Objectives

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 266 214.
The project has started on 1st October 2010 for a duration of 54 months.

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The goal of the HYSOP project  is to develop solutions for manufacturing lightweight high temperature (HT) turbine components and to design new coating systems (protection against oxidation, water vapour and CMAS).

Nb/Nb5Si3 and Si3N4/MoSi2 composites are lightweight high temperature materials (with a density lower than about 6.5~7 g/cm3 and < 5.6 g/cm3, respectively) with application potential above 1300°C making them candidates for advanced aero-engine components, allowing reduction of fuel consumption, CO2 emissions and cooling air needs, hence a further increase in efficiency and reduction in engine weight.

Though remarkable high temperature mechanical properties have been achieved (strength, creep), especially in the FP6 ULTMAT project, short/medium term application cannot be envisaged since improved oxidation resistance and optimised microstructures for enhanced mechanical properties are required.

The partners, an engine manufacturer, research centres and universities, will join their expertise to reach following objectives:

-  design static (vane, seal segment) and rotating (blade) components with tailored microstructures and properties, including superalloy/HT-material hybrid structures where superior performance is foreseen over monolithic material,

- develop the corresponding advanced routes for processing (based on powder metallurgy: net-shape HIPing, powder injection moulding, laser fabrication) and joining,

- design oxidation/corrosion resistant coating systems, based on expertise gained on substrate/coating/environment interactions on Nb-Si materials, superalloys and Environmental/Thermal Barrier Coatings,

- test the coatings in service-like conditions: medium (~800°C) and high (1100-1300°C) temperatures in dry/wet air, corrosion by molten oxides, up to a burner rig test,

- converge the two approaches in assessing the mechanical behaviour of bare and coated specimens,

- finally, to propose a set of manufacturing and coating solutions for the high temperature materials for medium term application in aero- and small land-based turbines.

Notes: CMAS are CaO-MgO-Al2O3-SiO2 mixed oxides, coming from sands and dust ingested by the engine during take-off, flight and landing.