TF30 Third-Stage Composite Fan Blade Service Program.
Final technical rept. 1 Jul 70-31 Dec 77,
PRATT AND WHITNEY AIRCRAFT GROUP WEST PALM BEACH FL GOVERNMENT PRODUCTS DIV
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The successful application of advanced composites as the structural material for aircraft jet engine rotating parts will significantly reduce engine weight and improve engine performance characteristics. To solve the component design, manufacturing, and quality assurance problems associated with such an application, a program was conducted to design and develop BORSICAluminum third-stage fan blades, which would operate satisfactorily in the TF30-P-7 or P-9 engine models. Program objectives were to improve the existing design of a composite material fan blade, manufacture the blade, and demonstrate its quality by bench and engine environment testing. The scope of the program required to successfully meet these objectives included establishing design and fabrication procedures, developing special tooling, evaluating current nondestructive inspection techniques and adapting these techniques to composite materials, establishing quality assurance criteria, and developing comprehensive bench and engine environment test programs to adequately demonstrate fan-blade quality. During the program, several sets of BORSICAluminum blades weighing 40 percent less than comparable TF30 bill of material titanium blades were successfully produced and tested. Based on this extensive test program, and with the establishment of quality control criteria and repair procedures, the blades were deemed acceptable for evaluation in a flight program. During the total program, 246 engine-configuration blades were manufactured and non-destructively inspected with an overall acceptance rate of 92.3.
- Laminates and Composite Materials