endobj Also, the cost is reduced. 2 0 obj Two softwall structures were manufactured during the earlier program phase. It has leveraged the success of this product to introduce additional fan blades on the GEnx Engines that power the Boeing 787 and Boeing 747-8. The following is a brief discussion of the current methods for manufacturing composite blades in order that the relation of material choice, design, and manufacturing method to fatigue life may be presented. A ceiling fan blade includes a foamed layer, two paper layers, and two cover layers. Section 4.0 describes the ply lay-up tailoring using optimization methods, along with the mathematical optimization problem formulation. Furthermore, the triaxial fiber architecture limits linear crack propagation, confining failure to very limited regions. Carbon fiber is on the order of 2.5 times less dense than the Titanium used on older fan blades. EXPERIMENTAL IMPACT TESTING AND ANALYSIS OF COMPOSITE FAN CASES By Andrew Joe Vander Klok For aircraft engine certification, one of the requirements is to demonstrate the ability of the engine to withstand a fan blade-out (FBO) event. GEnx carbon fiber composite fan blades. One, the softwall fan case, features a casing of aluminum, over-wound with dry aramid fibers. Each blade requires 340 hours of manufacturing. It is designed to permit a broken blade to pass through its aluminum component, where it is stopped and contained within the external aramid fiber wrap. The Ballistic Impact Laboratory facilities at NASA were used to test various metallic materials and structural concepts for a lightweight fan containment case. Molded Fiber Glass Companies (MFG) is a premier supplier of wind blades and other composite components to the wind energy industry. Passive damping concepts were first validated on carbon fibre reinforced epoxy composite plates and then implemented in a 1:5 model of an open rotor blade manufactured by resin transfer moulding (RTM). In earlier work at NASA, damage testing was initially undertaken on flat panels to compare the CFRP panels with aluminum panels, using an air gun, with gelatin packs and then metal blade simulators as the projectiles. The technology has been mature *inside GE*.The ability to make large CFRP fan blades is a huge piece of valuable intellectual property for GE and they're not sharing.PW and RR had to re-engineer how to do it all while maintaining their Ti blade production. Together, the projectors and software simplify and accelerate manual composite layup processes. In fact, composite fan blades have certain advantages for blade-off failures. The French aerospace company was experienced in making high-tech composites. #aeroengines #aramidfiber #ndi. The braid architecture is very resistant to delaminations between plies. TPI’s extensive experience in high-volume high-quality wind blade production gives us a uniquely innovative and detailed application of the design for manufacturing process in collaboration with its customers. Materials, Manufacturing, and Test Development of a Composite Fan Blade Leading Edge Subcomponent for Improved Impact Resistance NASA/TM—2015-218340 February 2015 . The molding was undertaken by North Coast Composites (Cleveland, Ohio). After it is shipped to the component fabricator, the preform is simply wound onto the mandrel of a mold tool, where it is impregnated with resin via resin transfer molding (RTM) or vacuum-assisted RTM (VARTM), whichever is chosen by the part manufacturer. MATERIALS, MANUFACTURING AND TEST DEVELOPMENT OF A COMPOSITE FAN BLADE LEADING EDGE SUBCOMPONENT FOR IMPROVED IMPACT RESISTANCE Katherine M. Handschuh 2, Sandi G. Miller1, Matthew J. Sinnott , Lee W. Kohlman1, Gary D. Roberts 1, J. Michael Pereira , and Charles R. Ruggeri1 1NASA Glenn Research Center, Cleveland, OH 44135 2NASA LERCIP Intern, NASA Glenn … The fan blades of GE90 are 1.2m long. Measurement of damage propagation then will be analyzed and used to develop the capability to predict success or failure of the containment casing. There has been an evolutionary change in the design, size, structures, materials, and manufacturing process of fan blades over the past few decades. As the capstan turns, the tows that form the braid are drawn from spools through the braiding apparatus. The length of each tow is determined independently of the others, as it is drawn around the capstan's cir-cumference. A comparison of the hole sizes generated in a composite panel with that in the datum aluminum panel (representing a typical metal fan case) was very encouraging, since the much smaller hole created in the CFRP structure indicated that there would be a reduction in the stress level in a blade-damaged CFRP fan case, when out-of-balance loads were inflicted by an asymmetric fan. The super plies and drop off pliesrequired are shown.• A sizing optimization is performed for minimum weight. Compressor blades constructed of composite materials are disclosed. The blade’s onyx black sinuous curves are pleasing to look at, but for Kray they are no longer state of the art. Bob Griffiths Share. If the fan case were to fail completely, then the consequences for the engine and aircraft could be catastrophic. NASA is planning to perform impact testing and post-impact loading on composite fan cases from the SBIR program. There are two approaches to blade containment currently in common use. 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