Hybrid Materials and Construction Principles for Aero Engine Components Materials Day@ILA 2006 Frank Kocian,, Joachim Hausmann DLR German Aerospace Center Folie 1 BDLI 2006 Kocian 17.05.2006
Content Hybrid Unison Ring for a High Pressure Compressor Hybrid Fan Blade Two Different Approaches CF-PEEK Titanium Hybrid Fan Blade Continuously Reinforced Titanium Matrix Composites (TMC) High Performance Shaft for an Aero Engine Folie 2 BDLI 2006 Kocian
Hybrid Unison Ring - A component for BR700 HP compressor Aims: better functionality reduced weight reduced cost Project partners: RR-Deutschland as end user Fa. Ensinger as prospective supplier DLR Stuttgart as developer Folie 3 BDLI 2006 Kocian
Hybrid Design - A new Approach Implementation of adjustable thermal strain compatibility Simple multifunctional substructures Optimised combination of high performance materials Folie 4 BDLI 2006 Kocian
Theoretical Investigation of Design Principles Solution of specific joining problems with the help of universal mechanical fasteners Usage of DLR competence to demonstrate technical feasibility Thermal strain compatibility by use of a CFRP band in combination with aluminium segments Avoiding internal stress by efficient usage of thermal strain Folie 5 BDLI 2006 Kocian
Manufacturing of the Hybrid Unison Ring Manufacturing of CFRP components in the Institute Testing of several manufacturing procedures - Wet filament winding - Dry filament winding in combination with RTM - Tape laying technology Manufacturing of metal and HT- plastic components by the industrial partner Folie 6 BDLI 2006 Kocian
Verification of the Whole System Assembly tests at RR Deutschland in Dahlewitz with the help of RRtechnicians Successful mechanical rigtest at RR-Deutschland in Oberursel Confirmation of functionality of the Hybrid Unison Ring concept during a coreengine-test at the Institut für Luftfahrtantriebe (ILA) in Stuttgart Folie 7 BDLI 2006 Kocian
Verification of Structural Durability Hysteresis ±7mm deflection Resolver angle [ ] 10 8 6 4 2 0-8 -6-4 -2 0-2 2 4 6 8-4 -6 Resolver1 [ ] -8 Resolver2 [ ] Resolver3 [ ] -10 Force [N] Tie rod deflection [mm] -5000-4000 -3000-2000 -1000 0 1000 2000 3000 4000 5000 Tie rod force [N] Evidence of three life time cycles on a test rig regarding maximum loads of all compressor stages Evidence of damage tolerance of CFRP parts Evidence of surge loads Folie 8 BDLI 2006 Kocian
Results Hybrid Unison Ring (CHUR) 40% reduction of structural weight Improved functionality due to efficient management of thermal strain Reduction of component cost Demonstration of practicable manufacturing routes Material appropriate hybrid design Hybrid Unison Ring is an option for future aero engine development at RR Deutschland Folie 9 BDLI 2006 Kocian
Hybrid Fan Blade Two different Approaches Interdisciplinary collaboration of several DLR institutes within the project NDV 4.5 Institute of Propulsion Technology Institute of Aeroelasticity Institute of Materials Research Institute of Structures and Design Folie 10 BDLI 2006 Kocian
Material and Design Concepts Continuously reinforced Titanium Matrix Composites (TMC) CF-PEEK / Titanium hybrid blade Folie 11 BDLI 2006 Kocian
Basic Concept or a CFRP Hybrid Fan Blade Aims: Reduction of structural weight Resistance against erosion and FOD by having a metal leading edge Reduced rotational blade energy with view on a fan blade off Increasing structural damping Hybrid fan blade for NDV 4.5 Design Principles: Usage of high inherent bonding strength between CF-PEEK and Titanium Usage of an extended bonding area which is not primary loaded due to its radial orientation Folie 12 BDLI 2006 Kocian
Verification of Material Interface in a HCF test mass specific strain energy density [J/kg] 50 45 40 35 30 25 20 15 10 5 HCF specimen was tested in a second bending mode titanium single lap single lap from individual plies double lap inverted double lap (CFRP clamped) 0 1,00E+04 1,00E+05 1,00E+06 1,00E+07 cycles Folie 13 BDLI 2006 Kocian
Realised Compressor Blade Hybrid fan blade for NDV Present development status: Experimental verification of joining technique and assessment of load carrying capacity on specimen level is completed Preparation of FE modelling technique for hybrid structures is successfully demonstrated Demonstration of a material appropriate manufacturing technique Tests of a complete structure is projected Mass of the blade can be reduced in the range of 15% to 20% Folie 14 BDLI 2006 Kocian
Material and Design Concepts Continuously reinforced Titanium Matrix CF-PEEK / Titanium Composites hybrid blade (TMC) Folie 15 BDLI 2006 Kocian
Continuously Reinforced Titanium Matrix Composite (TMC) E = ~ 400 GPa SiC σ = fibre > 4000 MPa (SCS-6, α = 3 4 d=142 ppm/k μm) Metal E = ~ 115 matrix GPa σ = ~ 1000 MPa (Ti-6Al-2Sn-4Mo-2Zr) α = ~ 11 ppm/k Carbon core 1 mm Reaction barrier coating Folie 16 BDLI 2006 Kocian
TMC-Production by the MCF-Route Consolidation (HIP) Final machining and integration in fan blade Component Fibre stacking Matrix-coated fibre (MCF) Ti-Matrix Magnetron-Sputtering SiC-Fibre Folie 17 BDLI 2006 Kocian
Design Principles for TMC Specimens High costs properties in the application Not suitable for relaxation process Suitable Costly quality for relaxation controlprocess Reinforcement Oversized reinforcement where needed Folie 18 BDLI 2006 Kocian
Implemented Design Principles for a Fan Blade Integration of local reinforcement in terms of TMC sticks Calculation of monolithic Titanium fan blade with maximum stress in root section an in the middle of the blade Confirmation of stress reduction Folie 19 BDLI 2006 Kocian
Data and Experiments for Blade Applications High cycle fatigue under reversed loading (R=-1) Improvement of HCF strength by residual stress modification Influence of fibre ends on strength Strain rate sensitivity under tensile loading Foreign object damage resistance
Longitudinal Fatigue Behaviour of SiC/Timetal834 Maximum Applied Stress [MPa] 2500 2000 1500 1000 500 0 10 0 10 2 10 4 10 6 Cycles to Failure R=0.1 Excellent longitudinal fatigue resistance in general! R = 0.1 0.25-5 Hz lab air load controlled Folie 21 BDLI 2006 Kocian
1500 1000 500 Maximum Stress σ A [M Pa]2000 0 Life Prediction and Fatigue Experiments of TMC Matrix 20 C R = -1 F = 50 Hz TMC pre-strained TMC original TMC pre-strained +crept Experiments SCS-6/Ti-6242 10 0 10 2 10 4 10 6 Cycles to Failure N f Prediction reveals upper limit Multiaxial effects and irregularities are neglected Folie 22 BDLI 2006 Kocian
High Strain Rate Loading DLR Impact Probe v = 450 m/s 50 Gramm 3 1 2 5 4 6 Explicit FEA of TMC specimen impacted with 450 m/s TMC TMC solid titanium 305 m/s 345 m/s 342 m/s Impact resistance is reduced but may be sufficient for intended application Dr. Jörg Frischbier, MTU Aeroengines, München, Germany
High Performance Shaft for an Aero Engine Design principles: Fibre reinforcement only where necessary with view on maximum torque in one preferred direction Compensation of material rearrangement due to HIP process Adaptability of stress reduction process for maximum strength Folie 24 BDLI 2006 Kocian
Unidirectional Lay-Up for a TMC Shaft σ 1 M t σ 2 Fibres are mainly tension loaded Matrix is mainly compression loaded with view on efficient usage of fibre matrix interface Folie 25 BDLI 2006 Kocian
Scheme of Realizing the Fibre Orientation within the Preform Step 2: Twisting in combination with axial movement of preform Step 1: Generation a preform by using coated fibres fibre orientation in this stage parallel to rotation axis Step 3: Desired fibre orientation and pre consolidated structure Folie 26 BDLI 2006 Kocian
Realized Test Specimen TMC Ti 44 mm 74 mm Testable tube structure with attached tooting for load introduction Folie 27 BDLI 2006 Kocian
Results Several small shaft specimens have been manufactured D 39/44 mm failed beyond 6 knm [σ1/2=+/-980 MPa] Unidirectional angle ply lay-up is most promising for aero engine applications Other applications require special design methodologies Larger shaft demonstrators are in production DLR is partner of EU project Vital Folie 28 BDLI 2006 Kocian
Thank you for your attention! Folie 29 BDLI 2006 Kocian 17.05.2006