Grant: Alliance Grants
University of New Brunswick
$46,240.00
Fluid erosion and dynamic fatigue characteristics of high-pressure cold sprayed aerospace gas turbine engines
FY 2022-23
Summary
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.
Program
Alliance Grants
Recipient
Location
New Brunswick, Canada
Recipient Type
Academia
Type
Grant
Source
NSERC's Awards Data
As published
Application id
576835-2022
Name nom
Saha, Gobinda GC
Department département
Mechanical Engineering
Organization id
75
Institution établissement
University of New Brunswick
Province en
New Brunswick
Province fr
Nouveau-Brunswick
Country en
CANADA
Country fr
CANADA
Fiscal year exercice financier
2022
Competition year année de concours
2022
Award amount
46240
Program id
ALLRP
Program name en
Alliance Grants
Program name fr
Subventions Alliance
Group en
RESEARCH PARTNERSHIPS
Group fr
PARTENARIATS DE RECHERCHE
Committee code
96
Committee name en
RPP Internal Decision Cttee
Committee name fr
Cté de décision interne - PPR
Area of application code
1208
Area of application group en
Advancement of knowledge
Area of application group fr
Avancement des connaissances
Area of application en
Materials sciences
Area of application fr
Sciences des matériaux
Research subject code
2002
Research subject group en
Materials science and technology
Research subject group fr
Science et technologie des matériaux
Research subject en
Materials processing
Research subject fr
Transformation des matériaux
Installment
inst:1
Partie
1
Nb partie
1
Application title
Fluid erosion and dynamic fatigue characteristics of high-pressure cold sprayed aerospace gas turbine engines
Application summary
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.
