Development of Low-Cost Austenitic Stainless Gas-Turbine and Diesel Engine Components with Enhanced High-Temperature Reliability
- Solar Turbines, Inc.
- Caterpillar, Inc.
In July of 1999, a Cooperative Research and Development Agreement (CRADA) was undertaken between Oak Ridge National Laboratory (ORNL) and Solar Turbines, Inc. and Caterpillar, Inc. (Caterpillar Technical Center) to evaluate commercial cast stainless steels for gas turbine engine and diesel engine exhaust component applications relative to the materials currently being used. If appropriate, the goal was to develop cast stainless steels with improved performance and reliability rather than switch to more costly cast Ni-based superalloys for upgraded performance. The gas-turbine components considered for the Mercury-50 engine were the combustor housing and end-cover, and the center-frame hot-plate, both made from commercial CF8C cast austenitic stainless steel (Fe-l9Cr-12Ni-Nb,C), which is generally limited to use at below 650 C. The advanced diesel engine components considered for truck applications (C10, C12, 3300 and 3400) were the exhaust manifold and turbocharger housing made from commercial high SiMo ductile cast iron with uses limited to 700-750 C or below. Shortly after the start of the CRADA, the turbine materials emphasis changed to wrought 347H stainless steel (hot-plate) and after some initial baseline tensile and creep testing, it was confirmed that this material was typical of those comprising the abundant database; and by 2000, the emphasis of the CRADA was primarily on diesel engine materials. For the diesel applications, commercial SiMo cast iron and standard cast CN12 austenitic stainless steel (Fe-25Cr-13Ni-Nb,C,N,S) baseline materials were obtained commercially. Tensile and creep testing from room temperature to 900 C showed the CN12 austenitic stainless steel to have far superior strength compared to SiMo cast iron above 550 C, together with outstanding oxidation resistance. However, aging at 850 C reduced room-temperature ductility of the standard CN12, and creep-rupture resistance at 850 C was less than expected, which triggered a focused laboratory-scale alloy development effort on modified cast austenitic stainless steels at ORNL. Isothermal fatigue testing at 700 C also showed that standard CN12 was far superior to SiMo cast iron, but somewhat less than the desired behavior. During the first year, 3 new modified CF8C heats and 8 new modified CN12 heats were made, based on compositional changes specifically designed to change the nature, dispersion and stability of the as-cast and high-temperature aging-induced microstructures that consisted of carbides and other precipitate phases. Screening of the alloys at room-temperature and at 850 C (tensile and creep-rupture) showed -a ten-fold increase in rupture life of the best modified CN12 relative to the baseline material, better room-temperature ductility after aging, caused by less precipitation in the as-cast material and much less aging-induced precipitation. The best new modified CF8C steel showed strength at tensile and creep-rupture strength comparable to standard CN12 steel at 850 C, due to a unique and very stable microstructure. The CRADA was scheduled to end in July 2001, but was extended twice until July 2002. Based on the very positive results on the newly developed modified CF8C and CN12 cast austenitic stainless steels, a new CRADA with Caterpillar has been set up to commercially scale-up, test and evaluate, and make trial components from the new steels.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE Office of Heavy Vehicle Technologies (EE-33)
- DOE Contract Number:
- DE-AC05-00OR22725
- OSTI ID:
- 940385
- Report Number(s):
- ORNL99-0533; TRN: US200824%%270
- Country of Publication:
- United States
- Language:
- English
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