Evaluation of Durable Metallic Supports for Catalytic Combustors
In 2000, a Cooperative Research and Development Agreement (CRADA) was undertaken between the Oak Ridge National Laboratory (ORNL) and Catalytica Energy Systems Incorporated (CESI) to determine the properties of current metallic catalyst supports and examine new candidate alloys for this application. A team was established at ORNL to examine oxidation-limited lifetime of these thin-walled metallic components using standard lifetime models and to measure the mechanical properties of the foils (40-200:m in thickness) which can differ substantially from bulk properties. Oxidation experiments were conducted on foil specimens at 700-1100 C in laboratory air and in air with 10 vol.% water vapor to better simulate the combustor environment. At the higher test temperatures, time to oxidation-induced (i.e. breakaway oxidation) failure was determined in 1h cycles in order to verify predictions from a standard reservoir-type oxidation lifetime model. Selected specimens were run for >10,000h in 100 or 500h cycles at lower test temperatures in order to determine the oxidation kinetics for the model. The creep properties of selected foils were measured for 4,000-8,000h at operation-relevant stresses and temperatures. None of the new candidate alloys significantly out-performed currently used alloys in laboratory testing, particularly in oxidation lifetime testing. Therefore, engine testing was not performed on any of the new candidate alloys. Both the oxidation- and creep-resistance of FeCrAl alloys was greater than expected and the results of the CRADA allowed CESI to extend life or increase operating temperatures for these lower cost substrate alloys in the next generation of catalyst modules. Three work areas were defined for the CRADA. The first area was investigating the oxidation behavior of current and candidate alloy foils. The goal was to obtain data such as the oxidation rate as a function of temperature and environment, the time to breakaway oxidation at high test temperatures and the residual Al alloy content at breakaway oxidation. These inputs are needed for a standard reservoir-type oxidation model. The second work area was to use the experimental data to model the oxidation-limited lifetime of foil materials as a function of temperature, foil thickness and composition. The third task was to measure mechanical properties, in particular creep rates and creep to failure life, of similar foils at application relevant temperatures and stress levels.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- DE-AC05-00OR22725
- OSTI ID:
- 885689
- Report Number(s):
- C/ORNL 00-0570; TRN: US200617%%138
- Country of Publication:
- United States
- Language:
- English
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