Experimental verification of vapor deposition model in Mach 0.3 burner rigs

A comprehensive theoretical framework of deposition from combustion gases was developed covering the spectrum of various mass delivery mechanisms including vapor, thermophoretically enhanced small particle, and inertially impacting large particle deposition. Rational yet simple correlations were provided to facilitate engineering surface arrival rate predictions. Experimental verification of the deposition theory was validated using burner rigs. Toward this end, a Mach 0.3 burner rig apparatus was designed to measure deposition rates from salt-seeded combustion gases on an internally cooled cylindrical collector

Chemical vapor deposition modeling: An assessment of current status

The shortcomings of earlier approaches that assumed thermochemical equilibrium and used chemical vapor deposition (CVD) phase diagrams are pointed out. Significant advancements in predictive capabilities due to recent computational developments, especially those for deposition rates controlled by gas phase mass transport, are demonstrated. The importance of using the proper boundary conditions is stressed, and the availability and reliability of gas phase and surface chemical kinetic information are emphasized as the most limiting factors. Future directions for CVD are proposed on the basis of current needs for efficient and effective progress in CVD process design and optimization

Determination of convective diffusion heat/mass transfer rates to burner rig test targets comparable in size to cross-stream jet diameter

Two sets of experiments have been performed to be able to predict the convective diffusion heat/mass transfer rates to a cylindrical target whose height and diameter are comparable to, but less than, the diameter of the circular cross-stream jet, thereby simulating the same geometric configuration as a typical burner rig test specimen located in the cross-stream of the combustor exit nozzle. The first set exploits the naphthalene sublimation technique to determine the heat/mass transfer coefficient under isothermal conditions for various flow rates (Reynolds numbers). The second set, conducted at various combustion temperatures and Reynolds numbers, utilized the temperature variation along the surface of the above-mentioned target under steady-state conditions to estimate the effect of cooling (dilution) due to the entrainment of stagnant room temperature air. The experimental information obtained is used to predict high temperature, high velocity corrosive salt vapor deposition rates in burner rigs on collectors that are geometrically the same. The agreement with preliminary data obtained from Na2SO4 vapor deposition experiments is found to be excellent

A kinetic and equilibrium analysis of silicon carbide chemical vapor deposition on monofilaments

Chemical kinetics of atmospheric pressure silicon carbide (SiC) chemical vapor deposition (CVD) from dilute silane and propane source gases in hydrogen is numerically analyzed in a cylindrical upflow reactor designed for CVD on monofilaments. The chemical composition of the SiC deposit is assessed both from the calculated total fluxes of carbon and silicon and from chemical equilibrium considerations for the prevailing temperatures and species concentrations at and along the filament surface. The effects of gas and surface chemistry on the evolution of major gas phase species are considered in the analysis

Experimental verification of corrosive vapor deposition rate theory in high velocity burner rigs

The ability to predict deposition rates is required to facilitate modelling of high temperature corrosion by fused salt condensates in turbine engines. A corrosive salt vapor deposition theory based on multicomponent chemically frozen boundary layers (CFBL) has been successfully verified by high velocity burner rig experiments. The experiments involved internally air-impingement cooled, both rotating full and stationary segmented cylindrical collectors located in the crossflow of sodium-seeded combustion gases. Excellent agreement is found between the CFBL theory an the experimental measurements for both the absolute amounts of Na2SO4 deposition rates and the behavior of deposition rate with respect to collector temperature, mass flowrate (velocity) and Na concentration

Comparisons of rational engineering correlations of thermophoretically-augmented particle mass transfer with STAN5-predictions for developing boundary layers

Modification of the code STAN5 to properly include thermophoretic mass transport, and examination of selected test cases developing boundary layers which include variable properties, viscous dissipation, transition to turbulence and transpiration cooling. Under conditions representative of current and projected GT operation, local application of St(M)/St(M),o correlations evidently provides accurate and economical engineering design predictions, especially for suspended particles characterized by Schmidt numbers outside of the heavy vapor range

Engineering correlations of variable-property effects on laminar forced convection mass transfer for dilute vapor species and small particles in air

A simple engineering correlation scheme is developed to predict the variable property effects on dilute species laminar forced convection mass transfer applicable to all vapor molecules or Brownian diffusing small particle, covering the surface to mainstream temperature ratio of 0.25 T sub W/T sub e 4. The accuracy of the correlation is checked against rigorous numerical forced convection laminar boundary layer calculations of flat plate and stagnation point flows of air containing trace species of Na, NaCl, NaOH, Na2SO4, K, KCl, KOH, or K2SO4 vapor species or their clusters. For the cases reported here the correlation had an average absolute error of only 1 percent (maximum 13 percent) as compared to an average absolute error of 18 percent (maximum 54 percent) one would have made by using the constant-property results

Convection and chemistry effects in CVD: A 3-D analysis for silicon deposition

The computational fluid dynamics code FLUENT has been adopted to simulate the entire rectangular-channel-like (3-D) geometry of an experimental CVD reactor designed for Si deposition. The code incorporated the effects of both homogeneous (gas phase) and heterogeneous (surface) chemistry with finite reaction rates of important species existing in silane dissociation. The experiments were designed to elucidate the effects of gravitationally-induced buoyancy-driven convection flows on the quality of the grown Si films. This goal is accomplished by contrasting the results obtained from a carrier gas mixture of H2/Ar with the ones obtained from the same molar mixture ratio of H2/He, without any accompanying change in the chemistry. Computationally, these cases are simulated in the terrestrial gravitational field and in the absence of gravity. The numerical results compare favorably with experiments. Powerful computational tools provide invaluable insights into the complex physicochemical phenomena taking place in CVD reactors. Such information is essential for the improved design and optimization of future CVD reactors

Computer Program for the Calculation of Multicomponent Convective Diffusion Deposition Rates from Chemically Frozen Boundary Layer Theory

The computer program based on multicomponent chemically frozen boundary layer (CFBL) theory for calculating vapor and/or small particle deposition rates is documented. A specific application to perimter-averaged Na2SO4 deposition rate calculations on a cylindrical collector is demonstrated. The manual includes a typical program input and output for users

CVD of silicon carbide on structural fibers: Microstructure and composition

Structural fibers are currently being considered as reinforcements for intermetallic and ceramic materials. Some of these fibers, however, are easily degraded in a high temperature oxidative environment. Therefore, coatings are needed to protect the fibers from environmental attack. Silicon carbide (SiC) was chemically vapor deposited (CVD) on Textron's SCS6 fibers. Fiber temperatures ranging from 1350 to 1500 C were studied. Silane (SiH4) and propane (C2H8) were used for the source gases and different concentrations of these source gases were studied. Deposition rates were determined for each group of fibers at different temperatures. Less variation in deposition rates were observed for the dilute source gas experiments than the concentrated source gas experiments. A careful analysis was performed on the stoichiometry of the CVD SiC coating using electron microprobe. Microstructures for the different conditions were compared. At 1350 C, the microstructures were similar; however, at higher temperatures, the microstructure for the more concentrated source gas group were porous and columnar in comparison to the cross sections taken from the same area for the dilute source gas group