous ODS coatings can be integrated with near surface embedded micro channels (NSEMC) and film cooling configurations in cast metal airfoil geometries

· Porous ODS and integrated cooling features provide a component design to achieve transpiration cooling of airfoils for use at high temperature and extended time periods

· Transpiration cooling is achieved by allowing coolant to diffuse through an array of discrete pore holes through the porous ODS layer, forming a uniform protective barrier against the hot combustion gases

· The combination of NSEMC and porous ODS reduces the superalloy substrate airfoil temperature and improves the durability of the turbine component

· Double-wall cooling concept is introduced by combining the NSEMC and primary cooling channel, with/without surface roughness

· By forming the NSEMC via deposition of an ODS layer, near surface micro-channels can be realized

Applications and Industries

· Natural gas and fossil fuel-fired combined cycle power plant componentry

· Advanced turbine airfoils for land-based power generation

· Aero-engines for commercial and defense industries

· Additional applications including, high temperature heat exchange tubing, porous hot gas filters for fine particulate removal, and metal alloy materials used in glass production

Patents and Patent Applications
ID Number
Title and Abstract
Primary Lab
Date
Patent 9,579,722
Patent
9,579,722
Method of making an apparatus for transpiration cooling of substrates such as turbine airfoils
A method and apparatus for generating transpiration cooling using an oxidized porous HTA layer metallurgically bonded to a substrate having micro-channel architectures. The method and apparatus generates a porous HTA layer by spreading generally spherical HTA powder particles on a substrate, partially sintering under O.sub.2 vacuum until the porous HTA layer exhibits a porosity between 20% and 50% and a neck size ratio between 0.1 and 0.5, followed by a controlled oxidation generating an oxidation layer of alumina, chromia, or silica at a thickness of about 20 to about 500 nm. In particular embodiments, the oxidized porous HTA layer and the substrate comprise Ni as a majority element. In other embodiments, the oxidized porous HTA layer and the substrate further comprise Al, and in additional embodiments, the oxidized porous HTA layer and the substrate comprise .gamma.-Ni+.gamma.'-Ni.sub.3Al.
U.S. Department of Energy 02/28/2017
Issued
Technology Status
Development StageAvailabilityPublishedLast Updated
PrototypeAvailable06/23/201706/23/2017

Contact NETL About This Technology

To: Jessica Sosenko<jessica.sosenko@netl.doe.gov>