Fabricating hollow turbine blades using short carbon fiber-reinforced SiC composite

Abstract

The development of hollow turbine blades fabricated by nickel-base superalloy is limited by its high density and low operating temperature (<1,100 °C). A new technology for fabricating hollow turbine blades of fiber-reinforced SiC composite was put forward. The chemical corrosion process of DSM Somos 19120 resin mold was investigated, and the pyrolysis of phenolic resin and the infiltration of liquid silicon were analyzed by using scanning electron microscope and X-ray diffraction. The influence of carbon fiber content on fracture strength and fracture toughness of fiber-reinforced SiC composite was investigated using the measurement of three-point flexural strength test. Results showed that stereolithography molds of photosensitive resin were corroded perfectly using KOH alcohol water solution. The porous carbon preforms were obtained after phenolic resin was pyrolyzed from 400 to 800 °C, which were then infiltrated with molten silicon to gain SiC matrix at the temperature of 1,450 °C in 1 h. The fracture strength and fracture toughness of SiC ceramic matrix were enhanced with the increase of short carbon fiber content. The maximum fracture strength and fracture toughness of samples were about 270 MPa and 5.1 MPa m1/2, respectively. Finally, hollow turbine blades were successfully fabricated using short carbon fiber-reinforced SiC composite.