Additive Manufacturing 3100F Nanolaminate Matrix for Turbine Engines

Major manufacturers of stationary gas turbines for electrical power generation are studying the potential for using higher temperature and environmentally stable ceramic matrix composites (CMC) as engine components to improve turbine engine efficiencies. One manufacturer estimates that a simple 2% increase in efficiency would save more than $50MM over the life of one generator. Higher operating temperatures could dramatically improve the thermodynamic efficiency of gas turbine generators, saving 300 billion BTU a year in natural gas alone (a $1.3 billion dollars savings for utility customers) while meeting long cycle life requirements (greater than 100,000 hours). Another manufacturer suggests that a 2% efficiency improvement will reduce NOx emissions by 50% and other emissions equivalent to taking 10,000 cars off the road per year. In order to achieve these advancements, CMC materials and matrices will be required to be developed. Recent advancements in ultra-high temperature materials and manufacturing methods suggest a pathway toward development of new CMCs which can operate at high temperatures for extended periods of time without the brittleness and oxidation concerns which have plagued ceramics in the past. The Proposer proposes a SBIR Phase I project focused on the utilization of new reinforcing fibers, nano-materials and matrix having high thermal conductivity, increased mechanical strength properties, resistance to crack-propagation, and long life-cycle utilization. Furthermore, these materials will be developed for the high-rate production of turbine engine components using additive manufacturing methods. The proposed CMC and manufacturing methods will have significant impact in the turbine engine markets for both stationary electrical power generation and aerospace applications. These high-temperature materials could provide a pathway for development of rotating detonation engines and improvements in micro-turbines to generate on-board electrical power for cars, trucks, buses and aircraft, not to mention true distributed energy systems to generate electricity in every home or building and provide significant protections to the security of our electrical grid. These CMC innovations could dramatically improve technology developments in heat exchangers, hypersonics, nuclear fuels and safety.