A high temperature engine materials test facility

Gas turbine engines subject materials to extreme conditions. Their high temperature materials and co-developed coatings must survive combustion gas temperatures currently approaching 1800 °C, large thermal gradients, severe thermal shock, and static and fatigue inducing applied stresses, all the while operating in highly reactive, high-pressure, high-speed combustion gas flows containing significant partial pressures of water vapor, oxygen, and other reactive species for many tens of thousands of hours. We describe the design and development of a test facility for the study of materials under individual and combinations of test parameters similar to those experienced within legacy and future engines. A hydraulic load frame capable of applying static or cyclic tension-compression stresses up to 400 MPa to flat-dog bone-shaped test specimens is integrated within an environmental test chamber capable of sustaining gas pressures from 0.1 to 1.2 MPa (1-12 atm). An adjustable 0.1-2 kW power CO2 laser whose 10.6 µm wavelength radiation is strongly absorbed by ceramic coating materials is used to heat sample surfaces to temperatures of 1800 °C and above, while rear surface air jet cooling establishes through-thickness thermal gradients. Rapid laser heating in conjunction with transiently applied front and/or rear-side air cooling is used to create hot or cold thermal shock effects. This is accompanied by the impingement of a high pressure (up to 1.3 MPa) reactive gas jet upon the sample with speeds up to 300 m/s by preheating dry air, mixing it with steam to the desired humidity, heating to 850 °C, and then expanding it through a converging nozzle. Thermal imaging pyrometers measure specimen front and back surface temperature fields, while environmental test chamber view ports permit digital image correlation and strain mapping.