Fluid erosion and dynamic fatigue characteristics of high-pressure cold sprayed aerospace gas turbine engines

该计划为期3年，旨在通过材料设计和先进制造解决方案策略，改善飞机发动机部件（主要是风扇叶片）的侵蚀/动态疲劳性能。这项工作的创新之处在于设计和开发了一种特定于TiAl合金基板的纳米结构陶瓷金属（cermet）保护涂层，该涂层可以通过粘合到母材GFRP/CFRP转子叶片的前缘，也可以作为涂层的TiAl带本身延伸，然后再粘合。该研究方法结合了UNB纳米复合材料和力学实验室（NCM实验室）和合作伙伴MDS涂层技术公司（MDS）的一套基础设施和专业知识。这些包括但不限于，高能球磨机；流化床化学气相沉积（FBCVD）反应器；高压冷喷涂增材制造（HPCS-AM）系统；FilmDoctor、ABAQUS、EXN/Aero材料设计/建模工具；高温循环疲劳、水滴动态侵蚀试验机；具有材料设计/制造/表征/测试/认证技能的专业知识。该项目的成功实施将为薄涂层和厚3D分层功能梯度（FG）组件的金属陶瓷失效机制建立新的知识，为建立具有原料-涂层-微结构-工艺-性能联系的“侵蚀磨损”图创造途径。预计TRL将达到3-4级，MDS将在模拟操作环境中进行涂层/3D组件原型测试，在为期3年的项目结束后的24个月内将TRL水平提高到5-6级，并在确定客户应用后进一步提高到TRL 7-9级。因此，该项目的远见之处在于，通过为轻型新发动机和维修发动机部件创造创新的制造解决方案，并结合操作安全和环境可持续性原则，使加拿大工业在全球范围内具有竞争力。

The proposed 3-year project aims to improve the erosion/dynamic fatigue performance of aircraft engine components, primarily the fan blades through material design and advanced manufacturing solution strategy. The work's innovation is in the design and development of a TiAl alloy substrate specific nanostructured ceramic-metallic (cermet) protective coating, extended through either bonded to the parent GFRP/CFRP rotor blade leading edge or as the coated TiAl strip itself, which will later be bonded.The research methodology combines a suite of infrastructure and expertise available at the UNB Nanocomposites and Mechanics Laboratory (NCM Lab) and the partner company, MDS Coating Technologies (MDS). These include, but not limited to, high-energy ball mill; fluidized bed chemical vapor deposition (FBCVD) reactor; high-pressure cold spray additive manufacturing (HPCS-AM) system; FilmDoctor, ABAQUS, EXN/Aero material design/modelling tools; high-temperature cyclic fatigue, water-droplet dynamic erosion testers; and expertise with material design/manufacturing/characterization/testing/certification skills.The successful execution of the project will build new knowledge concerning cermet failure mechanisms in both thin coatings and thick 3D tiered functionally-graded (FG) components, creating a path to establish an 'erosion wear' map with feedstock-coating-microstructure-process-property linkage. Anticipating a TRL 3-4 outcome, the work is projected to be carried on by MDS through coatings/3D component prototype testing in simulated operational environments to raise the TRL level to 5-6 in the 24 months following this 3-year project, and further to TRL 7-9 when a customer application has been identified.Thus, the visionary character of the project is to position Canadian industry competitively on a global scale by creating innovative manufacturing solutions for both new and repair engine components that are lightweight and incorporate operational safety and environmental sustainability principles.