Development of low modulus material for use in ceramic gas path seal applications
Three candidate materials were examined: Brunsbond (R) Pad; plasma sprayed porous NiCrAlY; and plasma sprayed low modulus microcracked zirconia. Evaluation consisted of mechanical, thermophysical, and oxidation resistance testing along with optical microscopy and a feasibility demonstration of attaching the material to a suitable substrate. The goals of the program were the following: feasibility of fastening or depositing the low modulus system onto a broad range of substrate alloys; feasibility of depositing or forming the low modulus system to a thickness of 0.19 cm to 0.38 cm; potential to attain a modulus of elasticity in the range of 3.4 to 6.9 GPa (0.5 to 1.0 MSI), and an ultimate strength of 17.2 MPa (2.5 ksi); suitable thermal conductivity; and static oxidation life of at least 1000 hours at 1311 K. The results of the program indicate that all three systems offer attractive properties as a strain isolator material.