Final Report Summary - HICOMP (Development and Manufacture of High Temperature Composite Aero Engine Parts)
Executive Summary:
Pressure from ACARE and civil aircraft operators is driving the need to continually improve the efficiency of turbofan engines. These improvements in efficiency result in engine designs with both lower weight and higher operating temperatures. This trend opens up opportunities for components made from composite materials which can operate for extended periods at moderately high temperatures (in the region of 300C) to replace heavier and more expensive metallic designs (typically in titanium). The HICOMP programme has the overall objective of developing a component to replace such a titanium part in the compressor of a turbofan engine. The most suitable materials will be selected and characterised, and the manufacturing process optimised. parts will then be manufactured and delivered to the Topic Manager for incorporation into a test engine.
Project Context and Objectives:
HICOMP addresses the requirements to develop robust, cost effective composite materials and manufacturing processes for use in high temperature aero engine applications. Until now, the use of high temperature composites in production applications has been limited to small quantities and niche technology areas (principally military applications) due to high raw materials costs and difficult processing parameters. Continued developments in high temperature resin technologies are facilitating the introduction of composites in a wider range of high temperature applications for commercial uses.
HICOMP is focussed on delivering a cost effective manufacturing solution for production of carbon fibre reinforced polymer matrix composite aero engine components. Demonstrator high temperature aero engine components will be designed, developed and manufactured for testing in an operational environment.
Project Results:
The demonstrator component to be studied under this programme was selected and initial working sessions were conducted between the Coordinator and the Topic Manager to assess the current metallic design and define the key requirements for a composite design.
The composite materials (high temperature resin system and fibre reinforcement) were selected following a review of the technical and commercial requirements and the completion of a materials screening programme. The materials screening programme included process development trials and characterisation testing of test laminates to generate mechanical and physicochemical material properties.
The detailed design of the demonstrator component was carried out, including a design for manufacturing assessment to optimise the component geometry for the selected composite manufacturing process. A gap/clearance analysis was conducted to derive the required component tolerances for interfaces with the mating parts.
Mould tool design activities were conducted and two off prototype tooling sections were manufactured to further refine the tooling concept and to quantify the expected level of springback in the cured component. The results were employed to define the correct tooling geometry for the demonstrator parts.
A series of process optimisation iterations were performed to arrive at the best solution for manufacture of production standard demonstrator parts, which were assessed against agreed acceptance criteria and then delivered to the Topic Manager for test in an operational environment (ground based test engine). Sectioned parts and prototype parts were also provided to the Topic Manager for dynamic and static load testing.
In addition to the process development and manufacture of demonstrator components, comprehensive characterisation data has been generated for the selected material in order to validate the component design. Data has been generated for unaged and thermally aged test coupons to represent the in-service environment of the component.
A report covering activities in Period 2 (01/10/2012 to 31/01/2014) is attached.
Potential Impact:
The wider impact of the successful completion of this project is the validation of high temperature composite materials and manufacturing processes for aerospace applications. The subsequent path to development and qualification of a wider range of lightweight components to replace existing metallic parts will be developed with the Topic Manager and other aerospace OEMs. The introduction of composite parts in the first stages of high pressure compressors will contribute to reduced fuel burn and improved efficiency.
List of Websites:
www.cobham.com
nick.savage@cobham.com
Pressure from ACARE and civil aircraft operators is driving the need to continually improve the efficiency of turbofan engines. These improvements in efficiency result in engine designs with both lower weight and higher operating temperatures. This trend opens up opportunities for components made from composite materials which can operate for extended periods at moderately high temperatures (in the region of 300C) to replace heavier and more expensive metallic designs (typically in titanium). The HICOMP programme has the overall objective of developing a component to replace such a titanium part in the compressor of a turbofan engine. The most suitable materials will be selected and characterised, and the manufacturing process optimised. parts will then be manufactured and delivered to the Topic Manager for incorporation into a test engine.
Project Context and Objectives:
HICOMP addresses the requirements to develop robust, cost effective composite materials and manufacturing processes for use in high temperature aero engine applications. Until now, the use of high temperature composites in production applications has been limited to small quantities and niche technology areas (principally military applications) due to high raw materials costs and difficult processing parameters. Continued developments in high temperature resin technologies are facilitating the introduction of composites in a wider range of high temperature applications for commercial uses.
HICOMP is focussed on delivering a cost effective manufacturing solution for production of carbon fibre reinforced polymer matrix composite aero engine components. Demonstrator high temperature aero engine components will be designed, developed and manufactured for testing in an operational environment.
Project Results:
The demonstrator component to be studied under this programme was selected and initial working sessions were conducted between the Coordinator and the Topic Manager to assess the current metallic design and define the key requirements for a composite design.
The composite materials (high temperature resin system and fibre reinforcement) were selected following a review of the technical and commercial requirements and the completion of a materials screening programme. The materials screening programme included process development trials and characterisation testing of test laminates to generate mechanical and physicochemical material properties.
The detailed design of the demonstrator component was carried out, including a design for manufacturing assessment to optimise the component geometry for the selected composite manufacturing process. A gap/clearance analysis was conducted to derive the required component tolerances for interfaces with the mating parts.
Mould tool design activities were conducted and two off prototype tooling sections were manufactured to further refine the tooling concept and to quantify the expected level of springback in the cured component. The results were employed to define the correct tooling geometry for the demonstrator parts.
A series of process optimisation iterations were performed to arrive at the best solution for manufacture of production standard demonstrator parts, which were assessed against agreed acceptance criteria and then delivered to the Topic Manager for test in an operational environment (ground based test engine). Sectioned parts and prototype parts were also provided to the Topic Manager for dynamic and static load testing.
In addition to the process development and manufacture of demonstrator components, comprehensive characterisation data has been generated for the selected material in order to validate the component design. Data has been generated for unaged and thermally aged test coupons to represent the in-service environment of the component.
A report covering activities in Period 2 (01/10/2012 to 31/01/2014) is attached.
Potential Impact:
The wider impact of the successful completion of this project is the validation of high temperature composite materials and manufacturing processes for aerospace applications. The subsequent path to development and qualification of a wider range of lightweight components to replace existing metallic parts will be developed with the Topic Manager and other aerospace OEMs. The introduction of composite parts in the first stages of high pressure compressors will contribute to reduced fuel burn and improved efficiency.
List of Websites:
www.cobham.com
nick.savage@cobham.com