Unclassified Cold Spin Test CST of Silicon Nitride

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Unclassified Cold Spin Test (CST) of Silicon Nitride Discs for Jet-Engine Applications Ido Koresh

Unclassified Cold Spin Test (CST) of Silicon Nitride Discs for Jet-Engine Applications Ido Koresh 1, Shimshon Bar-ziv 1, Ahron Halevy 2, Anat Shenar 1, Shlomit Zamir 1 1. 2. Advanced Materials Department, MANOR, RAFAEL. Jet Propulsion Department , MANOR, RAFAEL. Founding : MAFAT, Ministry of Defense, Israel. 1 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Content • Motivation and objectives. • Silicon nitride - process flow chart. •

Unclassified Content • Motivation and objectives. • Silicon nitride - process flow chart. • Cold spin test - Preparation. • The cold spin test. • Summary and future challenges. 2 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Motivation and Research Objectives 3 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems

Unclassified Motivation and Research Objectives 3 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Silicon Nitride Combines excellent high-temperature mechanical properties, resistance to oxidation and thermal shock,

Unclassified Silicon Nitride Combines excellent high-temperature mechanical properties, resistance to oxidation and thermal shock, making it a promising candidate for high temperature jet engine parts. More efficient engines: • Low density 3. 25 gr/cm 3 • Higher turbine inlet temperature. • Reduction in cooling needs. Effect of Y 2 O 3 and Yb 2 O 3 on the microstructure and mechanical properties of silicon nitride, Horng-Hwa Lu, Ceramic international, V. 27, p. 621, 2001 4 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Cold Spin Test (CST) Research objectives: 1. Assessing the feasibility of using RAFAEL’s

Unclassified Cold Spin Test (CST) Research objectives: 1. Assessing the feasibility of using RAFAEL’s developed Silicon Nitride for jet-turbine engine applications. 2. Evaluation of the mechanical durability by CST at jet-engine’s RPM (115, 000 RPM). drawing R 00 -199236 5 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Silicon Nitride - Process Flow Chart 6 Raf#10544855 Proprietary of Rafael - Advanced

Unclassified Silicon Nitride - Process Flow Chart 6 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Silicon Nitride - Process Flow Chart Powder Granulation: Mixing silicon nitride, sintering aids

Unclassified Silicon Nitride - Process Flow Chart Powder Granulation: Mixing silicon nitride, sintering aids and binder aids (organic system) H = 25 mm , h = 7 mm D = 83. 6 mm Powder Compaction: Particle Size Distribution Cold Iso-Static Pressing (1000 -3000 atm) H SEM h Firing in air 500 -600 o. C 10 μm Sintering (thermal treatment): 1700 -1800 o. C in inert atmosphere Machining 7 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Cold Spin Test (CST) - Preparation 8 Raf#10544855 Proprietary of Rafael - Advanced

Unclassified Cold Spin Test (CST) - Preparation 8 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Cold Spin Test (CST) - Preparation Two silicon nitride discs were manufactured (8

Unclassified Cold Spin Test (CST) - Preparation Two silicon nitride discs were manufactured (8 S and 5 S). Characteristics Density [%TD] TD=3. 25 gr/cc Requirements 8 S 5 S >97. 5% TD 97. 6 642. 1 642. 6 σ=28. 1 σ=19. 0 Minor non- conformances Bending strength [MPa] >600 MPa 8 specimens Dimensional inspection 9 Raf#10544855 drawing R 00 -199236 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified CST - Preparation - Stereoscope inspection 8 S Machining defect Ceramics are highly

Unclassified CST - Preparation - Stereoscope inspection 8 S Machining defect Ceramics are highly sensitive to surface defects. Should this part be incorporated in the CST? 10 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified CST - Preparation – Stress Analysis Maximum Stress 395 MPa We decided to

Unclassified CST - Preparation – Stress Analysis Maximum Stress 395 MPa We decided to take the chance. 11 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified CST - Preparation - Balancing ~2400 rpm Steel mandrel Polyamide Silicon Nitride Disc

Unclassified CST - Preparation - Balancing ~2400 rpm Steel mandrel Polyamide Silicon Nitride Disc Polyamide steel screw-nut M 8 x 1 • Material was removed by diamond grinding tool. • High Dynamic balancing (0. 1 gr∙mm) was hardly achieved. • Finally, the parts were only statically balanced (0. 1 gr∙mm). 12 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified The Cold Spin Test (CST) 13 Raf#10544855 Proprietary of Rafael - Advanced Defense

Unclassified The Cold Spin Test (CST) 13 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Cold Spin Test (CST) • The CST was done at T. A. T

Unclassified Cold Spin Test (CST) • The CST was done at T. A. T Technologies’s test rig. • Static balancing was checked on-site prior to testing. 14 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

Unclassified Cold Spin Test (CST) 1 st Test: 5 S 2 nd Test: 8

Unclassified Cold Spin Test (CST) 1 st Test: 5 S 2 nd Test: 8 S - Contains the surface defect. 3 rd Test: 8 S - Contains the surface defect (faster profile: 0 to 115, 000 rpm in ~50 sec ). All parts passed the test successfully with no damage. RPM 115, 000 5 sec 1000 rpm/sec 60, 000 35, 000 1000 rpm/sec Test profile 15 sec 4000 rpm/sec ~2500 rpm/sec Illustrative graph 15 sec ~2500 rpm/sec 15 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. Time 17 September 2021

Unclassified Summary • Silicon nitride fabrication process was developed to achieve required material properties.

Unclassified Summary • Silicon nitride fabrication process was developed to achieve required material properties. • Large parts showed a very narrow strength distribution. • Silicon nitride discs were manufactured, complying with the CST required specifications. • All the silicon nitride discs successfully passed the CST. Future Challenges • Optimization of the fabrication process. • Manufacturing a real silicon nitride turbine (blades included). • High temperature material characterization and hot spin test. 16 Raf#10544855 Proprietary of Rafael - Advanced Defense Systems Ltd. 17 September 2021

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