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Ceramic Materials and Components for Engines
Edited
by
Jurgen
G.
Heinrich and Fritz Aldinger
@WILEY-VCH
Further Titles
of
Interest
J.
Bill,
F.
Wakai,
F.
Aldinger (Eds.)
Precursor-Derived Ceramics
ISBN
3-527-298 14-2
R. Riedel (Ed.)
Handbook
of
Ceramic Hard Material
ISBN
3-527-29972-6
G.
Miiller (Ed.)
Ceramics
-
Processing, Reliability, Tribology and Wear
ISBN
3-527-30194-1
Ceramic Materials
and
Components
Ior
Engines
Edited
by
Jurgen
G.
Heinrich and Fritz Aldinger
Deutsche Keramische Gesellschaft
Weinheim
-
New York
-
Chichester
Brisbane
-
Singapore
-
Toronto
Prof. Dr. Jiirgen G. Heinrich
TU Clausthal Max-Planck-Institut
fiir
Metallforschung
Institut fur Nichtmetallische Werkstoffe
Professur fur Ingenieurkeramik 70569 Stuttgart
ZehntnerstraBe 2a Germany
38678 Clausthal-Zellerfeld
Germany
Prof. Dr. Fritz Aldinger
Heisenbergstrak
5
71h International Symposium “Ceramic Materials and Components for Engines” Applications in Energy, Transportation and
Environment Systems
Organizer: Deutsche Keramische Gesellschaft
This book was carefully produced. Nevertheless, editors, authors and publisher do not warrant the information
contained therein to be free of errors. Readers
are
advised to keep in mind that statements, data, illustrations, procedural
details or other items may inadvertently be inaccurate.
Cover: The cover picture shows the high-performance brake of the new Mercedes-Benz CL
55
AMG “F1 Limited Edition”.
The brake discs are made of a carbon fiber-reinforced ceramic and
are
the fist CMC material that is introduced to series
production in the automobile industry. The picture is courtesy of DaimlerChrysler Communications, Stuttgart (Germany).
Library of Congress Card
No.:
applied for
A catalogue record for this book is available from the British Library.
Die Deutsche Bibliothek
-
CIP Cataloguing-in-Publication-Data
A
catalogue record for this publication is available from Die Deutsche Bibliothek
ISBN
3-527-30416-9
0
WILEY-VCH Verlag GmbH, D-69469 Weinheim (Federal Republic of Germany). 2001
Printed on acid-free paper.
All rights reserved (including those
of
translation in other languages).
No
part of this book may be reproduced
in
any form
-
by photoprinting, microfilm, or any other means
-
nor transmitted or translated into machine language without written
permission from
the
publishers. Registered names, trademarks, etc. used
in
this book, even when not specifically marked as
such,
are
not to be considered unprotected by law.
Printing: betz-druck gmbh, 64291 Darmstadt. Bookbinding: Wilhelm Osswald
&
Co., 67433 Neustadt.
Printed in the Federal Republic of Germany.
Foreword
With the
7'h
International Symposium
Ceramic Materials and Components for Engines,
June 19-2 1, Goslar, the German Ceramic Society was hosting this international conference for
the second time since 1986.
Since that time a lot has changed in regard to the use of ceramic components in engines.
A
number
of
parts have proven their suitability through large-scale experiments for seriel
application in very impressive ways, especially in Japan, the
USA
and in Germany. Despite
this fact, neither ceramic gas turbines in automobiles nor ceramic components in reciprocating
engines, as for example valves, turbocharger motors, precombustion chambers or portliners,
were successful in mass production. While the reliability
of
these components could be
proven by seriel application, there is still a lack of economical quality assurance concepts.
The ceramic components are still too costly compared to metallic components. Therefore the
main emphasis of research for these
conventional
products is the reducement of costly starting
materials and the development of processing techniques at a good price.
For the past few years a new generation of ceramic components, for the use in energy,
transportation and environment systems, has been developed. The efforts are more and more
system oriented in this field. The only possibility to manage this complex issue in the future
will be interdisciplinary cooperation. Chemists, physicists, material scientists, process
engineers, mechanical engineers and engine manufacturers will have to cooperate in a more
intensive way than ever before. This is the only way to successfully develop the complicated
systems by using ceramic materials. The R&D activities are still concentrating on gas turbines
and reciprocating engines, but also on brakes, bearings, fuel cells, batteries, filters,
membranes, sensors and actuators as well as on shaping and cutting tools for low expense
machining of ceramic components.
As
a result, the range of materials, which are actually in
discussion for these applications, have considerably increased.
Besides presentations on the systems mentioned, this conference offered discussions on
important issues such as performance, reliability, design, modelling and simulation, expense
effective manufacturing as well as material design and process development. This book
summarizes the scientific papers of the conference. Especially in the plenary lectures some of
the most fascinating new applications of ceramic materials in energy, transportation and
environment systems are presented They are followed by special articles on the main topics
of
the conference. The symposium led to a lot of contacts between collegues from industry
universities and research institutes. The proceedings shall lead to new ideas for
interdisciplinary activities in the future.
Goslar, June
2000
Jurgen
G.
Heinrich
Fritz Aldinger
Contents
1.Systems.
...............................
New Technologies in the Light of Materials
The Promise of SOFC Power Generation Technology
Ceramic Cutting Tools
............................
Practical Use of Ceramic Components and Ceramic Engines
................
Beta Ceramic in Zebrae and NAS Batteries
Oxygen Sensors for Lean Combustion Engines
....................
Ceramic Gas Turbine
..
CGT302" Development Summary
.....................
..................
Ceramic Matrix Composites for Disk Brakes and Their Manufacturing Technologies
........
.....................
................
Preparation of Planar SOFC-Components Via Tape Casting of Aqueous Systems. Lamination and Cofiring
.
Glasses from the System RO.R,O,.SiO, as Sealants of High Chromium Steel Components
in the Planar SOFC
.............................
Development of Ceramic Sheathed Type Thermocouple with High Heat Resistance and High Durability
.
Lightweight and Wear Resistant CMC Brakes
Advances in Hot Gas Filtration Technique
Nano-Scaled Ceramic Membranes for the Filtration of Fine and Sticky Dust
...........
Sensitivity Characterization to Flamable Gas
.....................
....................
.
.....................
Production and Characterization of TiCN-Based Materials for Cutting Tool Applications
......
I1
.
Performance
/
Reliability
.........................
Evaluation of Mechanical Reliability of S1.N. Nozzles after Exposure in an Industrial Gas Turbine
Friction and Wear of Advanced Ceramics
Lifetime Prediction for Silicon Nitride
Standardising Measurement and Test Methods for Advanced Technical Ceramics
Prediction of Thermal Shock Resistance of Components Using the Indentation-Quench Test
.....
Effect of Grain Boundary Composition on High-Temperature Mechanical Properties of Hot-Pressed
...
.....................
......................
........
Investigations on the Stable Crack Growth of Indentation Cracks
..............
Ceramic Components for Metal Forming Tools
...................
Silicon Carbide Sintered with Yttria
......................
Thermal Shock Properties of SiALON Ceramics
...................
Corrosion of Nonoxide Silicon-Based Ceramics in a Gas Turbine Environment
.........
Mechanical Properties and Wear Behaviour of Differently Machined Silicon Nitride and Silicon Carbide
Ceramic Surfaces
............................
Design of Wear Resistant Polycrystalline Alumina
Crack Growth of Ceramic Materials in Sliding Contact
.................
Reliability and Reproducibility
of
Silicon Nitride Valves: Experiences of a Field Test
Ceramic Coatings with SolidLubricant Ability for Engine Applications
............
Tribological Behavior
of
Silicon Nitride/Steel Contacts under Lubricated Conditions
Optimization of the Brazilian Disc Test for Ceramic Materials
...............
..................
Damage Detection in Tetragonal Zirconia Polycrystals (TZP) by Impedance Spectroscopy
......
Self-Mated Tribological Properties of Plasma Sprayed Chromium Carbide Coating
........
Role of Grain Size in Scratch Damage Resistance in Zirconias and Silicon Nitrides
........
.......
.......
1
3
7
13
21
27
33
39
45
51
57
63
69
73
79
85
91
95
97
103
109
115
121
127
133
139
147
153
157
163
169
175
181
187
193
199
205
211
VI
The Impulse Excitation Technique for Rapid Assessment
of
the Temperature Dependence of Structural
Properties of Silicon Nitride and Zirconium Oxide Ceramics
...............
217
VAMAS Round Robin Testing of High Temperature Flexural Strength
............
223
Effect of High Voltage Screening Method on Titania Ceramics with Different Surface Finishing
....
229
.
In Situ Observation of Tension and Cyclic Fatigue Damage in Hi-NiCALON Fiber/SiC Composite
...
233
Multi-Axial Strength Data for A1.0.. and MgO-ZQ-Ceramics
..............
239
I11
. Design. Modelling and Simulation
......................
245
Fatigue Design and Testing of Ceramic Intake and Exhaust Valves
.............
247
Design and Testing of a Prototype SiSiC heat Exchanger for Coal Combustion Power Stations
....
255
DesignandTestingofCeramicComponentsforIndustrialGasTurbines
...........
261
An
Investigation on Paste Flow in a Press-Moulded Ceramic Dome
.............
267
Design Standard for Advanced Ceramic Materials and Components
.............
273
Static and Cyclic Stress-Lifetime Curves of Ceramics
.................
279
Lifetime Prediction of Ceramic Thermal Barrier Coatings Based on Lifetime Analyses of Close
CreepofaSiliconNitrideunderVariousSpecimen/LoadingConfigurations
..........
291
Mathematical Model
of
Microhardness of Plasma Sprayed Chromium Oxide Coating
.......
299
Lifetime Prediction Model for Plasma-Sprayed Thermal Barrier Coatings Based on a Micromechanical
Analytical Design and Experimental Verification Methods of Ceramic Radial Turbine Rotors
The Evolution of Damage in Ceramic Materials for Gas Turbine Applications under Complex Load
to Reality Tests
.............................
285
Approach
...............................
305
for a Gas Turbine
............................
311
Conditions
..............................
319
Mechanical Failure of Electroceramic Components
..................
325
Based Model
..............................
333
The Energy and The Power Time Dependence on the Ultrasonic Welding Process
-
A Weibull Statistical
IV
. Cost Effective Manufacturing
Advances in Brazing
of
Ceramic Materials for Engines
.................
Stereolithography for Ceramic Part Manufacturing
..................
353
Potential of the Hydrolysis Assisted Solidification Process for Wet Forming of Si.N. Ceramics
Green Machining
of
Aluminium Oxide Ceramics
...................
Laser-Assisted Turning of Silicon-Nitride Ceramics
..................
Ceramic Engineering with Preforms for Locally Reinforced Light Metal Components
Laser Beam Welding of Alumina
-
a New Successful Technology
SRBSN Material Development for Automotive Applications
...............
393
New Ceramic Excellence for Complex Machining of Engine Materials
............
Process Strategies for Grinding of Advanced Ceramic Cutting Tools
.............
.......................
345
347
Application of the Mold SDM Process to the Fabrication of Ceramic Parts for a Micro Gas Turbine Engine 359
365
371
377
383
387
.....
399
405
411
.........
417
....
.......
.............
Process Design for High Performance Grinding of Advanced Ceramics in Mass Production
Ultrasonic Assisted Face Grinding and Cross-Peripheral Grinding of Ceramics
V
.
Material Design and Process Development
...................
423
Advancing in Mechanical Properties of Silicon Nitride: The Roles
of
Starting Powders and Processing
.
Materials Design of Composite Materials
.
Compatibility of Self-Damage Monitoring and Strengthening
.
The Design of Composition and Mechanical Properties of
a-P
SiAlON Ceramics Densified with
.
425
43 1
Higher Atomic Number Rare Earths
......................
435
Grain-Boundary Phase Control of Silicon Nitride Materials
...............
439
Characterisationof Multi-Cation Stabilised Alpha-SiALONMaterials
............
447
Sintering and Microstructure of Silicon Nitride with Magnesia and Cerium Additives
.......
443
VII
Grain Boundaries of SiC.Si0. Composite
Millimeter Wave Sintering of Ceramics
....................
Internally Cooled Monolithic Silicon Nitride Aerospace Components
Preparation and High Temperature Strength of Gd.Al. 0JMg0 Composites
.........
Characterization of
In
Situ Sic-BN Composites
Coating Experiments on Carbon Fibers Using a Continuous Liquid Coating Process
......
Effect of A1 Component on Mechanical Properties
in
Al-Penetrated Alumina
........
Cavitation Creep
in
the Next Generation Silicon Nitride
...............
Thermal Conductivity and Phonon Scattering Mechanisms of p-Si3N4 Ceramics
A High Thermal Conductive p-Silicon Nitride Substrate for Power Modules
...................
..........
.................
.......
........
Characterisation
of
the Pore Structure of Biomorphic Cellular Silicon Carbide Derived from Wood
by Mercury Porosimetry
........................
TBC Consisting
of
New Metal-Glass Composites
.................
Aspects on Sintering of EB-PVD TBCs
....................
Crack Propagation in a Thermal Barrier Coating System
..............
Porous Ceramics Functional Cavities for System Innovation
.............
Feasibility Studies on Applying
In
Situ Single Crystal Oxide Ceramic Eutectic Composites
................
Synthesis and Property Tailoring of Reaction-Based Composites: The RBAO and the
3A
Process
.
Properties of Silicon NitrideKarbide Nano/Microcomposites
-
Role of Sic Nanoinclusions and
Grain Boundary Chemistry
.......................
Layered Si. Nd(SiAlON+TiN) Composites with Self-Diagnostic Ability
..........
Multilayer C/SIC Composites for Automotive Brake Systems
.............
Sinter Additive Optimization in Processing of Aluminum Nitride for Heat Exchanger Components
.
New Opportunity for Bimodal Microstructure Control
in
Silicon Nitride
.........
Design
of
SiCN
-
Precursors for Various Applications
...............
Gelatin Casting and Starch Consolidation of Alumina Ceramics
............
Liquid-Phase Sintered Silicon Carbide Based Ceramics with AlN.Y,O, and AlN.L%O. Additives
.
Slip Casting of ATZ Ceramics
.......................
The Preparation for Sintered Body of CeO. Based Complex Oxide in Low Temperature Solid Oxide
Fuel Cells Using Colloidal Surface Chemistry
.................
Processing and Properties of Tic-Ni3Al Composites
................
Ceramic Joints Between Sic Bodies: Microstructure. Composition. and Joining Strength
....
Fatigue Behaviour of Ceramics Stressed Near Fatigue Limit under Rotary Bending
......
Laser Cutting and Joining of 2D-Reinforced CMC
................
Analysis of Compounding and Injection Moulding Process of Ceramic Powders
.......
Use of the SOL-Gel Method in the Extrusion of Alumina Ceramics and ATZ Ceramics
.....
Advanced Hot-Pressed Ceramic Matrix Composites (CMC)
in
Sicw. Sic. C,,/Si.N. Systems
...
High Temperature Si3N4-BN Composite
....................
Processing of SICN-Fibres Prepared from Polycarbosilazanes
.............
Design
of
Grain Boundary Phases in Silicon Nitride
-
Silicon Carbide Nano-Composites
....
Yb-Si-A1-0-N Glasses and Glass-Ceramics as Grain-Boundary Phases
for
Silicon Nitride Materials
.
Porosity Graded Silicon Carbide Evaporator Tubes for Gasturbines with Premix Burners
....
in Non-Cooled High Efficiency Turbine System
. .
453
.
.
457
. .
463
. .
469
. .
471
.
3
.
477
.
.
483
.
.
487
. .
495
. .
499
. .
505
. .
513
.
.
517
. .
523
. .
531
. .
537
543
549
.
.
553
. .
559
.
.
565
. .
571
.
.
577
. .
581
. .
587
. .
593
.
.
599
. .
605
.
.
611
. .
617
. .
621
. .
627
. .
631
. .
637
. .
641
. .
647
. .
653
.
.
657
.
.
661
Index .................................
665
VIII
I.
Systems