APPLICATION AREAS

1
APPLICATION AREAS Gas turbines /
Aerospace Nuclear Power generation (Traditional
and new technologies) Petro-chemical Industrial /
Metal processing / Glass / Furnaces Transport /
Automotive MAIN THEMES Ceramic matrix
composites Monolithic ceramics and discontinuous
composites Coatings
2
DRIVERS Gas turbines / Aerospace Legislation to
reduce emissions translates as higher
temperatures Improved engine efficiency and
reduced levels of component cooling
air Reduced component, module and/or engine life
cycle costs Nuclear Power generation
(Traditional and new technologies) Petro-chemical
Industrial / Metal processing / Glass /
Furnaces Transport / Automotive Drivers for
above industries are unknown
3
ENABLING TECHNOLOGIES ??? Material system with
improved temperature capability
(gt1500C) improved environmental
resistance improved useable strength (gt180
MPa) improved integrity Develop enabling
technologies to design, life, inspect (NDE),
machine and repair ceramic material systems. An
established robust supply chain for material
production and manufacture of components from
ceramic material systems. Look to reduce
material costs through alternative methods of
material production and increased volumes. Clear
vision of end user requirements and applications
4

• CERAMIC MATRIX COMPOSITES
• Objectives
• Identify short, medium and long term research
  themes
• Develop enabling technologies for implementation
  of CMCs
• Develop modelling capabilities process models,
  structure/property models
• Identify complementary technologies from other
  industries
• Improve thermal and environmental capabilities of
  CMCs
• Improve useable strength of CMCs
• Understand cost/benefit trade for CMC
  applications
• Identify future funding opportunities
• Identify areas where education and training are
  required
• Identify end user requirements and market
  opportunities
• Establish UK CMC manufacturing capability

5
CERAMIC MATRIX COMPOSITES For structural
applications (aerospace) For functional
applications (aerospace) For nuclear
applications Furnace burners and hot gas
flow Component elements of ceramic matrix
composites Fibres SiC, C, oxide, others Preform
fabrication (fibre weavers) Fibre/matrix
interface coating compositions
processes Matrix SiC, C, oxide, other Coatings
- environmental, thermal or functional Enabling
technologies
6
CMC Road Map
VISION 5
VISION 10
VISION 20
Evaluate develop methods for manufacture of low
cost fibres
Develop higher strength fibres
Establish UK fibre manufacturing capability
Investigate weaving technologies to support
manufacture of complex 3D geometries
Develop alternative fibre coatings and process
routes for improved environmental capability and
reduced cost
Develop alternative densification processes and
matrix compositions that offer zero porosity,
improved compliance, higher proportional limit,
improved thermal conductivity, self healing
properties and reduced cost
Establish UK CMC manufacturing capability
Develop functional CMC (eg Low Observable system)
Develop material property databases for design
and lifing studies
Develop design and joining methodologies for CMC
Establish lifing methodologies for CMC
Establish machining capability for CMC
Develop coating compositions and processes that
offer thermal and/or environmental protection at
1500C. Consideration should be given to
bonding, compatibility, thermal stability,
thermal conductivity and strain tolerance of
coating
Develop functional coating (eg Low Observable
coating)
Establish lifing methodologies for coatings
7

• MONOLITHIC CERAMICS AND DISCONTINUOUS COMPOSITES
• Objectives
• Identify short, medium and long term research
  themes
• Develop enabling technologies
• Develop modelling capabilities process models,
  structure / property models
• Surface treatments or coatings to improve
  toughness or wear or corrosion.
• Improve useable strength, fracture toughness,
  Weibull modulus, defect tolerance, high
  temperature mechanical properties
• Improved oxidation and corrosion resistance.
• Cheaper processing of nano- and micro-composites
• Understand cost/benefit trade (reduced cost).
• Identify future funding opportunities
• Identify areas where education and training are
  required
• Identify end user requirements and market
  opportunities

8
MONOLITHIC CERAMICS AND DISCONTINUOUS
COMPOSITESFor gas turbine applications
(micro-turbines, wear components)Automotive /
transport applicationsFor functional
applicationsFor nuclear applicationsFurnace
furnitureFluid handling (pumps, valves, bushes,
bearings)Jigs and toolingComponent elements of
monolithic ceramics etc.Matrix (SiC, Si3N4,
Al2O3, BN)2nd phase micro- and
nano-particulatesDensification aidsSurface
treatments
9
Monolithic Ceramics and Discontinuous Composites
Road Map
VISION 5
VISION 10
VISION 20
Alternative matrix compositions
Improve toughness of monoliths through
engineering of particle morphology and reduction
in defect size.
Develop toughening mechanisms for monolithics
Introduce improved processing routes and
alternative sintering processes
Investigate alternative short fibres /
particulates
Investigate interface technology for short fibres
Investigate alternative sintering aids and
mechanisms
Develop surface coatings and treatments to
improve toughness, wear and residual stress state.
10

• THERMAL BARRIER COATINGS
• Objectives
• Identify short, medium and long term research
  themes
• Develop enabling technologies (lifing, failure
  mechanisms, NDE)
• Increase temperature capability of TBC and bond
  coat
• Reduce propensity of TBC to sinter
• Develop thick TBC capability (circa 3 mm)
• Improve strain tolerance of coatings
• Improve compatibility of coating with substrate
• Understand cost/benefit trade
• Identify future funding opportunities
• Identify areas where education and training are
  required
• Identify end user requirements and market
  opportunities

11
THERMAL BARRIER COATINGSFor gas turbine
applications For functional applicationsCompone
nt elements of thermal barrier coatingsCoating
compositions - bond coat and top coatApplication
techniques
12
TBC Road Map
VISION 5
VISION 10
VISION 20
Compositions for higher temperature capability
Compositions or techniques that reduce propensity
of TBC to sinter
Compositions with improved substrate compatibility
Coatings with multi-functional capabilities
(thermal, wear)
Functional coatings
Improved bond coats
Improved application processes
Techniques to produce a thick TBC
Techniques to produce strain tolerant TBC
Low cost coating techniques
Develop enabling technologies for TBC lifing
methodologies, failure mechanisms, NDE
13
Generic Technologies / Activities
VISION 5
VISION 10
VISION 20
ENABLING TECHNOLOGIES - GENERIC
Establish NDE capability
Develop design, fixturing and joining
methodologies
Establish lifing methodologies
Establish machining capability
Develop understanding of failure and degradation
mechanisms
Models Process. Structure / Property
FUNDING - GENERIC
Government and Industry funding of promising
systems
Government funding of blue skies research
Industry and government funding of systems with
market opportunities
Identify funding opportunities
EDUCATION / TRAINING - GENERIC
Introduce education/ training modules in
materials, design, processing and manufacture
14
Generic Technologies / Activities
VISION 5
VISION 10
VISION 20
ROUTE TO MARKET
Identify end user requirements and applications
Prioritise research activities
Develop supply chain