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

拟议的为期3年的项目旨在通过材料设计和先进的制造解决方案战略来改善飞机发动机部件，主要是风扇叶片的冲蚀/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合金基板特定的纳米结构陶瓷-金属陶瓷(Ceret)保护涂层，通过粘结到母公司GFRP/CFRP转子叶片前沿或作为涂层TiAl条本身延伸，稍后将其粘合在一起。研究方法结合了UNB纳米复合材料和机械实验室(NCM Lab)及其合作伙伴MDS涂层技术公司(MDS)提供的一套基础设施和专业知识。这些设备包括但不限于高能球磨机、流态化化学气相沉积(FBCVD)反应器、高压冷喷涂添加剂制造(HPCS-AM)系统、FilmDoctor、ABAQUS、EXN/AERO材料设计/建模工具、高温循环疲劳、水滴动态冲蚀试验机以及材料design/manufacturing/characterization/testing/certification技术方面的专业知识。该项目的成功实施将建立关于金属陶瓷在薄涂层和厚3D分层功能梯度(FG)组件中的失效机理的新知识，为建立与feedstock-coating-microstructure-process-property链接的“冲蚀磨损”图开辟了一条道路。预计TRL 3-4的结果将由MDS在模拟操作环境中通过涂层/3D部件原型测试进行，以在这个为期3年的项目之后的24个月内将TRL级别提高到5-6，并在确定客户应用后进一步提高到TRL 7-9。因此，该项目的远见卓识特征是通过为新的和维修引擎组件创建创新的制造解决方案，使其在全球范围内具有竞争力。该解决方案轻量化，并纳入操作安全和环境可持续性原则。

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.