Silica Particle Ingestion Damage Model and Sensors for Turbomachinery

ABSTRACT: A plan is outlined for the development of (I) a computational tool to quantify damage imparted by CMAS (calcium magnesium alumino-silicate) particulate matter infiltrating into Thermal Barrier Coatings (TBCs); and (II) sensor tools to monitor CMAS composition and mass density, and to diagnose damage to TBCs. The computational tool provides a means to accurately model the dynamics of CMAS infiltration into TBCs, including reaction and solidification, and compute the resulting changes in stress distributions. One of the proposed optical sensors enables monitoring CMAS elemental composition and mass density. Another sensor is proposed for diagnosis of TBCs. During Phase I, a range of model scenarios will be evaluated, including the role of the thermal history of the components of interest. Experimental model validation tests will be designed in detail. Furthermore, optical sensor concepts will be demonstrated experimentally, critical components will be analyzed and a quantitative analysis of the sensor operating envelope will be made. BENEFIT: The proposed modeling and optical CMAS sensor tools have significant potential for quantifying CMAS damage due to particles ingested by modern high performance aero derivative turbines. The envisioned model and sensor tools quantify CMAS accumulation effects under varying exposures and take into account the variability of CMAS composition. Thus, the proposed advanced model and sensor technology allows large cost-savings by enabling improved damage mitigation strategies, improved timing of component replacement and increased confidence levels when operating in environments with moderate particle loading.