Damage resistant materials for aero-engine applications

Abstract

Aero-engine fan and compressor components are subject to impact threats from runway debris, hail ice, and birds. Damage resistant composite material concepts and architectures were investigated under the Affordable Composites for Propulsion (ACP) program using impact testing over the full range of impact threat conditions experienced during engine operation. Automated tow placed materials along with fabric and tape materials were investigated to assess the impact damage threshold and resistance under low velocity impact. The effects of hybridization, matrix material, fiber type, and manufacturing process on impact characteristics were evaluated. Another hail ice impact investigation was conducted on fabric composites to study the effects of ice size, incidence angle, and laminate thickness. Finally, soft body, gelatin bird impact testing was conducted on several laminated, stitched, and integrally woven resin transfer molded (RTM) materials. Effects of material architecture on the impact characteristics were investigated. Based on these impact characterizations, it was possible to identify material characteristics and concepts that lead to improved impact resistance.