Experimental study of ceramic coated tip seals for turbojet engines

Ceramic gas-path seals were fabricated and successfully operated over 1000 cycles from flight idle to maximum power in a small turboshaft engine. The seals were fabricated by plasma spraying zirconia over a NiCoCrAlX bond boat on the Haynes 25 substrate. Coolant-side substrate temperatures and related engine parameters were recorded. Post-test inspection revealed mudflat surface cracking with penetration to the ceramic bond-coat interface

Experimental and analytical study of ceramic-coated turbine-tip shroud seals for small turbine engines

The results of an experimental and analytical evaluation of ceramic turbine tip shrouds within a small turbine engine operating environment are presented. The ceramic shrouds were subjected to 1001 cycles between idle and high power and steady-state conditions for a total of 57.8 engine hr. Posttest engine inspection revealed mud-flat surface cracking, which was attributed to microcracking under tension with crack penetration to the ceramic and bond coat interface. Sections and micrographs tend to corroborate the thesis. The engine test data provided input to a thermomechanical analysis to predict temperature and stress profiles throughout the ceramic gas-path seal. The analysis predicts cyclic thermal stresses large enough to cause the seal to fail. These stresses are, however, mitigated by inelastic behavior of the shroud materials and by the microfracturing that tensile stresses produce. Microfracturing enhances shroud longevity during early life but provides the failure mechanism during life but provides the failure mechanism during extended life when coupled with the time dependent inelastic materials effects