High performance materials in coal conversion utilization. Final report, October 1, 1993--September 30, 1996

This report describes the research conducted at the University of Tennessee Space Institute on high performance materials for use in corrosive environments. The work was supported by a US Department of Energy University Coal Research grant. Particular attention was given to the silicon carbide particulate reinforced alumina matrix ceramic composite manufactured by Lanxide Corporation as a potential tubular component in a coal-fired recuperative high-temperature air heater. Extensive testing was performed to determine the high temperature corrosion effects on the strength of the material. A computer modeling of the corrosion process was attempted but the problem proved to be too complex and was not successful. To simplify the situation, a computer model was successfully produced showing the corrosion thermodynamics involved on a monolithic ceramic under the High Performance Power System (HIPPS) conditions (see Appendix A). To seal the material surface and thus protect the silicon carbide particulate from corrosive attack, a dense non porous alumina coating was applied to the material surface. The coating was induced by a defocused carbon dioxide laser beam. High temperature corrosion and strength tests proved the effectiveness of the coating. The carbon dioxide laser was also used to successfully join two pieces of the Lanxide material, however, resources did not allow for the testing of the resulting joint