A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

:ŽƐĞƉŚ͘'ƌĂĚLJ

:ĂŶƵĂƌLJϮϱʹϯϬ͕ϮϬϭϱ

ĂLJƚŽŶĂĞĂĐŚ͕&ůŽƌŝĚĂ

E^'ůĞŶŶZĞƐĞĂƌĐŚĞŶƚĞƌ

/ŶƚĞƌŶĂƚŝŽŶĂůŽŶĨĞƌĞŶĐĞĂŶĚdžƉŽƐŝƚŝŽŶŽŶ

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ĚǀĂŶĐĞĚĞƌĂŵŝĐƐĂŶĚŽŵƉŽƐŝƚĞƐ

ŶĂďůĞĚďLJĚĚŝƚŝǀĞDĂŶƵĨĂĐƚƵƌŝŶŐ

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&ƵůůLJEŽŶͲDĞƚĂůůŝĐ'ĂƐdƵƌďŝŶĞŶŐŝŶĞ

Outline

ĨŽƌƚƵƌďŝŶĞĞŶŐŝŶĞĐŽŵƉŽƐŝƚĞƐ

WƌŽũĞĐƚĞƐĐƌŝƉƚŝŽŶ ĞǀĞůŽƉŵĞŶƚŽĨĂĚĚŝƚŝǀĞŵĂŶƵĨĂĐƚƵƌŝŶŐ ŽŵƉŽŶĞŶƚƉƉůŝĐĂƚŝŽŶƐ ŶŐŝŶĞ^LJƐƚĞŵĞŶĞĨŝƚƐ dĞĐŚŶŽůŽŐLJDĂƚƵƌŝƚLJ EĞdžƚ^ƚĞƉƐ

• • • • • •

Project Innovation & Approach

: to fabricate gas turbine engine components from polymer and ceramic matrix composites.

Assess the feasibility of using additive manufacturing technologies Fabricate and test prototype components in engine operating conditions Conduct engine system studies to estimate the benefits of a fully non- metallic gas turbine engine design in terms of reduced emissions, fuel burn and cost Conducted the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully non-metallic gas turbine engines for reduced aircraft emissions, fuel burn and noise.

• • • Innovation Approach:

Accomplishments

&ŝƌƐƚƚŽƵƐĞĂĚĚŝƚŝǀĞŵĂŶƵĨĂĐƚƵƌŝŶŐƉƌŽĐĞƐƐĞƐƚŽĨĂďƌŝĐĂƚĞ ƚƵƌďŝŶĞĞŶŐŝŶĞĐŽŵƉŽŶĞŶƚƐĨƌŽŵĞƌĂŵŝĐDĂƚƌŝdžŽŵƉŽƐŝƚĞƐ ĂŶĚWŽůLJŵĞƌDĂƚƌŝdžŽŵƉŽƐŝƚĞƐ ĞŵŽŶƐƚƌĂƚĞĚĂĚǀĂŶĐĞĚƐƚƌƵĐƚƵƌĂůĐŽŶĐĞƉƚƐĞŶĂďůĞĚďLJ ĂĚĚŝƚŝǀĞŵĂŶƵĨĂĐƚƵƌŝŶŐƚĞĐŚŶŽůŽŐŝĞƐ ƐƚŝŵĂƚĞĚƚŚĞƌĞĚƵĐƚŝŽŶŽĨĞŶŐŝŶĞĞŵŝƐƐŝŽŶƐĂŶĚĨƵĞůďƵƌŶ ĚƵĞƚŽƚŚĞƐĞŵĂƚĞƌŝĂůƐĂŶĚĨĂďƌŝĐĂƚŝŽŶƉƌŽĐĞƐƐĞƐ ĞƚĞƌŵŝŶĞĚƚŚĞŵĂƚƵƌŝƚLJŽĨĂĚĚŝƚŝǀĞŵĂŶƵĨĂĐƚƵƌŝŶŐƚĞĐŚŶŽůŽŐŝĞƐ ĨŽƌĨĂďƌŝĐĂƚŝŽŶŽĨĐŽŵƉŽƐŝƚĞƚƵƌďŝŶĞĞŶŐŝŶĞĐŽŵƉŽŶĞŶƚƐ

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Jones Chao Lao (Cal Poly), (Acoustic testing): Mike Project Team (Engine Systems & Components): (Additive Manufacturing): Tom Santelle, Clark Patterson - Mike Vinup, Natalie Wali, Don Weir - Engine Systems Analysis: Bill Haller, Sydney Schnulo, Bob Plencner - Materials Characterization: Kathy Chuang, Mike Halbig, Bob Draper - Component Rig Testing: Phil Poinsatte, Doug Thurman - Ceramic Processing: Mrityunjay Singh - Polymer characterization: Eugene Shin Jeremy Mehl (Princeton), Morgan Rhein (Purdue) RP+M Honeywell Aerospace Ohio Aerospace Institute NASA Glenn Research Center NASA Langley Research Center NASA Aeronautics Academy Students: • • • • • • exhaust components & nozzles turbine shroud compressor vanes stator fan bypass fan duct hƐĞŽĨƚŚĞƐĞŵĂƚĞƌŝĂůƐΘŵĂŶƵĨĂĐƚƵƌŝŶŐƚĞĐŚŶŽůŽŐŝĞƐŝŶĐƌŝƚŝĐĂůĐŽŵƉŽŶĞŶƚƐǁŝůů Business Jet size turbofan engine ƌĞĚƵĐĞĞŵŝƐƐŝŽŶƐ;ϴйͿ͕ĨƵĞůďƵƌŶ;ϱйͿ͕ĞŶŐŝŶĞǁĞŝŐŚƚ;ϭϱйͿĨŽƌ ďƵƐŝŶĞƐƐũĞƚƐŝnjĞĞŶŐŝŶĞƐ

Lightweight, high temperature composite materials improve engine efficiency

ϳ processing quite similar Materials and challenges are Material and Property and behavior of Sintering and Process modeling Mechanical behavior NDE and in-situ damage starting materials densification challenges characterization Material and property databases Process Challenges ƒ ƒ ƒ ƒ ƒ ඵ Additive Efforts in this very promising field are just now underway.

Manufacturing Small series of Specific molds are not Different designs can Parts with significant ƒ ceramic parts can be manufactured rapidly and cost-effectively. ƒ required. ƒ be optimized (no major cost of changes) ƒ geometric complexity.

resulted in applications.

Largest barrier to CMC insertion has been high acquisition cost Conventional turbine engine Manufacturing commercialized Efforts in the last Customized parts in small volumes are time consuming and expensive to produce. Complex shape fabrication issues: mold design, dimensional tolerances, etc.. Manufacturing of multifunctional parts are challenging.

>30 years have now For AM, the starting materials are very low cost (powders and fibers).

• • •

Additive Manufacturing of Composite Materials

ϴ

&ĂďƌŝĐĂƚŝŽŶWƌŽĐĞƐƐ DĂƚĞƌŝĂůŚĂƌĂĐƚĞƌŝnjĂƚŝŽŶ ŽŵƉŽŶĞŶƚĞŵŽŶƐƚƌĂƚŝŽŶƐ

• • •

WŽůLJŵĞƌDĂƚƌŝdžŽŵƉŽƐŝƚĞƐ

ϭͬϭϮͬϮϬϭϱ ϵ Fused Deposition Modeling Quick turn around time for complex parts Shorter component production and testing cycle Reduced cost of low production volume components • Chopped-fiber reinforcement • Moisture reduction in FDM filament • Versatile printing pattern design Benefits: • • • Fabrication of high temperature PMC was enable by: Melts polymer filament and deposits it layer-by-layer following CAD files

Fused Deposition Modeling for Polymer Matrix Composites

fracture surface fibers are visible in composite neat matrix Addition of 10% chopped fiber (AS4) increased modulus 40% chopped fiber composite

Fiber reinforcement increases modulus of high temperature polymers

ϭϭ composites 㼻 for +/- 45 Process improvement reduced porosity 20% strength increase measured 27% modulus increase and 20% Initial composites were porous mechanical properties Porosity reductions improved and improved composite properties Reduction of moisture content in FDM polymer filament resulted in lower porosity Processing approach was refined to optimize properties of high temperature polymer composites decreasing layer thickness by reducing layer thickness during FDM process Experience with ABS composites shows strength and modulus can be increased • • Optimization of processing temperature & speed will also improve properties Further reduction of porosity is needed for structural components

ĚĚŝƚŝŽŶĂůƉƌŽĐĞƐƐŝŵƉƌŽǀĞŵĞŶƚƐŝĚĞŶƚŝĨŝĞĚ ĨŽƌŝŵƉƌŽǀŝŶŐWDƉƌŽƉĞƌƚŝĞƐ

ϭϯ

ŽŵƉƌĞƐƐŽƌ'ƵŝĚĞsĂŶĞ ĐŽƵƐƚŝĐ>ŝŶĞƌ

• •

WDŽŵƉŽŶĞŶƚƉƉůŝĐĂƚŝŽŶƐ

ϭͬϭϮͬϮϬϭϱ Attachment detail Ultem 1000 composite vane

сϰϮϯ϶&ͿǁŝƚŚĐŚŽƉƉĞĚĐĂƌďŽŶĨŝďĞƌ

by fused deposition Ő First Stage Compressor Blade

hůƚĞŵϭϬϬϬ;d &ŝƌƐƚWŽůLJĞƚŚĞƌŝŵŝĚĞĐŽŵƉŽƐŝƚĞĨĂďƌŝĐĂƚĞĚ

• •

F operating temperature ͼ Vane Inlet Guide

Fabricated Compressor Inlet Guide Vanes with High Temperature Polymer Matrix Composites

ϯϱϬ Ϯϳϱ ϮϬϬ hƐĞdĞŵƉĞƌĂƚƵƌĞ;϶&Ϳ ^ hůƚĞŵ ϭϬϬϬ hůƚĞŵ ϵϬϴϱ DĂƚƌŝdž;нĨŝďĞƌͿ Vane Configuration in Cascade Rig Other FDM composites being evaluated: ĞĨŽƌŵĂƚŝŽŶDĞĂƐƵƌĞŵĞŶƚƐ E^'ůĞŶŶ ĂƐĐĂĚĞZŝŐ ^ƚƌĞƐƐŶĂůLJƐŝƐ

^ƚƌƵĐƚƵƌĂůŝŶƚĞŐƌŝƚLJŽĨŝŶůĞƚŐƵŝĚĞǀĂŶĞ ǁĂƐĞǀĂůƵĂƚĞĚƵŶĚĞƌĂĞƌŽĚLJŶĂŵŝĐůŽĂĚŝŶŐ

сϯϲϳ϶&Ϳ Ő Honeycomb complex geometries Bonded Structure F operating temperature ͼ integral facesheet/honeycomb structure is fabricated in one step using Fused Deposition Modeling standard liner configuration &ĂďƌŝĐĂƚĞĚǁŝƚŚŵŽŶŽůŝƚŚŝĐhůƚĞŵϵϬϴϱƚŚĞƌŵŽƉůĂƐƚŝĐ;d Perforated Facesheet Current manufacturing approach requires metal forming, bonding and drilling

Fused Deposition Modeling Simplifies Acoustic Liner Fabrication

ϭϳ corner detail shows acoustic perforations panel location ഼

Fabrication of full-scale engine access panel demonstrated

inner surface incorporates acoustic treatment ůŝŶĞƌ >ĂZ ĂĐŽƵƐƚŝĐŵĞĂƐƵƌĞŵĞŶƚƐƐƵŐŐĞƐƚ ƚŚĂƚŽƉƚŝŵŝnjĞĚĐŽŶĐĞƉƚĐŽƵůĚ ŽƵƚƉĞƌĨŽƌŵĐƵƌƌĞŶƚůŝŶĞƌĚĞƐŝŐŶƐ ŽĨĂĚǀĂŶĐĞĚ &DƐĂŵƉůĞ &ĂďƌŝĐĂƚĞĚϭϲdžϮŝŶĐŚƚĞƐƚĂƌƚŝĐůĞ ĐŽƵƐƚŝĐĂůůLJͲƚƵŶĞĚƉĂƐƐĂŐĞƐƉƌŽǀŝĚĞ ďƌŽĂĚďĂŶĚŶŽŝƐĞĂƚƚĞŶƵĂƚŝŽŶ

Fused Deposition Modeling enables fabrication of advanced acoustic liner concepts

ϭϵ

&ĂďƌŝĐĂƚŝŽŶWƌŽĐĞƐƐ DĂƚĞƌŝĂůŚĂƌĂĐƚĞƌŝnjĂƚŝŽŶ ŽŵƉŽŶĞŶƚĞŵŽŶƐƚƌĂƚŝŽŶ

• • •

ĞƌĂŵŝĐDĂƚƌŝdžŽŵƉŽƐŝƚĞƐ

ϭͬϭϮͬϮϬϭϱ print machine tailored binders ExOne’s M-Flex for fabricating advanced ceramics chopped fiber reinforcements and Binder jet printing allows for powder bed processing with An inkjet-like printing head moves across a bed of ceramic powder depositing a liquid binding material in the shape of the object’s cross section

Binder Jet process was adapted for fabricating Ceramic Matrix Composites

Ϯϭ SiC powder SiC powder SiC powder Materials, LLC) Si-TUFF SiC fibers (Advanced Composite SiC powder SiC powder loaded SMP-10 Phenolic infiltrant : SiC chopped fiber; 7 micron mean dia, : Carborex 220, 240, 360, and 600 powders SMP-10 (polycarbosilane), SMP-10 w/ SiC powder, (median grain sizes of 53, 45, 23, and 9 microns) Optical microscopy Scanning electron microscopy Material density (as-manufactured and after infiltration) Mechanical properties Processing, microstructure, and property correlations • • • • SiC powders Infiltrants: phenolic (C, Si, SiC powder loaded), pure silicon Fiber reinforcement 65-70 micron mean length, 350 GPa Modulus provide an iterative process for optimizing CMC materials optimization of powder spreading and bimodal distribution of powders is critical • • • Constituents Microstructure Properties

Powder composition is key to Binder Jet processing for structural ceramics and composites

ϮϮ Panels and test coupons fabricated for mechanical property measurements Infiltrations increased density 30% by optimizing composition of ceramic powders used ŵƵůƚŝƉůĞŝŶĨŝůƚƌĂƚŝŽŶƐǁŝƚŚ^ŝ ƉŽǁĚĞƌͲůŽĂĚĞĚƉŽůLJŵĞƌƐ ŝŶĐƌĞĂƐĞŵĂƚĞƌŝĂůĚĞŶƐŝƚLJ

Optimization of Binder Jet process for ceramics

SiC SiC SiC Powder Infiltrant SiC Fiber SiC powders further improves density Loading infiltrant with smaller dia SiC Infiltrant SiC SiC Blending two powder sizes improves packing and infiltration SiC Powder CMC with 35 vol% SiC fiber loading (1000x magnification) SiC Fiber SiC 1. Densify SiC matrix with successive infiltrations SiC SiC powder bed packing and limited infiltration First iteration shows loose particle Infiltrant 2. Add chopped

Fabrication of chopped fiber CMC by Binder Jet + polymer infiltration

fiber to Binder Jet Ϯϰ first stage nozzle segments cooled doublet nozzle sections SiC/SiC CMCs have 20% chopped SiC fiber high pressure turbine nozzle segments

The first CMC turbine engine components by additive manufacturing

tĞŝŐŚƚZĞĚƵĐƚŝŽŶ &ƵĞůƵƌŶZĞĚƵĐƚŝŽŶ ŵŝƐƐŝŽŶƐZĞĚƵĐƚŝŽŶ EŽŝƐĞZĞĚƵĐƚŝŽŶ ^ƚƌƵĐƚƵƌĂůĞƐŝŐŶKƉƚŝŵŝnjĂƚŝŽŶ

• • • • •

/ŵƉĂĐƚŽŶŶŐŝŶĞ^LJƐƚĞŵƐ

impacts (using WATE) Model Propulsion system weight impacts (using NPSS) aircraft (using FLOPS) Quantify fuel burn impacts on Model Propulsion system performance

Engine systems analysis & modeling tools were used assess impact of advanced technologies

Impact: Advanced materials & manufacturing technologies would reduce engine weight by 15%

4.9% reduction 8.3% reduction in NOx and a corresponding due to the use of advanced materials and manufacturing processes Fuel Burn Sensitivities for baseline Regional Jet show in aircraft fuel burn Emissions Impact: Advanced materials & manufacturing technologies would reduce fuel burn by 5% and emissions by 8% for Regional Jets Ϯϵ

metric was used as a

Technology Readiness Level

ready for engine test for fabrication of Polymer Matrix Composites (TRL 4) fabrication of Ceramic Matrix Composites (TRL 3) Fused Deposition Modeling Binder Jet process for Test results were used to assess maturity of fabrication methods NASA measure of the maturity of Additive Manufacturing processes • • ϯϬ add carbon powder to utilize spherical shaped SiC powders for in polymers using higher temperature thermoplastic

Next Steps

investigate the effect of fiber coatings for optimization of fiber/matrix bond strength Constituent Optimization: improved packing Pursue Alternate Densification Approaches: powder bed for conversion to SiC during infiltration with molten silicon. Fiber Coatings: Reduce porosity filaments (FDM) or thermoset polymers (Selective Laser Sintering) Optimize fiber volume fraction based on property measurements Test components in relevant operating conditions to increase TRL • • • • • Optimize Processing & Improve Properties Thermomechanical Testing Turbine Engine Components •