Project Vision
Project Overview Fed. funding: $1.8M
Length 36 mo.
experience in ceramic engineering – More than 30 combined years professional
experience with supercritical CO2 technologies and power cycle development
– First-time working with ARPA-E (exception: Ma)
Akron, OH Golden, CO
compact heat exchanger for recuperated cycles featuring intense and/or uncooled heat sources.
Target applications: aeroengines, microturbines, direct fire, CSP sources
McDonald CF and Wilson DG. The utilization of recuperated and regenerated engine cycles for high-efficiency gas turbines in the 21st
century. Appl. Thermal Eng. 1996;16(8/9):635-653. McDonald CF. Recuperator considerations for future higher efficiency microturbines. Appl. Thermal Eng. 2003;23(12):1463-1487.
Objectives: – Mature materials and
– 10 $/kW
Heat Exchanger Design Counter-flow microchannel heat exchanger
Additively manufactured using ultra-high temperature ceramic materials
All-ceramic welded hot inlet ducting
Graded ceramic-to-metal joining
Pressurized shell via cold inlet leak
Prototype targets 50% effectiveness for 700°C outlet temperatures to leverage low cost stainless steel ducting
Doubling specific power density thought to be possible with further increases in hot inlet temperature up to 1500°C
3
Hot outlet and cold inlet/outlet > Graded ceramic-to-metal
Material (ZrB2 / 0-30 % SiC) Ultra-high
temperature ceramic (Tm.p. > 3000°C)
Various additives improve sintering, oxidation, creep, and toughness
TRL 4-6 depending on application
4
Neuman EW, Hilmas GE, Fahrenholtz WG. Mechanical behavior of zirconium diboride-silicon carbide-boron carbide ceramics up to 2200°C. J. Euro. Ceram. Soc. 2015;35(2):463-476.
Zimmermann JW, Hilmas GE, Fahrenholtz WG, Dinwiddie RB, Porter WD, Wang H. Thermophysical Properties of ZrB2 and ZrB2-SiC Ceramics. J. Am. Ceram. Soc. 2008;91(5):1405-1411.
Manufacturing Process (Additive Manufacturing)
Pink = ZrO2 Green = Al2O3 (Pastes colored by organic dyes)
McMillen D, Li W, Leu MC, Hilmas GE, Watts J. Designed Extrudate for Additive Manufacturing of Zirconium Diboride by Ceramic On-Demand Extrusion. Solid Freeform Fabrication 2016: Proc. 27th Annual Int. Solid Freeform Fabrication Symposium. 929-938.
Leu MC, Ghazanfari A, Li W, Hilmas GE, Landers RG. Method and apparatus for fabricating ceramic and metal components via additive manufacturing with uniform layered radiation drying. Patent No. US20170297221A1.
Ceramic On-Demand Extrusion
Eutectic solidification in fusion zone observed in ZrB2-SiC systems
Additives can refine FZ microstructure to improve properties
6
PAW TIG
Hilmas GE, Fahrenholtz WG, Watts JL, Brown-Shaklee HJ. Ceramic welds, and a method for producing the same. Patent No. US8715803 (2014).
a
d
b c
Plasma arc welding has been utilized for the fusion welding of ZrB2-based ceramics through the fabrication of (a) butt welds, (b) lap joints, and (c) angled joints. (d) A cross-section of ZrB2-ZrC fusion welding using pulsed plasma arc welding.
Video removed
a
d
b
c
Testing
Specialized materials testing capabilities at Missouri S&T include mechanical and thermal properties characterization up to 2800°C, and high pressure-high temperature sample environments for materials compatibility/corrosion testing
7
Technology-to-Market Strategy
High Power Density,
Efficiency, Low Cost
Exceeding limitations of
DOE NE, FE, EE
1 Additive manufacturing Missouri S&T $0.59M
2 Ceramic and dissimilar materials joining Missouri S&T $0.37M
3 Materials characterization Missouri S&T $0.38M
4 Corrosion studies Missouri S&T $0.29M
5 Design and modeling NREL $0.25M
6 Techno-economic analysis & TTO NREL $0.13M
Total Funds $2.01M
Cost Share (%) 10
Federal Funds $1.80M
Preliminary sCO2 corrosion assessment of UHTC-based materials
Perform preliminary corrosion assessment of ZrB2/SiC-based materials containing 0-100 % SiC by measuring parabolic rate constants for sCO2 exposure at up to 1100°C. Estimate likelihood of survival based on measured oxidation rates. Corrosion resistance shows a possible pathway toward meeting the requirements for target 40,000 hour performance metric.
BP 3 Go / No-Go:
Demonstrate the ability to additively manufacture sub-scale test components and test coupons featuring lower-level performance metrics and associated targets that satisfy heat exchanger design specifications determined in M5.1.
Sub-scale test components shall comprise unscaled sections of the approved full scale heat exchanger design with straight flow pathways for ease of laboratory scale test loop integration. Sub- scale test components shall feature additively manufactured bodies with representative feature sizes as set forth in M5.1, functionally graded fluid distributors, and/or fusion welded connectors, depending on sub-scale component test objective(s). Estimated sub-scale component external dimensions will be approximately 25 x 25 x 75 mm. Component integrity shall be demonstrated as set forth in M6.1. Test coupons shall be additively manufactured to produce at least ten total specimens with standard geometries for materials property testing to include flexural strength and thermal conductivity. Materials properties will meet or show a possible pathway to meet specifications set forth in M5.1.
BP Budget Period (BP) Milestones
1 (Q1-Q6) M1.1, M2.1, M2.2, M2.3, M3.1, M3.2, M4.1, M4.2, M5.1, M5.2, M6.1, M7.1, M7.2
2 (Q7-Q10) M2.4, M3.4, M5.3, M6.2, M6.3, M7.3 3 (Q11-Q12) M3.3, M6.3, M6.4, M6.5, M7.4
An ambitious development timeline 24 milestones pertaining to Tasks 1-6
Anticipated Challenges and Potential Partnerships Materials and manufacturing technology development for thermal stress management
Design and commissioning of lab-scale sCO2 test facilities for T > 1100°C
Standards development for analysis of ceramic HX reliability and life prediction for normal service and off-design excursions
Moss DR, Basic MM. Pressure Vessel Design Manual 4E. Butterworth-Heinemann; 4th edition (December 31, 2012).
= ± 2 1−
≅ ± 7.510−6 −1 400 400 2 1−0.15
≅ ± 700
UHT-CAMANCHE: Ultra High Temperature Ceramic Additively Manufactured Compact Heat ExchangersDavid Lipke, Missouri University of Science and Technology
Project Overview