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Abstract: This research paper is mainly focused on The engines which uses higher thrust when
the detailed study of the conventional materials that compared to fan thrust is known as high bypass
are usually employed in the front fan blade of turbofans and which has lower thrust when compared
turbofan engine. The operating conditions and the with fan thrust is known as low bypass turbofans.
major material indices which influences the Front fan blade usually undergoes heavy cyclic
performance are considered and detailed study has loads which leads to cyclic stresses on its surfaces.
been made. In the later part CES, the material Chances of corrosion is high because of the inlet air
selection software was introduced to suggest temperature, pressure and its composition. The mean
alternative advanced materials in the form of mass temperature of gas at the entry ranges from
polymers for the considered component. Then the 1300 to 1800 K. Due the increase in temperature of
machinability, crystalline structures and advanced gas, the pressure ratio of compressor grown
manufacturing techniques to be employed are also significantly. The combined increase in temperature
discussed in detail. and pressure ratio results in significantly more
intensive heat flows in turbines.
1. Introduction One of the main properties of turbo fan engine is a
significant number of variable conditions when the
level of temperatures and stresses differ significantly
To make an aero plane fly it requires lot of thrust from those measured in stationary conditions.
to be generated with help of some propulsive system. Statistical analysis shows that for aircraft engines,
Most flight uses turbofan engine to generate thrust about 20% of the flaws developed at operation are
which gives higher efficiency and also because of flaws resulting from the cyclic temperature
fuel efficiency. Turbofan engine is the modern day variations. [1] [2]
evolution of gas turbine. Turbofan engine comprises
of core compressor, core turbine and fan blades. The
energy stored in gas is converted in to kinetic energy 3. Operating Conditions
with the help of front fan blades. Like the
compressor, the turbine has a rotating disc along with
blades nozzle guide vanes. The pressure and The parameters that determine operating
temperature of gas both fall as it passes through the conditions of affront fan blade are as follows
turbine. Front fan blade is the first and foremost Gas temperature at the inlet
component of a turbo fan engine. Large quantity of Pressure, speed and composition of gas flow
air is sucked into turbine with the help of large Stresses due to the effect of centrifugal and
spinning fan. Fan helps the air to gain speed and also gas dynamic forces
splits into two parts. First part flows into the turbine Irregularity of temperature field
central part which acts as core of the turbine. The Based on the above parameters the element to be
second part "bypasses" the core of the jet engine. It selected for the front fan blade should be fatigue
goes through a duct that surrounds the core to the resistant, resistant to cracking, stiff and light. So the
back of the jet engine where it produces much of the element has to satisfy the following mechanical
force that propels the airplane forward. This cooler properties. [3]
air helps to quiet the jet engine as well as adding High endurance limit
thrust to the jet engine. [1] High fracture toughness, K1c
High Young’s Modulus
Low density
2. Loading Modes
4. Performance Indices for Material
The ratio of the mass-flow of air bypassing the Selection
engine core compared to the mass-flow of air passing
through the core is referred to as the bypass ratio.
5.1. Principles of Choosing Coatings for In immediate correlation to steels and aluminum
Engine Blades alloys, titanium and its composites may be
recognized as a much more youthful structural
material. The alloys of titanium are picked for
The requirement to attain highly protective utilization in aviation related provisions where the
coatings (i.e., adequate resistance to hot corrosion blending of weight, quality, consumption safety and
and oxidation) conflicts with the demand to preserve high quality steels and nickel based super alloys can
high mechanical properties in the “coating-super best case scenario be arranged as lacking and
alloy” system. deficient. The key factors for the selection of
Until recently, engine test have remained the main titanium alloys for front fan blade are as follows:
method of examining the properties of and choosing A reduction in weight (substitute for
optimized coatings for blades. However, the high steel and nickel-based super alloys)
cost of systematic studies of coating protectiveness Application temperature
using this approach has fueled the desire to seek Corrosion resistance
shorter equivalent trials. Under these conditions, Galvanic compatibility with polymer
laboratory research into physical-chemical and matrix composites [6]
physical-mechanical coating properties and their
blade service facilitates significantly the selection of
optical chemical composition of coatings, reduces
the number of their field tests, and promises high
cost efficiency of the study. [4] [6]
The key parameters to be considered in the
selection of coatings for turbine blades. The starting
points to be taken in to account when choosing a
coating of optimum life expectancy include:
Experience in applying protective coatings
on blades running under similar conditions Figure 1 Mechanical Properties of Ti Alloys
Analysis of causes of coating damage on
blades after long-time tests or service
The substantial front fan blade pieces of steels of
operation
present day plane engines are produced from
Presumable alterations in running
titanium alloys. In light of the relentlessly expanding
conditions of newly designed blades
engine by-pass ratio, the new steel fan blade plans
(changed parameters of gas flow, values of
surpasses length of one meter. At these extents, fan
thermal stresses, running conditions, etc.)
blade made of steel shudder can and does turn into a
Results of research into physical-
genuine issues since the cutting edge tips may
mechanical properties of coatings and their
achieve the speed of sound and reason blended
effects on the main properties of the super
supersonic/subsonic stream fields and partnered stun
alloy from which the blades are made
waves. To build their solidness, covers or snubbers,
(resistance to thermal fatigue, endurance,
were added to the center of the edges. The mid-span
high temperature strength) [4] [6]
covers can control vibration, however unfavorably
influence the air movement optimized effectiveness
of the fan and simultaneously bring down its fuel
5.2. Hot Corrosion of Front Fan Blade
proficiency. Propels in fan blade outline have helped
in wiping out covers by enhancing sharpened steel
Since aviation fuels contain insignificant of solidness through an increment in harmony width
Sulphur and vanadium, they do not destroy coatings that has brought about a diminishment in the amount
through hot corrosion below service live of 5000 to of edges by something like one third. [6]
10000 h. The environment is the main source of
aggressive components entering the hot channel of
aircraft engines. This applies, first of all, to sea 6.1. Influence of Material on the
regions, where a diverse variety of compounds Manufacturing Route
contained in the sea water get into the engine hot
channel. [6] Front fan blade of turbo fan engines are usually
manufactured from titanium alloys. To be more
precise front fan blades are most commonly
6. Justification for Selecting Titanium
manufactured from Ti-6Al-4V alloy which is also
Alloy known as grade 5 Titanium alloy. Ti-6Al-4V is
considered as a workhorse among all other grades of methodology. The 3 sheets are then sandwiched
titanium alloy because of its following properties: together, and set in a furnace where the dispersion
Fully heat treatable for sections up to 15 holding happens. A flat sheet is generated and all
mm for about temperature 400oC. layers are joined except in zones where stop-off has
Corrosion resistance been connected.
Weldability From that point, the flat sheet is formed at high
Fabric ability[4] temperatures, in a super plastic forming process.
High pressure gas is blown between the sheets, truly
like expanding the balloon forming the fan blade
aerofoil shape.
The Central sheet is extended and structures the
girder structure. After which the aerodynamic shape
of the fan blade is removed of the plate, the root
fixings are machined and the blades surface is
cleaned to make the surface smooth to guarantee the
engine is as effective as possible by diminishing the
surface drag. [6] [7]
Figure 2 Increase in application of Ti alloys in
Boeing aircraft
7.1. Application of STOP-OFF
6.2. Properties of Ti-6Al-4V
8.2. Grain Size Distribution
Where, σe is the endurance limit in ksi
Extra complexities emerge when grains are not K1C is the fracture toughness in ksi.in^0.5
uni-axed, then again change generally in size. The ρ is the density in kg/m3
vitality of this issue on super plasticity of Titanium E is the young’s modulus in N/m2
Based on the above conditions the following From the above table, it is clearly inferred that
graphs are plotted in order to find the suitable material properties of CFRP has been very much
advanced material for the front fan blade of turbo fan enhanced when compared with the conventional
engine.[9] material (Ti-6Al-4V). Thus, the CFRP has been
selected as the suitable advanced material for front
fan blade. [9]
http://www.tygavac.co.uk/process/resin-
infusion.html.
[12] J. D.Mattingly, Aircraft Engine Design,
NewYork: AIAA Education series, 1986.
[13] F. Whittle, Gas Turbine Aero-
Thermodynamics, Pergamon press, 2000.
[14] Noob, "Fan Blades," 29 07 2011. [Online].
Available:
https://www.academia.edu/3779848/Fan_Bl
ades.
[15] Julian, "Jet engine," 2005. [Online].
Available:
http://www.madehow.com/Volume-1/Jet-
Engine.html.