Overview of the Advanced Ceramics Industry in the United States John E. Holowczak Chair, United States Advanced Ceramics Association Associate Director – Advanced Materials United Technologies Research Center Glen Mandigo and Doug Freitag, USACA

1020 Nineteenth St. NW Suite 375 Washington, D.C. 20036 This document does not contain any export controlled technical data. Introduction to USACA  Established in 1985 to promote the research, development, and application of advanced ceramics  38 member companies and organizations  USACA works to promote advanced ceramic materials, disseminate information about the materials, and interface with the U.S. government on behalf of the industry.  Members advise federal agencies through technology roadmaps and conferences.  Active technology roadmaps include: Advanced Ceramics Technology Roadmap, 2001 Advanced Ceramics for Distributed Energy, 2004 Ceramic Composites Affordability and Producibility Initiative, 2009 Transparent Ceramic Armor Producibility Roadmap, 2013 Transparent Ceramic Sensor Windows Roadmap, 2017 Ceramic Composites Affordability and Producibility Roadmap update, 2016 2 This page does not contain any export controlled technical data.

What are Advanced Ceramics Lightweight, strong materials capable of performing in extreme environments:

 High Temperature and Pressure  High Stiffness and Durability  Ultra Hard & Tough Surface

Not This! 3 This page does not contain any export controlled technical data. Membership Across the Supply Chain

Design/Stds/ Raw Test & Research Fabrication Machining QC Integration Databases Materials Evaluation

Rutgers UDRI GE GE NCDMM CeraNova UDRI Applied Materials UDRI SoRI COI Ceramics COI Ceramics PSI UDRI SoRI GE Alfred MR&D CeraNova CeraNova Bullen P&W Johns Hopkins Exothermics Boeing CoorsTek Rolls Royce Missouri S&T Specialty Materials Saint Gobain MillenniTek Raytheon Free Form Fibers PSI Boeing Lithoz America II-VI Westinghouse MATECH Composite Horizons Starfire Ceramic Tubular Products Harper CoorsTek Advanced Ceramic Lancer Systems Fiber Lithoz America Axiom Materials Raytheon ATC Materials Rolls Royce Applied Thin Films United Technologies Westinghouse Kyocera Harper Advanced Thin Films Triton Systems MillenniTek ATC Materials

This page does not contain any export controlled technical data. 4 Comparison of Ceramics Focused and Related Organizations

Japan Fine Ceramics Association U.S. Advanced Ceramics Assoc. Promote Fine Ceramics Promote Advanced Ceramics Develop Standards and Research Projects Advise Federal Agencies Cooperate Government & Industry Interface with U.S. Government

Ceramic Society of Japan American Ceramic Society

New Energy & Industrial Tech. U.S. Dept of Energy (METI -> NEDO)

Acquisition, Technology U.S. Dept. of Defense & Logistics Agency (ATLA)

This page does not contain any export controlled technical data. 5 USACA Leadership

 John Holowczak, United Technologies, Chair  Tom Nixon, Rolls Royce, Vice Chair  Craig Iwano, MR&D, Treasurer  Andy Thomas, Coorstek, Secretary

 Glen Mandigo, Executive Director  Doug Freitag, Technical Director

1020 Nineteenth St. NW Suite 375 Washington, D.C. 20036

This page does not contain any export controlled technical data. 6 Primary Activities (Excluding Conference Hosting)

 Two meetings per year in Washington, DC focused on federal programs of interest to the ceramics industry.  Working Groups:

 Nuclear Materials Working Group

 Transparent Ceramics Working Group

 CMC Working Group

 Workforce Development Working Group  Current and planned initiatives:

 Support DOE Accident Tolerant Fuels program for development and qualification of ceramic cladding

 Increase federal funding for High Temperature CMCs consistent with recommendations in the USACA CMCs for Advanced Gas Turbines Roadmap for CMC manufacturing. 1020 Nineteenth St. NW Suite 375 Washington, D.C. 20036 This page does not contain any export controlled technical data. 7 U.S. Agencies Funding Advanced Ceramics  Department of Defense ($3-4 billion)

 Materials R&D and system development programs under Air Force, Army, Navy, and Defense Wide  Department of Energy ($250-300 million)

 Materials and applications development for nuclear, fuel cell, gas turbine, and renewable energy  NASA ($400-500 million)

 Materials R&D, Aeronautics, Space Exploration  FAA ($25-35 million)

 Databasing (including CMH-17 Handbook development), flight certification, component demonstrations 8 This page does not contain any export controlled technical data. USACA Dept. of Defense Priorities

 Materials in extreme dynamic environments  Energy efficient/increased performance gas turbine propulsion technologies  High-speed strike weapon technologies  Transparent armor for ground, air, sea vehicles  Electro-optic/radar transparencies for sensor windows  Defense Production Act Title III/ManTech

9 This page does not contain any export controlled technical data. USACA NASA Program Priorities

 Hypersonic Technology  Aeronautics  Space Exploration  SLS and Orion  Commercial Space

10 This page does not contain any export controlled technical data. USACA Dept. of Energy Program Priorities

 Accident Tolerant Fuels  Advanced Turbines  Solid Oxide Fuel Cells  Concentrating Solar  Harsh and Extreme Environment Materials

11 This page does not contain any export controlled technical data. Transparent Ceramics Working Group

 Developing roadmaps for use by DoD and Industry with the goals of delivering more affordable and capable transparent ceramic armor and sensor windows  Participates from throughout the supply Electro-Optical Targeting System chain with leadership from key (EOTS) for F-35 manufacturers and end users.  Technical challenges identified in feedstocks, shape forming, secondary processes, modeling and simulation and materials and component level characterization

1020 Nineteenth St. NW Suite 375 Naval Carrier Transparent Armor Washington, D.C. 20036 This page does not contain any export controlled technical data. 12 Workforce Development Working Group

 Focuses on enhancing communication and foster collaboration among industry, academia, and government, supporting recruitment and training efforts in fields enabled by advanced ceramics and composite materials.

 David Lipke from Missouri S&T, Rich Haber from Rutgers University are Co-Chairs of the working group.  Recommends best practices and strategies for increasing quantity and quality of prospective workforce participants  Outreach to students via the student page program at the annual Composites, Materials, and Structures Conference.

This page does not contain any export controlled technical data. 13 Nuclear Materials Working Group  Established to work with US Department of Energy and Congress to advance ceramic materials for nuclear energy applications.  Ed Lahoda from Westinghouse, and Herb Feinroth from Ceramic Tubular Products are Co-Chairs of the working group.  Supporting Department of Energy (DOE) and the nuclear power industry to develop and qualify ceramics for fuel rods and channel boxes as a safer and better performing alternative material to zirconium metal.  Activities include advice to DOE on ceramic materials and manufacturing capabilities, and supporting Accident Tolerant Fuels program with the Department of Energy budget.

This page does not contain any export controlled technical data. 14 CMC Working Group

 Established to create industry driven roadmaps for use in driving investment by DoD, DOE, NASA and Industry with the goals of delivering more affordable, producible and capable CMCs for use in aeropropulsion, aerostructure and stationary power generation. Boeing 787 CMC Exhaust Nozzle  Participates from throughout the supply chain with leadership from key manufacturers and end users.  Common technical challenges identified in raw materials, shape forming, secondary processes, attachments, materials characterization, databases, design tools, and sustainment. GE Leap Gas Turbine Shrouds

This page does not contain any export controlled technical data. 15 CMC Working Group Why the Need for New Materials?

Gas-inlet temperature (ºF) The National Academy of Sciences, Engineering, and 1500 2000 2500 3000 3500 4000 Medicine recently completed a study on Commercial Aircraft Propulsion and Energy Systems Research and concluded that additional Impact of 2700ºF CMC investment in gas turbine engine materials and coatings should be a high priority.

"2700ºF uncooled materials are required to achieve future targets for gas turbine performance, efficiency and emissions.” Adapted from a) Nature Materials, V15, 8/16 and b) NAS Commercial Aircraft Propulsion and Energy Systems No comparable study on Research: Reducing Global Carbon Emissions, 2016. power gen

This page does not contain any export controlled technical data. 16 CMC Working Group Industry Contributors

Systems

Components

Materials, Machining, Test, Design, Equipment

Research

Working group includes OEM’s developing new materials for system level cost, performance, and reliability, the supply chain supporting development of new materials, and academia and National Labs creating fundamental knowledge of new material behavior. This page does not contain any export controlled technical data. 17 CMC Working Group - Summary

 Broad government / industry consensus that higher temperature CMCs offer the potential for large capability improvements and economic benefits – our immediate challenge is to quantify them.

 The High Temperature CMC Initiative aggressively attacks the major risk elements needed for successful development, certification, and acquisition.

 Continued government investment needed to bring higher temperature CMC materials systems to TRL/MRL for affordable , low-risk transition into operational platforms

• Successful achievement of the identified goals will insure a sustainable high temperature CMC parts production capability in the United States by 2025.

• USACA intends to continue to actively pursuing all available funding avenues and opportunities to make this vital national initiative a reality

This page does not contain any export controlled technical data. 18 Examples of Recent Work at UTRC in these areas

• Hybrid monolithic ceramic / CMC development – Turbine airfoil applications – Armor for soldiers and aircraft – Focus on non-oxide monolithics/non-oxide fiber CMCs

• Polymer derived silicon carbide matrices for Accident Tolerant Nuclear Fuels – Performed in support of Westinghouse – Potential to reduce cost – Enabling reduced nuclear waste – Improved ability to withstand reactor malfunctions • Retrofit existing reactor fleet – Reduce new light water reactor system cost

This page does not contain any export controlled technical data. 19 Work in Hybrids Extension of FT8 Cooled Ceramic Vane

Aeroderivative first stage turbine vanes after 8 hours high pressure sector rig testing DARPA, Navy and U.S. Dept of Energy funded

Chart as presented in “Hybrid Monolithic Ceramic/Ceramic Matrix Composites; from Turbine Airfoils to Armor”, presented by Holowczak et. al. At the 35 Annual International Conference & Exposition on Advanced Ceramics & Composites (ICACC), January 26, 2011 , American Ceramic Society Engineered Ceramics Division meeting, Daytona Beach, Fl., Jan. 2011

This page does not contain any export controlled technical data. 20 How to Use Monolithics for Hi Reliability Applications?

Challenge: Harness benefits of ceramics for turbine static structures WITHOUT resorting to all CMC Hybrid Ceramic/CMC construction Concept

Monolithic Si3N4 Ceramic Shell

Ceramic Matrix Composite Inner Support Structure (Spar) Cooled monolithic ceramic FT8 HPT vane cross section – Trailing Edge Cooling Slots aerothermal analysis

This page does not contain any export controlled technical data. 21 UTRC effort in CMCs for Nuclear Fuel Containment

• Desire for low cost method of providing a silicon carbide matrix – Must withstand high pressure/temperature water – Need to withstand irradiation over long periods

• Focus on polymer infiltration and pyrolysis (PIP) derived silicon carbide matrices

• PIP SiC matrices were limited in pyrolysis temperature by limit of Hi Nicalon Type S – These showed poor resistance to simulated LWR environments (high temperature & pressure water)

• Use of refractory SiC fibers with greater heat tolerance enabled higher pyrolysis temperatures; yielded much greater resistance to simulated LWR exposure

• Example of how those studying turbine CMC materials and applications can help developers of accident tolerant nuclear fuel systems

Lahoda, Edward J., and Boyan, Frank A. Development of LWR Fuels with Enhanced Accident Tolerance ATF Feasibility Analysis Report Deliverable for the Westinghouse Accident Tolerant Fuel Program. United States: N. p., 2018. Web.

22 This page does not contain any export controlled technical data. U.S. Advanced Ceramics Association - Summary

 The Japan Fine Ceramics Association and U.S. Advanced Ceramics Association share common interests and goals

 One important difference lies in USACA’s lobbying efforts with U.S. Congress for further research and development and manufacturing scale up funding

 There are synergies between CMC development for turbine engines, and for accident tolerant nuclear fuel encapsulation  Groups involved in these separate applications should work together to accelerate development  Greater international cooperation needed

 USACA intends to continue to actively pursuing all available funding avenues and opportunities to make new applications of ceramics and CMC’s a reality

23 This page does not contain any export controlled technical data.