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

拟议的3年项目旨在通过材料设计和先进的制造解决方案策略来改善飞机发动机部件（主要是风扇叶片）的腐蚀/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TiAl合金基体特定的纳米结构陶瓷-金属（金属陶瓷）保护涂层，该涂层延伸到与母体GFRP/CFRP转子叶片前缘结合或作为涂层TiAl带材本身，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）的一套基础设施和专业知识MDS Coating Technologies（MDS）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、水滴动态侵蚀测试仪;和材料设计/制造/表征/测试/该项目的成功实施将建立有关薄涂层和厚3D分层功能梯度（FG）组件中金属陶瓷失效机制的新知识，创建了一条路径，以建立具有原料-涂层-显微组织-工艺-性能联系的“侵蚀磨损”图。预计TRL 3-4的结果，这项工作预计将由MDS通过在模拟操作环境中进行涂层/3D组件原型测试来进行，以在这个为期3年的项目之后的24个月内将TRL水平提高到5-6，并在确定客户应用时进一步提高到TRL 7-9。该项目具有前瞻性的特点是，通过为新的和维修的发动机部件创造创新的制造解决方案，使加拿大工业在全球范围内具有竞争力，这些部件重量轻，并结合了操作安全和环境保护可持续性原则。

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.