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

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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.