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Future Challenges of
Advanced Polymer
Composites
Introduction into
Aircraft Engines
Artem Korotygin
Project Manager (Polymer Composites)
NPO Saturn
www.npo-saturn.ru
April 2015
1
EVOLUTION OF CIVIL AIRCRAFT ENGINES
GE90
Trent 800
GEnx
Trent 900 Trent 1000
PW4000-112
Trent XWB
GP7200
LEAP-X
GE9x
Trent XWB+
PW1000G
GTF+
SaM146
1990
1995
2000
2005
2010
2015
2020
2
ACTUALITY OF COMPOSITES APPLICATION
 Absence of composite parts leads to lack of
competitive strength of Russian aircraft engines
3
COMPOSITE PARTS DEVELOPMENT CYCLE
NPO Saturn maturity
– high level of skills and knowledge
– medium
– basic
4
COMPOSITE TECHNOLOGY TENDENCIES
1
2
3
Cheap
Composite
Part
• High-Performance Thermoplastic Composites (PEEK, PPS, PEI, etc)
forming methods: thermoforming, injection molding and hybrid
technologies
• 2.5D & 3D-preform manufacturing (3D-Weaving, Braiding, Stitching)
and RTM forming
• Automated prepreg lay-up
Cost
Reduction
Repeatability
Improvement
Manual Work
Minimization
Automation
5
Cost and time of part manufacturing
EVOLUTION OF COMPOSITE TECHNOLOGIES
Compression
Autoclave
RTM+Fabrics
AFP+ATL
RTM+Braiding
RTM+3D-Weaving
Thermoforming
Injection Molding
1980
1990
2000
2010
2020
Start of intensive introduction, year
6
HP THERMOPLASTIC COMPOSITES TECHNOLOGIES
Thermoforming
Injection Molding
7
HP THERMOPLASTIC COMPOSITES ADVANTAGES
 Advantages:
+ Working temperatures up to 260 °С
+ High radiation resistance
+ High impact resistance
+ Excellent tribologic properties and environmental
resistance
+ Highly repairable
+ Almost unlimited storage time
+ Wide list of technological processes (molding,
bending, welding, etc)
+ Reprocessing of items and waste
+ Shortened molding time
+ Low emission
+ High fire-retarding quality
+ Energy efficient cheaper serial production
8
3D-WEAVING ADVANTAGES
3D-Weaving + RTM
 Advantages:
+ Preform manufacturing process
automation
+ No delamination
+ Shear strength increase
+ Foreign object damage
resistance increase
+ 3D-preform geometry is very
similar with final part geometry
+ Material design with required
performance in all dimensions:
3D-material
+ Waste material reduction
=> The technology is not
developed by Russian
industrial facilities
9
NPO SATURN COMPOSITE PROJECT
Overview
OGV Blade
Fan Fairing
Weight, kg
Now
4
Target
1.7
Cost
100%
60%
Weight, kg
Now
18
Target
10
Cost
100%
60%
OGV Shroud
Weight, kg
Now
5
Target
1.8
Cost
100%
50%
Internal Panels
Weight reduction ~16.5 kg
Cost reduction ~1 mln. RUB
Weight, kg
Now
4
Target
1
Cost
100%
90%
10
NPO SATURN COMPOSITE PROJECT
Internal Panels
What’s Already Done
Parts Design
Static Strength and Modal Analysis
Tooling Design
Tooling Production
First Prototypes Production
Current Status: Production of Parts for Testing
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NPO SATURN COMPOSITE PROJECT
Fan Fairing
What’s Already Done
f2D
f3D
f4D
f5D
f24D
Static Strength and Modal Analysis
Composite +
Titanium
Part Design
Bird Strike Imitation Modeling
Tooling Design & Production
Composite-Titanium Joints
Adhesion Tests
Current Status: First Prototypes Production
12
NPO SATURN COMPOSITE PROJECT
OGV Blade
What’s Already Done
V
Static Strength and Modal Analysis
Bird Strike Imitation
Modeling
Technological Modeling
Weld Lines Analysis
Tooling Design
Material Properties Research
Current Status: Tooling Production
13
NPO SATURN COMPOSITE PROJECT
OGV Shroud
What’s Already Done
Part
Design
Technological Modeling
FBO Strength Analysis
Static Strength and Modal Analysis
Distortion Analysis
Tooling
Design
Current Status: Tooling Production
14
NPO SATURN COMPOSITE PROJECT
3D-Weaving
What’s Already Done
2-2
1-1
1-2
2-1
2-3
2-4
3D-Weaving Structures Choice & Design
Tooling Design & Production
Production of Specimens Preforms by 3D-Weaving
Specimens Production
Current Status: Mass Production of Specimens for Testing
15
WHAT’S NEXT?
4 questions, that must be answered to leap forward
How to design a 3D-reinforced part?
? Modeling of 3D-weaving process
? Simulation of 3D-preform deformation
process in the RTM mould
? Simulation of RTM process for 3D-preform
? Strength analysis of a 3D-reinforced part
+ Reduction of technological iterations
+ Low number of impregnation defects
+ Ability to design a 3D-structure with
predetermined mechanical properties
How to impregnate a 3D-reinforced preform with HP thermoplastic resin?
? High viscosity of resin blocks impregnation
? It is hard to achieve high fiber content
? Possibility of fiber deformation during RTM
+ Repairability of the part
+ Significant reduction of part production time
+ High resistance to erosion and climatic factors
How to create thermoplastic composite part with a hybrid reinforcement ?
? Adhesion between different reinforcements
? Selection of injection process parameters
? Minimizing of consolidation time
+ Benefits of long and short-fiber reinforcement
+ High part strength with low production time
How to repair thermoplastic composite engine parts ?
? Determination of critical damage criteria
? Design of tools for on-site repairs
+ Exclude of main operational advantage of metals
over composites – their high on-site repairability
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Thank you for your attention
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