Ceramics International 47 (2021) 567–580

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Ceramics International
journal homepage: www.elsevier.com/locate/ceramint

Thermo-mechanical simulation of ultrahigh temperature ceramic T

composites as alternative materials for gas turbine stator blades
Kourosh Vaferia, Mohammad Vajdia,∗, Sanam Nekahia, Sahar Nekahia,
Farhad Sadegh Moghanloua, Mehdi Shahedi Aslb,∗∗, Mohsen Mohammadib
a
Department of Mechanical Engineering, University of Mohaghegh Ardabili, Ardabil, Iran
b
Marine Additive Manufacturing Centre of Excellence (MAMCE), University of New Brunswick, Fredericton, NB, E3B 5A1, Canada

ARTICLE INFO ABSTRACT

Keywords: The efficiency of the Bryton cycle strongly depends on the maximum temperature of the cycle. However, re-
Gas turbine strictions on metallurgical problems deprive engineers from the benefit of high temperatures. Ultrahigh tem-
Ultrahigh temperature ceramics perature ceramics can be considered in such cases, instead of traditional materials like M152 superalloy. In this
Heat transfer study, SiC reinforced HfB2 and ZrB2 ultrahigh temperature ceramics were proposed as gas turbine stator blades.
Thermal stress
The heat transfer and stress-strain equations were solved numerically by the finite element method to obtain
Stator blade
temperature and stress distributions. The results showed that the maximum thermal stress occurs in vicinity of
Numerical simulation
the cooling ducts where the temperature gradient is maximum. The maximum displacements of 1.2 mm (for
HfB2–SiC) and 1.14 mm (for ZrB2–SiC) occur in the upper wall. It can be noticed that the ZrB2–SiC made blade
showed lower maximum stress and displacement than those for the HfB2–SiC made one, as a result of lower
expansion coefficient of ZrB2–SiC system. The addition of SiC to monolithic HfB2 and ZrB2 ceramics decreases
their thermal conductivity and following that, the temperature uniformity in blades reduces. Although the
thermal stresses and the probability of failure in these stator blades enhance, the ZrB2–SiC material presented the
best performance among the other investigated samples. Both Coulomb-Mohr and Von Mises failure analyses
were employed. It was understood that both blades made of HfB2–SiC and ZrB2–SiC composites simply withstand
the applied stresses with the safety factors of about 1.5.

1. Introduction improve their thermal efficiency [14], however, as the temperature

Global energy demand is expected to increase by around 60% with
an average annual growth rate of about 1.6% until next 50 years.
Industries and energy technologies will play a crucial role in meeting
the world energy needs. Although sustainable energy technologies have
attracted much attention in recent years [1–5], gas and steam turbines
are still the main movers in industrial applications [6–8]. Although
internal combustion engines are also used for power generation [9,10],
high operation speeds, low working pressures, and very high power-to-
weight ratio, compared to reciprocating engines, are the main ad-
vantages of gas turbines [11,12]. Gas turbines are very crucial in terms
of future worldwide electricity generation, therefore, it is essential to
acquire the highest possible efficiency from these engines or used op-
timization methods to increase the efficiency of the whole system [13].
The thermal efficiency of a gas turbine is strongly dependent upon the
inlet air temperature. Increasing the inlet temperature of turbines can
increases, some defects may occur and greatly decrease the durability of
hot section components, especially the blades [15–17].
The blades, as the most sensitive parts of a gas turbine, operate at
high temperatures and harsh conditions of centrifugal force and gas
pressure tensions. They are normally exposed to high thermal stresses
that can lead to fracture or plastic deformation of the blades. Thermal
stress is a remarkable factor in turbine blade designing, which is af-
fected by the blade's temperature distribution [18,19]. Thus, accurately
anticipating blade heat transfer parameters is important to enhance the
blade's life and decrease its repair and maintenance expenses [20,21].
Kim et al. [22] numerically examined the thermal stresses and heat
transfer behavior of an engine turbine blade with 10 circular cooling
ducts. The highest and lowest values of the heat transfer coefficient
were on the stagnation point of the leading and trailing edges on suc-
tion and pressure sides, respectively. Hou et al. [23] investigated the
turbine blade's fatigue failure by a series of mechanical analyses. The

∗
Corresponding author.
∗∗
Corresponding author.
E-mail addresses: vajdi@uma.ac.ir (M. Vajdi), Mehdi.Shahedi.Asl@unb.ca (M. Shahedi Asl).

https://doi.org/10.1016/j.ceramint.2020.08.164
Received 18 July 2020; Received in revised form 17 August 2020; Accepted 18 August 2020
Available online 20 August 2020
0272-8842/ © 2020 Elsevier Ltd and Techna Group S.r.l. All rights reserved.
K. Vaferi, et al.
results indicated that the maximum stress in the blade is on the top fir
tree of the trailing corner. They also concluded that thermal expansion
and centrifugal load do not remarkably affect crack initiation at the top
fir tree. Graham et al. [24] studied the thermal characteristics of the gas
flows and recommended several basic methods to promote the heat
transfer estimation of turbine blades. Han and Goldstein [25] examined
the effect of several parameters on heat transfer and flow characteristics
of impinging-jets in gas turbines. They understood that nozzle geo-
metry, curved surfaces and turbulence could affect the heat transfer rate
of impinging jets.
Different methods have been proposed to increase the blade's life,
which can be categorized into three major groups including blade
cooling methods such as active and passive methods [26–28], thermal
barrier coating methods, and using proper material for producing
blades. Utilizing cooling lines is the most common method to reduce the
temperature of blades and retain it below the allowable temperature
[29,30]. However, it should be noted that the cooling of blades results
in a considerable decrease in thermal efficiency [20,31–33]. Thermal
barrier coatings (TBCs) can protect the turbine components against
excessive temperatures by providing thermal insulation. TBCs are ad-
vanced ceramic coatings, which consist of oxidation- and corrosion-
resistant layers. Because of lower thermal conductivity of these coat-
ings, they can act as a thermal barrier to reduce the blade surface
temperature [34,35]. Moreover, TBCs are transparent to radiations of
hot gases and can decrease the thermal stresses [36,37]. The third
method for increasing the blade's life is using materials with high re-
sistance against heat and hot-corrosion. Superalloys and ceramics are
two groups of promising alternative materials utilized in the hottest
parts of turbines. They retain their durability, structural stability, and
mechanical properties at high temperatures better than the other ma-
terials. Predominantly turbine blades are made of stainless steel, tita-
nium, nickel alloys, etc. [38]. Since the turbine is directly located after
the combustion section, the hot combustion gases pass into the first
stage of turbine blades. Thus, the blades need to withstand tempera-
tures over 2000 °C, while steel and nickel possess the melting points of
about 1480 °C and 1455 °C [39,40].
Ceramics, in particular the ultrahigh temperature ceramics
(UHTCs), have much higher melting points (over 3000 °C) [41–49].
UHTCs are a specific type of ceramics, which can be utilized in harsh
environments containing extreme temperatures and chemical re-
activity. Considering the melting temperature as a criterion, a handful
of carbides [50–59], borides [60–103], and nitrides [104] of transition
metals can be considered as UHTCs [66,105–107]. High strength, long
fatigue life, good resistance to oxidation and corrosion at high tem-
peratures are some of the most important features of UHTCs [108–125].
Borides such as TiB2, ZrB2, and HfB2 offer high thermal and electrical
conductivities, good elastic modulus and excellent hardness [99–101].
They have widely used in oxidizing environments because of their su-
perior oxidation resistance in comparison with the other materials
[126–129].
The mentioned features and the high thermal conductivity of UHTCs
have encouraged researchers to utilize these ceramics to enhance the
heat transfer performance of turbines. Vaferi et al. [130] examined the
temperature distribution and deformations of a gas turbine stator blade
made of monolithic TiB2. They reported a reduction in thermal stresses,
as well as an enhancement in maximum displacement using TiB2
ceramic instead of ZrB2. Nekahi et al. [131] numerically investigated
the heat transfer behavior and thermal stresses in a turbine blade made
of HfB2 ceramic. They achieved a safety factor of 1.28 (based on Cou-
lomb-Mohr theory) and reported that HfB2 made blades can simply
withstand the applied compressive stresses. Sadegh Moghanlou et al.
[71] offered a solution to decrease the gas turbine's defects at higher
temperatures by utilizing UHTCs such as ZrB2. They used Comsol
Multiphysics software to evaluate the temperature distribution and
thermal stresses of the blades. The obtained results depicted that ZrB2
ceramic provides more uniform temperature distribution in comparison
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Ceramics International 47 (2021) 567–580
with conventional superalloys such as M152.
Despite the remarkable thermo-mechanical properties of the
monolithic TiB2, ZrB2, and HfB2, they have limitations like weak flex-
ural strength and poor sinterability. The high amounts of oxide im-
purities on the powder particles of these ceramics decrease their sin-
terability. In general, these ceramics are combined with other refractory
phases such as SiC to promote the bending strength, fracture toughness
and oxidation resistance [26–28]. The SiC reinforced boride matrix
composites are promising alternatives for applications involving high
temperatures (e.g. cutting tools, heat exchangers, aerospace industry,
gas turbine blades, etc.) [65,132]. Sadegh Moghanlou et al. [65] nu-
merically investigated the heat transfer behavior and temperature dis-
tribution in the cutting tool made of SiC reinforced TiB2, HfB2 and ZrB2
ceramics. They pointed out that the addition of SiC to monolithic
ceramics leads to a better thermal performance of cutting tools made of
these composites.
Up to now, to the best of our knowledge, ZrB2–SiC or HfB2–SiC
composites have not been considered in the gas turbine blade's manu-
facturing. On the other hand, numerical methods are a powerful tool in
investigating the heat transfer and stress distribution or optimizing the
engineering problems [133–139]. So in the present work, the influence
of exploiting SiC doped ZrB2 and HfB2 composites on heat transfer rate
and thermal stresses in stator blades have not been examined. In the
present study, HfB2–SiC and ZrB2–SiC composites are selected as al-
ternative materials in the manufacturing of gas turbine stator blades.
The deformations, thermal stresses, and temperature distributions in
the blades made of these materials are investigated. Heat transfer in the
HfB2–SiC and ZrB2–SiC made turbine blades is investigated numerically
using finite element method analysis.
2. Stator blade geometry
The selected geometry for investigating thermal characteristics of
the gas turbine stator blade is same as the applied geometry in Refs.
[71,131]. Fig. 1 depicts an overview of the chosen geometry for the
investigated turbine blade. As mentioned in the introduction part, the
blades are exposed to very high temperatures and faced metallurgical
problems. Therefore, it is needed to cool the blades using the com-
pressor's outlet air. The bleed-air flow from the compressor (T = 600 K
and P = 30 bar) directed to the blade through internal cooling ducts.
For a better understanding of the cooling process, the cooling ducts and
some mounting details are indicated in Fig. 2. The detailed information
about the geometry of ribs is neglected to simplify the calculation, and
the average Nusselt number correlation is utilized to predict the heat
transfer coefficient accurately.
3. Governing equations
The gas turbine components are exposed to high-temperature flue
gases. The high-temperature combustion gases transfer heat to the
blade surfaces by convection mechanism. Computational Fluid
Dynamic (CFD) principles can predict the temperature distribution in
turbine blades. In the present study, conjugate heat transfer is carried
out to acquire thermal and mechanical performance data on the stator
blade. The heat diffusion and linear elastic equations are considered as
the governing equations to cover thermo-mechanical characteristics of
blades. The heat diffusion equation in the stator blade is as follow
[71,131]:
T
C = . (k T )
t (1)
where t (s ) and T (K ) are allocated to time and temperature. ( ), C
kg
m3
( )J
kg . K
and k ( )
W
m.K
indicate density, specific heat capacity, and thermal
conductivity of the material used in the turbine blade, respectively. The
material properties are considered temperature-dependent in Eq. (1).
K. Vaferi, et al. Ceramics International 47 (2021) 567–580

Fig. 1. (a) An overview of selected geometry of the blades, and (b) the blade with cooling ducts shown.

symmetric conditions in stress and strain tensors, it can be formulated

as Eq. (5):
E
D=
(1 + )(1 2 )
1 0 0 0
1 0 0 0
1 0 0 0
0 0 0 (1 2 )/2 0 0
0 0 0 0 (1 2 )/2 0
0 0 0 0 0 (1 2 )/2 (5)
where E (Pa) and represent the Young's modulus and Poisson's ratio,
respectively. Shear stress and strain components are related to each
other according to Eq. (6), in which ij(Pa) shows the shear stress tensor.
E ij
=
ij
1 2 (6)
Brittle materials such as ceramics and concrete are specified by high
compressive strength, little plastic deformation, and low tensile
strength. They are remarkably stronger in compression than in tension,
and usually fracture easily. Because a crack does not propagate under
compression loads and any flaws in the structure or the transverse
cracks tend to close [140]. In order to investigate the crack propagation
Fig. 2. The internal cooling passages of the turbine stator blade. or failure modes, the fracture mechanics theories are needed. In the
present study, the Coulomb-Mohr criterion and Von Mises theory are
The Newton cooling low is utilized to compute the transferred heat selected to examine the possibility of failure. In general, the Coulomb-
from the hot/cold fluids to the blade surfaces which is as Eq. (2): Mohr criterion is more accurate failure theory than Von Mises, because
it considers the difference between tensile and compressive stresses
q0 = h (Text T) (2)
[131], while the Von Mises theory predicts the failure considering yield
in which q0 ( )
W
represents the heat flux, h
m2 ( W
)
is allocated to con-
m2 . K
strength. Fig. 3 compares the safe areas provided by Coulomb-Mohr
criterion and Von Mises theory and states that no failure stress occurs in
vective heat transfer coefficient, Text and T depict the external fluid and
the solid surface temperatures, respectively. The strain-displacement the colored area. The equations that describe the Von Mises theory and
equation for the solid domain can be formulated as Eq. (3), in which u Coulomb-Mohr criterion mathematically are as Eq. (7) [71] and Eq. (8)
(m) represents the displacement vectors [71,131]. Duhamel-Hook's law [130], respectively.
gives a linear relation between strain and stress tensors regarding the ( 2 2 2 2 2 2
x y) +( z y) +( x z) + 6( xy + xz + zy )
temperature effect (Eq. (4)). v =
2 (7)
1
= u + ( u)T =
Sut
0
2 (3)
A n A B
A B 1
Sut Suc
= n A 0 B
= D( (T Tref )) (4) Suc
B = 0 A B (8)
where (Pa) , , T , and Tref belong to stress, strain, the temperature at n

any point, and the reference temperature at points with no strain, re-
spectively. The initial strains and stresses are not taken into account in
these equations, and the properties of the applied material are regarded
to be isotropic. In Eq. (4), D(Pa) states the sixth order elasticity tensor.
It demonstrates the stiffness matrix of the material and because of the
where v represents the Von Mises stress. Moreover, x , y and z are
allocated to the normal stresses, and xy , zx and zy show the shear
stresses in three directions. In Eq. (8) n exhibits the safety factor, Sut (Pa)
and Suc (Pa) display the ultimate tensile strength and ultimate com-
pressive strength, respectively. It should be mentioned that A and B

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Fig. 3. The comparison between the safe areas in (a) Von Mises, and (b) Coulomb-Mohr criteria.

are the principle stresses of the blade in different directions. The gen- The turbine engine works at the local temperature of 900 K, and the
erated temperature gradient together with no movement feasibility in heat transfer coefficient is about 25 m2.K . The average Nusselt number of
W

the fixed supports of the stator blade lead to thermal stresses. When the 400 is regarded for the cooling passages to simplify the calculations of
blades made of composites such as ZrB2–SiC, or HfB2–SiC are heated flow inside the ducts. The heat flux in cooling ducts is calculated by Eq.
and expanded, they are exposed to compressive stresses. Hence, the (10) [71].
third case of Eq. (8) is suitable to estimate the failure possibility in the
1
blades made of such UHTCs. k 1 0.332 Re x2 Rex 5 × 105
h= Pr 3 × 4 Re 5
x x 5 × 10
0.0296 Re x5 (9)
4. Boundary conditions
Nucool µcool Ccool
q = (Tcool T)
Fig. 4 demonstrates the different surfaces of the turbine blade, 2Prcool Hcool (10)
which are exposed to thermal boundary conditions. The hot flow of
combustion gases with the temperature around 1100 K and pressure of in which C ( ), µ( ), and H(m) indicate the heat capacity, visc-
J
kg . K
kg
m.s
30 bar passes over the blade surfaces. The related heat flux is specified osity, and the characteristic length of cooling air, respectively. Fig. 5
utilizing the convective heat transfer coefficient which is presented by displays the surfaces with the thermally insulated boundary condition.
Eq. (9) [141]. In this equation, x (m) shows the distance from the be- Moreover, it is needed to apply solid mechanics boundary condi-
ginning of the plate. The sound speed is considered 650 m/s, and the tions to solve the linear elastic equations. Spring foundations and roller
subsequent Mach number is about 0.7 for the pressure side and 0.45 for are the boundary conditions used to control the movement of the blade.
The rest of the boundaries are free to move as a result of thermal ex-
( )
the suction side [71,130]. The parameter U s in Reynolds number
m

pansion. Spring foundation limits the top and bottom displacements of

Ux
(Re x = µ ) is devoted to fluid flow velocity, and the assigned values for the blade based on Hook's low (Eq. (11)).
the velocities over the upper surface, lower surface, and the alongside
platform walls are about 450, 300, and 350 m/s, respectively [71,142]. .n= k s (u u 0) (11)

Fig. 4. The different surfaces of the blade with the convective cooling boundary condition.

570
K. Vaferi, et al.
Fig. 5. The surfaces with the thermally insulated boundary condition.
where ks (
m . m2
N
)
shows the stiffness of the spring foundation and n
displays the surface normal vector. Fig. 6 demonstrates the spring
foundation boundary conditions from the top and bottom view. The
roller boundary allows the body to deform only in the parallel direction
to its normal surface and the related relation is given by Eq. (12). The
roller boundary condition of the stator blade is presented in Fig. 7.
n. u = 0
5. Material properties
As mentioned earlier, the increase in temperature at the turbine
inlet can improve the thermal efficiency of a gas turbine. However, as
the temperature rises, some metallurgical problems may occur, hence,
specific materials or active cooling of turbine blades are needed. It has
been proved that utilizing blade cooling systems decrease the thermal
efficiency and output work of the gas turbine engines. Hence, it seems
that using materials with high heat resistant and excellent thermal
properties is more efficient [20,131].
Since there is no centrifugal force in stator blades and the
Fig. 6. The (a) top and (b) bottom views of the spring foundation.
Ceramics International 47 (2021) 567–580
Fig. 7. The roller boundary condition of the stator blade.
subsequent tensile stresses can be ignored, thermal stresses and fluid
flow forces are the main sources of generated stresses [130,131]. The
thermal stresses in stationary blades are compressive, and it is required
to use materials with great compressive strength like UHTCs to produce
the blades. Monolithic ZrB2 and HfB2 have been selected and in-
vestigated in the authors' previous works [71,131]. The present study
examines the ZrB2–SiC and HfB2–SiC composites as alternatives to
conventional materials in gas turbines. Thermal stress and heat transfer
behavior in a turbine blade made of the mentioned composites are
analyzed numerically. Figs. 8 and 9 indicate the thermal characteristics
of the mentioned materials (ZrB2, HfB2, ZrB2–SiC, and HfB2–SiC) [143].
The Young's modulus of the used materials are presented in Table 1.
6. Results and discussion
(12)
The objectives of the present study are: to investigate the heat
transfer behavior; to acquire the temperature distribution; and to pre-
dict the deformations and thermal stresses on the stator blade. The fi-
nite element method was utilized to solve the heat diffusion and elastic
equations in a steady state. The applied grid geometry on the turbine
stator blade is demonstrated in Fig. 10. The unstructured tetrahedral
cells were utilized to mesh the whole computational domain. After re-
fining the grid in the entire domain sufficiently, the grid independency
was achieved by 147,481 cells. Then, the procedure of validation was
carried out with the authors' previous works [71,131] to ascertain the
credibility of the simulation. For the blade material, two different
composites (ZrB2–SiC, and HfB2–SiC) were chosen. The temperature
distribution in blades made of ZrB2–SiC and HfB2–SiC composites is
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K. Vaferi, et al. Ceramics International 47 (2021) 567–580

Fig. 8. The thermal conductivity variations of the studied materials vs. temperature [143].

Fig. 9. The coefficients of thermal expansion (CTE) for the studied materials as a function of temperature [143].

Table 1
The Young's modulus values for the used materials.
Material Young's modulus (GPa) Reference

HfB2 450 [131,144]

ZrB2 490 [145]
HfB2–20 vol% SiC 489.6 [146,147]
ZrB2–20 vol% SiC 480 [147,148]

demonstrated in Figs. 11 and 12, respectively. The temperature dis-

tribution is not uniform and a low-temperature area can be seen in the
adjacency of the internal cooling ducts. The minimum temperature in
both blades made of ZrB2–SiC and HfB2–SiC materials is on the second
baffle wall of the internal cooling, while the maximum temperature is at
the end of the blade with the value of ~1100 K. Based on the tem-
perature contours, it can be seen that internal cooling has a consider-
able effect on the cooling process of the blades, which can increase the
life of the stator blades. However, the cooling process reduces the ef-
ficiency of the turbines because it decreases some parts of the inlet gas
energy. The mounting parts and trailing edge as the hottest parts of the
blade can fail simply due to the metallurgical defects [131,149]. On the
other hand, internal cooling ducts are the most capable area to start and
Fig. 10. The applied grid on the turbine stator blade.
propagate the cracks in the blade as a result of temperature gradient

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Fig. 11. The temperature distribution in the blade made of ZrB2–SiC composite.

Fig. 12. The temperature distribution in the blade made of HfB2–SiC composite.

Fig. 13. The temperature contours in the blades made of (a) HfB2, (b) ZrB2, (c) HfB2–SiC, and (d) ZrB2–SiC UHTCs.

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K. Vaferi, et al. Ceramics International 47 (2021) 567–580

Fig. 14. The principal stresses in the blade made of ZrB2–SiC composite.

Fig. 15. The principal stresses in the blade made of HfB2–SiC composite.

Fig. 16. The stress distribution in the blades made of (a) HfB2, (b) ZrB2, (c) HfB2–SiC and (d) ZrB2–SiC UHTCs based on the Coulomb-Mohr criterion.

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Fig. 17. The stress distribution in the blades made of (a) HfB2, (b) ZrB2, (c) HfB2–SiC and (d) ZrB2–SiC UHTCs based on the Von Mises criterion.

Table 2 efficiency. The addition of SiC to monolithic HfB2 and ZrB2 ceramics
The safety factor values for the ZrB2–SiC and HfB2–SiC materials. reduces their thermal conductivity (Fig. 8), and following that, the
Material Safety factor
temperature uniformity in blades decreases. As a result, the thermal
stresses and the probability of failure in the stator blades increase.
Coulomb-Mohr Von Mises However, it seems that the other properties of the material such as
coefficient of thermal expansion and Young's modulus have better im-
ZrB2–SiC 1.32 1.6
HfB2–SiC 1.4 1.7
pacts on the exposed stresses.
ZrB2 [153,154] 1.02 1.27 Figs. 14 and 15 illustrate the principal stresses of the stator blade
HfB2 [131] 1.28 1.56 made of ZrB2–SiC and HfB2–SiC composites, respectively. As can be
seen, the utilization of ZrB2–SiC composite caused to produce less
maximum principal stress in the stator blades compared to using
and subsequent thermal stresses [131,150]. Fig. 3 provides a compar- HfB2–SiC one. As mentioned earlier, the thermal characteristics of
ison between the temperature contours of the four proposed materials. materials such as thermal conductivity and thermal expansion have
According to Fig. 13a–b, at temperatures above 500 K, ZrB2 has higher significant effects on the thermal stresses, which are appeared in the
thermal conductivity than HfB2 (as shown in Fig. 8), which causes more blades. By decreasing the temperature gradient in the stator blade, the
uniform temperature distribution in the blade made of ZrB2. Therefore, applied thermal stresses are reduced. In order to diminish the tem-
it can be concluded that the high thermal conductivity of materials perature gradients, it is required to use a material with higher thermal
results in temperature gradients reduction, which subsequently de- conductivity. According to Fig. 8, it can be seen that because of the
creases the related thermal stresses. The lower thermal stresses in the higher thermal conductivity of ZrB2–SiC in comparison with HfB2–SiC,
turbine components, the longer life span of them. It should be noted the utilization of ZrB2–SiC reduces the stresses in the blade through
that the high thermal conductivity of materials causes more dissipation providing a better temperature distribution. On the other hand,
in the heat and energy of the inlet gases, which reduces turbine

Fig. 18. The force distribution plots for blades made of (a) HfB2–SiC and (b) ZrB2–SiC composites.

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K. Vaferi, et al.
Fig. 19. The displacement plots for blades made of (a) HfB2–SiC and (b) ZrB2–SiC composites.
Fig. 20. The displacement plots for the blades made of (a) HfB2, (b) ZrB2, (c) HfB2–SiC and (d) ZrB2–SiC UHTCs.
ZrB2–SiC has a lower thermal expansion coefficient than HfB2–SiC
(Fig. 9), which is another reason for the lower stresses in the blade
made of ZrB2–SiC. In the present study, two criteria of Coulomb-Mohr
and Von Mises are used to measure the safety factor of the stator blade.
Figs. 16 and 17 show the stress distribution plots based on Coulomb-
Mohr and Von Mises criteria, respectively. Among the investigated
UHTCs, the utilization of ZrB2 causes the highest stress; whereas ap-
plying ZrB2–SiC in the manufacturing of blades provides the best per-
formance for turbines by inducing less stresses. In the Coulomb-Mohr
criterion, the compressive principal stresses are used to calculate the
safety factor, while in the Von Mises theory, the factor of safety is
computed by normal and shear stresses. The values of 0.9 and 0.75 GPa
were reported for the compressive strength of HfB2–SiC and ZrB2–SiC
composites, respectively [145,151,152]. By comparing the obtained
maximum principle stresses and values of the compressive strength for
each material, it can be understood that both composites simply
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Ceramics International 47 (2021) 567–580
withstand the applied stresses. The calculated safety factors for the
proposed materials based on both Coulomb-Mohr and Von Mises cri-
teria are presented in Table 2. Based on these results, Coulomb-Mohr is
more accurate criterion than Von Mises for investigating the probability
of failure in brittle materials.
Fig. 18 shows the force distribution plots on the blade surfaces in
contact with the turbine walls. As can be expected, lower force is ap-
plied on the blade made of ZrB2–SiC composite. Displacements and
deformations of the stator blades made of HfB2–SiC and ZrB2–SiC ma-
terials are indicated in Fig. 19. The minimum displacement occurs at
the thermal insulation wall and increases to the leading edge of the
blade. The maximum displacements of blades made of these composites
are approximately same (with a difference of 0.06 mm). Spring foun-
dations and rollers are the main reasons to decrease the displacement
values from the upper surface to the thermal insulation wall. Fig. 20
compares the displacement and deformation plots of stator blades made
K. Vaferi, et al.
of different materials. As discussed before, the largest displacement
belongs to the blade made of ZrB2 ceramic.
7. Conclusions
In the present numerical work, HfB2–SiC and ZrB2–SiC were pro-
posed as alternative materials to use in the construction of the gas
turbine stator blade. The deformations, stresses, and temperature dis-
tributions for turbines made of these materials were investigated. Due
to the higher thermal conductivity of ZrB2–SiC composite, in compar-
ison with HfB2–SiC UHTC, utilizing this material provided a more
uniform and proper temperature distribution in the stator blade.
According to the analytical results, ZrB2–SiC with a lower heat expan-
sion coefficient reduced the applied stresses and displacements in the
blade. Higher temperature gradient and higher thermal expansion
coefficient led to the thermal stresses and consequent thermal expan-
sion. The probability of failure in the blades made of HfB2–SiC and
ZrB2–SiC composites was evaluated using the criteria of Coulomb-Mohr
and Von Mises. The data obtained from these theories indicated the
ability of the blades made of HfB2–SiC and ZrB2–SiC in withstanding the
applied operational conditions. The Coulomb-Mohr theory was more
accurate and rigorous than the Von Mises for investigating the failure
possibility in brittle materials. Among the four studied materials,
ZrB2–SiC UHTC caused the lower displacement and better thermal
distribution as a suitable material in the gas turbine blade manu-
facturing industries.
Declaration of competing interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influ-
ence the work reported in this paper.
Acknowledgements
Mohsen Mohammadi acknowledges the funding received from
Natural Sciences and Engineering Research Council of Canada (NSERC)
Grant No. RGPIN-2016-04221. Mehdi Shahedi Asl thanks the McCain
Foundation for providing enough funding through the McCain
Foundation Postdoctoral Fellowship in Innovation program to conduct
this work.
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