Optimisation of fireproof, pressurized acoustic sandwich structures

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The use of materials based on lightweight composite and aluminum, although common in other parts of the aircraft, remains a challenge around the engines because of the fire resistance prescribed by certification requirements. The present project focuses on the use of such materials for the manufacturing of fan cases and bypass ducts for turbofan aircraft engines. These components serve a dual purpose, the first is to contain the fast bypass flow and the second is to damp the acoustic emissions of the engine. Such components are typically an assembly of three layers: an outer skin that carries most of the structural load, a honeycomb core and a perforated inner skin that allows acoustic energy to be dissipated in the core. Accordingly, such constructions are called acoustic sandwich panels. The work carried out in this collaborative project will focus on the outer skin and investigate fireproofing strategies to enable lightweight material systems to successfully pass certification tests. Fundamental understanding of the physical processes involved will be acquired through small-scale tests in controlled conditions and the failure modes will be characterized. From these results, a prediction model will be built and the best material systems investigated will be used for full-scale certification tests. The outcome of this project will provide valuable information to enable aircraft engine manufacturers to extend the use of lightweight materials for more demanding applications in terms of fire resistance. This will contribute to reduce aircraft weight and hence energy consumption as well as provide a competitive advantage for the Canadian aerospace sector.