Document
in Phoenix, Arizona
Mrityunjay Singh
October 25–30, 2015 for presentation at the
Cleveland, OH, USA
Ohio Aerospace Institute
NASA Glenn Research Center
International Symposium on Air Breathing Engines
Joseph E. Grady and Michael C. Halbig
nd
Enabled by Additive Manufacturing
A Fully Non-Metallic Gas Turbine Engine
Presentation Outline
for composite materials
• Project Background • Development of Additive Manufacturing processes • Component applications • Next Steps exhaust components & nozzles turbine shroud compressor vanes stator fan bypass fan duct Use of these materials & manufacturing technologies in critical components will Business Jet size turbofan engine reduce emissions (8%), fuel burn (5%), engine weight (15%) for business jet size engines
Lightweight, high temperature composite materials improve engine efficiency
Project Summary
: 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 Conduct 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.
• • • Objective Approach: Jones Chao Lao (Cal Poly), (Acoustic testing): Mike Project Team (Engine Systems & Components): (Additive Manufacturing): Tom Santelle, Clark Patterson Polymer characterization: Eugene Shin - 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 - 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: • • • • • •
Fabrication Process Material Characterization Component Demonstrations
• • •
Polymer Matrix Composites
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
composites ° 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
Compressor Guide Vane Acoustic Liner
• •
PMC Component Applications
7/23/2015 Attachment detail Ultem 1000 composite vane
= 423⁰F) with chopped carbon fiber
by fused deposition g First Stage Compressor Blade
Ultem 1000 (T First Polyetherimide composite fabricated
• •
F operating temperature ⁰ Vane Inlet Guide
Fabricated Compressor Inlet Guide Vanes with High Temperature Polymer Matrix Composites
350 275 200 Use Temperature (⁰F) ABS Ultem 1000 Ultem 9085 Matrix (+C fiber) Vane Configuration in Cascade Rig Other FDM composites being evaluated: Deformation Measurements NASA Glenn Cascade Rig Stress Analysis
Structural integrity of inlet guide vane was evaluated under aerodynamic loading
= 367⁰F) g Honeycomb complex geometries Bonded Structure F operating temperature ⁰ integral facesheet/honeycomb structure is fabricated in one step using Fused Deposition Modeling standard liner configuration Fabricated with monolithic Ultem 9085 thermoplastic (T Perforated Facesheet Current manufacturing approach requires metal forming, bonding and drilling
Fused Deposition Modeling Simplifies Acoustic Liner Fabrication
corner detail shows acoustic perforations panel location ″
Fabrication of full-scale engine access panel demonstrated
inner surface incorporates acoustic treatment liner LaRC acoustic measurements suggest that optimized concept could outperform current liner designs of advanced FDM sample Fabricated 16x2 inch test article Acoustically-tuned passages provide broadband noise attenuation
Fused Deposition Modeling enables fabrication of advanced acoustic liner concepts
Fabrication Process Material Characterization Component Demonstration
• • •
Ceramic Matrix Composites
7/23/2015 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
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
Panels and test coupons fabricated for mechanical property measurements Infiltrations increased density 30% by optimizing composition of ceramic powders used multiple infiltrations with SiC powder-loaded polymers increase material density
Optimization of Binder Jet process for ceramics
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
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 •