Periodic Reporting for period 3 - HIPERFAN (HIgh PERformance Journal Bearing Technology for new geared TurboFAN generations)
Período documentado: 2020-09-01 hasta 2022-02-28
The development of new journal bearing materials is viewed as key enabler for future geared turbofan engines where extreme operational conditions- out of industry experience- exist. The challenging conditions of having sliding speeds >40 m/s and loads exceeding 35 MPa are not met by state of the art journal bearing materials and new journal bearing material concepts are demanded.
Therefore, HIPERFAN aims for the development of the most robust and reliable high performance journal bearing materials and associated manufacturing processes, and supported the optimization of the entire tribological journal bearing system to enable the new Ultrafan™ and consequently the Very High Bypass Ratio (VHBR) engine technology.
HIPERFAN contributed to the development of new leadfree Journal Bearing Materials suitable for the geared turbofan application.
The HIPERFAN concept of direct coated bearing materials provides the most efficient solution for the new geared turbofan technology in comparison to coated bushings or roller bearings: due to decreased weight and space it will contribute to the operation of very high bypass ratio engines realizing significant environmental benefits e.g.:
• Up to 25% fuel burn and CO2 emission reduction relative to year 2000 baseline (consistent with 10% reduction relative to year 2014 baseline)
• Noise levels making a significant step towards to ACARE 2035 targets (- 11 EPNdB per operation relative to 2000 situation: including engine, nacelle, aircraft technologies airframe noise reduction, novel aircraft configurations and ATM benefits)
• Contribute to delivery of NOX emission reductions through reduced fuel burn. Specific objectives will not be defined owing to the strong dependency on overall core engine cycle decisions.
Conclusion of the action:
Within the HIPERFAN project, as part of the CleanSky2 program, the consortium has developed new journal bearing materials which can handle the stated challenging conditions. Especially the developed leadfree materials show the potential to be the key enabler needed for future geared turbofan engines.
Therefore, HIPERFAN aims for the development of the most robust and reliable high performance journal bearing materials and associated manufacturing processes, and supported the optimization of the entire tribological journal bearing system to enable the new Ultrafan™ and consequently the Very High Bypass Ratio (VHBR) engine technology.
HIPERFAN contributed to the development of new leadfree Journal Bearing Materials suitable for the geared turbofan application.
The HIPERFAN concept of direct coated bearing materials provides the most efficient solution for the new geared turbofan technology in comparison to coated bushings or roller bearings: due to decreased weight and space it will contribute to the operation of very high bypass ratio engines realizing significant environmental benefits e.g.:
• Up to 25% fuel burn and CO2 emission reduction relative to year 2000 baseline (consistent with 10% reduction relative to year 2014 baseline)
• Noise levels making a significant step towards to ACARE 2035 targets (- 11 EPNdB per operation relative to 2000 situation: including engine, nacelle, aircraft technologies airframe noise reduction, novel aircraft configurations and ATM benefits)
• Contribute to delivery of NOX emission reductions through reduced fuel burn. Specific objectives will not be defined owing to the strong dependency on overall core engine cycle decisions.
Conclusion of the action:
Within the HIPERFAN project, as part of the CleanSky2 program, the consortium has developed new journal bearing materials which can handle the stated challenging conditions. Especially the developed leadfree materials show the potential to be the key enabler needed for future geared turbofan engines.
HIPERFAN contributes to a new approach to direct coat the specimens and took the status quo of current established journal bearing materials to a new level. Simulation assisted design and production of the individual single layer combined with tribometer testings over the entire Stribeck curve and under emergency running conditions (already in the early development stage) has been established within HIPERFAN and enabled a fast screening of multiple material combinations and will develop a comprehensive understanding of the underlying tribological system. Within the frame of HIPERFAN new (systematically analysed, characterized and optimized) journal bearing materials have been developed.
In the first reporting period, various hardware setups located at the different project partners have been redesigned, adapted and successfully tested to cover the needs of HIPERFAN. Proper metallurgical screening methods and related analysis routines have been established to assess numerous coating properties. For the tribological testing appropriate test-programs have been designed to verify the capability of the state of the art materials and other deposited coatings. These State of the Art Materials were successfully characterized acting as Baseline for the new single layer materials established via HIPERFAN.
The process simulation tool has been updated and correlated with experiments to predict several properties such as film thickness distribution and chemical composition.
The second reporting period covered a systematic investigation of the strategies set in reporting period one. The coating development (starting with a metallurgical screening followed by scaleup activities and coating of the test specimens for sub- and full-scale testing) resulted in several different single layer materials fully characterized. The testing strategy itself generated a solid database to interpret and rank the results and draw conclusions for the real application.
The development of the simulation software showed good progress at the alignment of the calculation in comparison to experimental results. Adding new simulation features covering an extended range of the coating process generated additional value and deeper understanding
During the third and final reporting period the metallurgical screening as well as the upscaling of the results has been finished. The findings of the tribological tests during the previous reporting periods generated input in terms of structure and composition for the development of improved coatings resulting in various sub and full-scale testcampaigns. The functionality of the Virtual Machine has been extended significantly. A grain growth model has been implemented and it is possible to calculate the phases of multi material coatings aligned and verified by XRD patterns. The interface of the real coating rig and the digital twin thereof has been improved to actively monitor and control the coating process.
Conclusion of the results of Hiperfan as part of CleanSky2 program:
• Representative sub and fullscale testing methodologies have been established to screen and characterize new journal bearing materials over the entire stribeck curve deposited on the bore or the shaft.
• Existing material limitations have been evaluated defining the development goals for new journal bearing materials
• Several journal bearing coatings have been deposited and their tribological, mechanical and chemical properties have been evaluated. The best performing coatings meet the agreed goals especially for lifetime wear requirements.
• A postmagnetron technology allows to coat bores from up to three different targets independently controlled.
• The developed process simulation tool (virtual machine, VM) is able to simulate the coating process and to calculate critical properties such as coating and precleaning distributions, complex kinematics, chemical and phase composition and the grain growth of coatings.
• The results of HIPERFAN have been disseminated on several conferences and three peer reviewed open access papers.
• Overall, the developed coatings show sufficient performance in the conducted tribological tests and set the basis for future exploitation activities targeting the final specifications of the application in terms of lifetime performance and initial adaptability
In the first reporting period, various hardware setups located at the different project partners have been redesigned, adapted and successfully tested to cover the needs of HIPERFAN. Proper metallurgical screening methods and related analysis routines have been established to assess numerous coating properties. For the tribological testing appropriate test-programs have been designed to verify the capability of the state of the art materials and other deposited coatings. These State of the Art Materials were successfully characterized acting as Baseline for the new single layer materials established via HIPERFAN.
The process simulation tool has been updated and correlated with experiments to predict several properties such as film thickness distribution and chemical composition.
The second reporting period covered a systematic investigation of the strategies set in reporting period one. The coating development (starting with a metallurgical screening followed by scaleup activities and coating of the test specimens for sub- and full-scale testing) resulted in several different single layer materials fully characterized. The testing strategy itself generated a solid database to interpret and rank the results and draw conclusions for the real application.
The development of the simulation software showed good progress at the alignment of the calculation in comparison to experimental results. Adding new simulation features covering an extended range of the coating process generated additional value and deeper understanding
During the third and final reporting period the metallurgical screening as well as the upscaling of the results has been finished. The findings of the tribological tests during the previous reporting periods generated input in terms of structure and composition for the development of improved coatings resulting in various sub and full-scale testcampaigns. The functionality of the Virtual Machine has been extended significantly. A grain growth model has been implemented and it is possible to calculate the phases of multi material coatings aligned and verified by XRD patterns. The interface of the real coating rig and the digital twin thereof has been improved to actively monitor and control the coating process.
Conclusion of the results of Hiperfan as part of CleanSky2 program:
• Representative sub and fullscale testing methodologies have been established to screen and characterize new journal bearing materials over the entire stribeck curve deposited on the bore or the shaft.
• Existing material limitations have been evaluated defining the development goals for new journal bearing materials
• Several journal bearing coatings have been deposited and their tribological, mechanical and chemical properties have been evaluated. The best performing coatings meet the agreed goals especially for lifetime wear requirements.
• A postmagnetron technology allows to coat bores from up to three different targets independently controlled.
• The developed process simulation tool (virtual machine, VM) is able to simulate the coating process and to calculate critical properties such as coating and precleaning distributions, complex kinematics, chemical and phase composition and the grain growth of coatings.
• The results of HIPERFAN have been disseminated on several conferences and three peer reviewed open access papers.
• Overall, the developed coatings show sufficient performance in the conducted tribological tests and set the basis for future exploitation activities targeting the final specifications of the application in terms of lifetime performance and initial adaptability
Novel simulation tools allow the design of new coatings and production processes in new ways that reduce development times significantly while ensuring that the new developments are more targeted to the desired characteristics of the coating.
The developed coatings are one of many crucial enablers of the technology “geared turbofan engines” allowing this technology to be implemented for high end products.
The HIPERFAN concept of direct coated bearing materials provides the most efficient solution for the new geared turbofan technology in comparison to coated bushings or roller bearings and contributes to significant reduction of CO2, NOx and Noise emission.
Additionally, especially lead-free journal bearing materials have been investigated and will provide additional environmental benefits over the whole life cycle (manufacturing, operation, maintenance and disposal) of the new journal bearing components.
The developed coatings are one of many crucial enablers of the technology “geared turbofan engines” allowing this technology to be implemented for high end products.
The HIPERFAN concept of direct coated bearing materials provides the most efficient solution for the new geared turbofan technology in comparison to coated bushings or roller bearings and contributes to significant reduction of CO2, NOx and Noise emission.
Additionally, especially lead-free journal bearing materials have been investigated and will provide additional environmental benefits over the whole life cycle (manufacturing, operation, maintenance and disposal) of the new journal bearing components.