16T_C1_Blade_Design_Specification_14424-001-17.pdf

14424-16-001

Distribution A - Public Release Distribution Unlimited

IRA-2620, PA-AEDC2016-195

SPEC NO. 14424-16-001

30 SEPTEMBER 2016

EQUIPMENT/SERVICE SPECIFICATION

FOR

16T C-1 COMPRESSOR BLADE STRUCTURAL DESIGN/ANALYSIS, TOOLING

TESTING UNITS, AND MANUFACTURING

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

Distribution A Public Release Distribution Unlimited

Table of Contents-1

TABLE OF CONTENTS

1. Scope

2. Applicable Documents

2.1. Government Documents

2.2. Non-Government Documents

3. Requirements

3.1. General

3.2. Service

3.3. Workmanship

3.4. Dimensional

3.5. Structural

3.6. Mechanical

3.7. Marking

3.8. Cleaning

4. Verification and Testing

4.1. Engineering Analysis

4.2. Testing

5. Notes

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1. SCOPE

1.1 This specification establishes the performance, design, analysis, inspection, verification, and shipping requirements for tooling, limited initial production, and final production of new composite compressor blade assemblies to be provided by the Contractor.

1.2 The C1 Compressor provides airflow for the 16T wind tunnel. The C1 compressor accomplishes this through standard axial flow technology. The compressor is a large three-stage axial flow machine with a rotor blade tip-to-tip diameter of 30.2

ft. Each stage is composed of rotating blades separated by variable pitch stator blades. The composite rotor blades are designed with an offset center of gravity (CG) which limits the bending stress in the blade by resisting aerodynamic loading. In addition the blades are pinned which allows them to rotate which further reduces the blade stresses and the load which is transferred into the composite spacers which are installed between the blades. The spacers restrict blade rotation to prevent interference between the rotor and stator blades.

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1 Drawings:

A. Drawing number 3202100.6 – Blade Assembly C1 Compressor – 16T, Sheets 1, 2, 3, , and 6

B. Drawing Number 3202100.23 – Blade Cap C-1 Compressor, Sheet 1

C. Drawing Number 6440-1102 – Weld Assembly – Strongback C1 Compressor

D. Drawing number PU630917.01 – Blade Cuff Details

2.1.2 Reference Drawings:

A. Drawing number PG631713.01 – Blade Adapter Details Sheets 1 &

2 and associated .STEP file

B. Drawing number PG632883.05 – General Disc Ass’y 16T-C1, Sheets 1 thru 4

C. Drawing number AR1001C – Spacer, Row C and associated .STEP file

D. Drawing number AR1001B – Spacer, Row B and associated .STEP file

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E. Drawing number AR1001A – Spacer, Row A and associated .STEP file

F. Drawing number PG108761, C1 Compressor Rotor Disc Row C – Details, Sheets 1 & 2 and associated .STEP file

G. Drawing number PG108760, C1 Compressor Rotor Disc Row B – Details, Sheets 1 & 2 and associated .STEP file

H. Drawing number PG108745, C1 Compressor Rotor Disc Row A – Details, Sheets 1 & 2 and associated .STEP file

2.2. Non-Government Documents:

2.2.1. Metallic Material Properties Development and Standardization

A. MMPDS Handbook- MMPDS-01 (formally known as MIL-HDBK-5 Aerospace Metals, This handbook is for reference only)

2.2.2. Occupational Safety and Health Administration (OSHA)

A. OSHA Section III: Chapter 1, Polymer Matrix Materials: Advanced Composites.

2.2.3. American Society for Testing and Material (ASTM)

A. ASTM D-2734 Standard Test Methods for Void Content of Reinforced Plastics

B. ASTM D-3171 Test Method for Fiber Content of Resin-Matrix Composites by Matrix Digestion

C. ASTM D-3800 Test Method for Density of High-Modulus Fibers

D. ASTM D-3039 Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials

E. ASTM D-6641 Standard Test Method for Determining the Compressive Properties of Polymer Matrix Composite Laminates Using a Combined Loading Compression (CLC) Test Fixture

F. ASTM D-5467 Standard Test Method for Compressive Properties of Unidirectional Polymer Matrix Composites Using a Sandwich Beam

G. ASTM D-2344 Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their Laminates

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H. ASTM D-5379 Standard Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method

I. ASTM D-5961 Standard Test Method for Bearing Response of Polymer Matrix Composite Laminates

J. ASTM D-953 Standard Test Method for Bearing Strength of Plastics

K. ASTM C-393 Standard Test Method for Flexural Properties of Sandwich Constructions

L. ASTM C-297 Standard Test Method for Shear Properties of Sandwich Core Materials

M. CMH-17, Polymer Matrix Composites, Composite Materials Handbook (ITAR and non-ITAR Sections)

N. CMH-17G, March 2012, Polymer Matrix Composites, Composite

Materials Handbook (ITAR and non-ITAR Sections)

Volume 1 – Guidelines for Characterization of Structural Materials Volume 2 – Material Properties Volume 3 - Materials Usage, Design, and Analysis

O. CMH-17G, March 2012 – Sections 6.6.6 (Fiber Volume Fraction) and Section 6.6.7 (Void Volume Fraction) – pertains to use of “Image Analysis” to determine fiber-resin-void content when hybrid fiber combinations are used (glass-fiber plus carbon-fiber mixed laminate)

2.2.4. American Society of Mechanical Engineers (ASME)

A. ASME-Y14.5M dated 1994 or 2009

2.2.5. Suppliers of Advanced Composite Materials Association (SACMA)

A. SACMA Recommended Test Methods (SRM 1 through SRM 27) as applicable to selection of glass fiber or carbon fiber composite materials.

(Available from the American Composites Manufacturing Association (ACMA), 3033 Wilson Blvd. Suite 420, Arlington, VA 22201 since SACMA terminated in 1998 and ACMA handles distribution.)

2.2.6. Society of Automotive Engineers

A. AS9100 - Quality Management Systems - Aerospace –Requirements

B. Nadcap AC/AS7118 Rev A-3 Composites Audit Handbook

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2.2.7. ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. In the event of a conflict between the text of this specification and the AEDC drawings, the Government shall be contacted for direction. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. General:

3.1.1 Life of the blades and blade cuffs shall be 20 years minimum as demonstrated through the service life analysis, assuming an average of 1500 operational cycles (operation cycle consists of compressor start up and shut down with five minutes minimum to 20 hours maximum at the conditions noted in section 3.2 and 3.4) during 2000 operating hours each year at the conditions noted in section 3.2 and

3.4. During non operating times the blades and disc/blade interface bushings will be exposed to conditions stated in section 3.3

3.1.2 The pre-production blades required under this contract shall be manufactured using the same materials, tooling, processing methods and assembly procedures as those that will be used for the production blades.

3.1.3 Delivered products shall not contain asbestos, lead, chromium, mercury, cadmium, silver, barium, or arsenic. Handling of the final delivered products shall not require the use of personal protective equipment (PPE).

3.1.4 Each blade shall be weighed (weight shall include the blade, blade cuff, and disc/blade interface bushings) and its weight marked with ink or paint (the ink or paint shall not adversely affect the performance of the blade and located as shown on AEDC drawings on the blade in 3 inch text height where practical. If a 3 inch text height is not practical other text height is permissible provided all information is present and legible using ink or paint capable of withstanding the conditions stated in sections 3.2 and 3.3.

3.1.5 The center of gravity of the assembled blade and blade cuff shall be analyzed in combination with the aerodynamic and centripetal loading to design the blade. The “bumper” load in the cuff shall be supplied with the analysis for each case. The bumper load shall be limited to 5000# at the worst case condition.

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3.1.6 The vendor shall be AS9100 certified, and shall be Nadcap certified for the proposed method of fabrication.

3.2 Operating Conditions -. The contractor provided equipment shall operate in the following environment, while fulfilling all other requirements set forth in this specification.

3.2.1 Standard operational temperatures from -20ºF to 280ºF (90% of blade life)

3.2.2 Exposure to hydraulic fluid, lubricating oil, a high humidity environment, plus occasional exposure to liquid water, gaseous nitrogen, carbon dioxide (fire protection).

3.2.3 Non-standard (occasional temperature excursions such as a compressor stall, etc.) operational temperatures as high as 320ºF (10% of blade life).

3.3.3 Operational pressures from 0.4 psia to 30 psia. All internal cavities shall be vented to avoid pressure differentials.

3.3 Non Operating Conditions - The contractor provided equipment shall be capable of long term storage, without degradation, in the conditions described in this section.

3.3.1 Temperatures from -20ºF to 130 ºF

3.2.3 Exposure to hydraulic fluid, lubricating oil, a high humidity environment, plus occasional exposure to liquid water, gaseous nitrogen, carbon dioxide (fire protection systems), and rocket and jet engine fuels and by-products.

3.4 Design Loads (all act simultaneously)

A. The maximum centrifugal load occurs at a disc speed of 600

RPM.

B. The load on the blade cuff shall be taken from the FEA model of the blade.

C. Pressure differential of 9.3 pounds per square inch (PSI) between the interior hub side (the interior hub side is the high pressure side) and the compressor air side (Reference AEDC drawing PG632883.05 sheet 1 for a representation showing the interior hub side and the compressor air side).

D. Loads from AEDC Computational Fluid Dynamics (CFD) shall be used as the governing aerodynamic loading. The

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Page-6 loads will be provided by the Government in the form of comma delimited text files. Other formats may be available upon request. A total of 7 conditions shall be analyzed.

Static analysis shall be performed for each condition, and dynamic analysis shall be performed for the maximum static loading condition and for the condition which shows the largest dynamic component from CFD analysis. The load cases will be given for each blade row. The maximum row load condition shall govern the overall blade design.

3.5 Blade and Cuff Physical Characteristics

3.5.1 The maximum weight for each blade (including blade, blade cuff, and blade pin bushing) less blade pin and telemetry box shall be no more than 116 pounds. While a lighter blade is desirable the current blades are designed with an offset center of gravity intended to reduce the bending moment in the blade. If the weight and/or CG offset is changed analysis shall performed to show that the adjacent blade spacers, blade cuff, and the rotor disc do not see excessive loads.

3.5.2 Blade to blade weight deviation (including blade cuff and disc/blade interface bushings) in each row shall be no more than 2.0 (two) pounds.

3.5.3 Blade Geometry:

A. Aerodynamic surface shall fall within the bounds shown on

AEDC drawings (Reference AEDC drawings 3202100.6, 3202100.23, and 6440-1102). Surface roughness in the aerodynamic area of the blade shall adhere to the surface roughness callout of 32 micro-inches shown on the reference drawings.

B. The trailing edge shall include at least 10 fiberglass plies. If this causes a conflict with the surface shown above the Government shall be advised and will have approval authority on any necessary design changes.

C. The blade shall connect to the existing blade adapter

D. The blade cuff geometry shall fall within the boundaries set by AEDC drawing 3202100.6.

3.6. Workmanship:

3.6.1. The blades shall be free of sharp edges that could pose an injury risk during their installation into the compressor.

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3.7. Structural:

3.7.1. Blade

A. The blade design shall have a minimum Factor of Safety of 5.0 on an appropriate composite failure theory for any combination of conditions stated in section 3.2-3.4.. The failure theory shall be approved by the Government and shall be presented at PDR.

B. The blade maximum deflection at full load shall not exceed 2” in the upstream or downstream flow direction including the tolerance limits on the 2-D drawings.

C. A trade study shall be performed to determine the suitability of fabricating the blade “strongback” (shown on drawing 6440-1102) from composite material as opposed to steel. This trade study shall be presented at the concept review discussed in section 3.1.2A of statement of work 14424- 002-16.

3.7.2. Blade Cuff

A. The blade design shall have a minimum Factor of Safety of 5.0 on an appropriate composite faiure theory for any combination of conditions stated in section 3.2-3.4.. The failure theory shall be approved by the Government and shall be presented at PDR.

B. A trade study shall be performed to show the advantages/disadvantages of integrating the cuff with the blade structure. The study shall include cost of tooling and production, inspectability of the final structure, ease of repair, and damage tolerance for an integrated cuff and a separate cuff. This trade study shall be presented at the concept review discussed in section 3.1.2A of statement of work 14424-002-16.

3.7.3. Material Requirements

A. The blades and cuffs shall be manufactured using polymer matrix composite materials. The aerodynamic surface of the blade shall be fabricated of fiberglass (E-glass or S-glass fabric).

B. The blade shall be split into 3 zones for inspectability as described herein and in Figure 1.

1.) Blade is not required to be translucent and is not required to have any surface layers of fiberglass unless required for galvanic corrosion.

2.) The blade is not required to be translucent, but shall have at least 8 layers of fiberglass at the surface.

3.) The blade shall be translucent.

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Figure 1- BLADE ZONES FOR INSPECTABILITY

C. Exposed composite edges and interfaces shall be sealed to minimize moisture and fluid absorption (reference sections 3.3.4 and 3.4.2). This sealant shall withstand the conditions in sections 3.3 and 3.4 without degradation of its sealing integrity.

D. Fiberglass shall be included at the surface of any carbon fiber composite which will interface with the blade adapter or blade/pin bushing to prevent galvanic corrosion. If these composite surfaces must be machined the contractor shall confirm that all fiberglass has not been removed.

E. The blade shall not contain Kevlar™/Aramid, Quartz, Basalt, Boron, Pitch-based Carbon/Graphite, Polyethylene or Natural fibers.

F. The disc/blade interface bushings shall be a Glacier DU type bearing from Garlock Corporation or government approved equal.

3.7.4. Blade Tooling

A. Sufficient blade tooling shall be fabricated such that 200 compressor blades may be manufactured within a 2 year period.

B. Sufficient tooling shall be supplied to the government such that 100 compressor blades can be fabricated beyond the 200 production units.

3.8. Mechanical / Maintenance

3.8.1. Blade Inspectability/Serviceability

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A. The contractor shall, prior to fabrication, provide to the Government an accept/reject criteria that will be used by the contractor during blade fabrication to determine if a blade is suitable for delivery to the Government.

This criterion shall be based upon the blade design, test results and component analysis.

B. The contractor shall provide reject/repair criteria to be used during blade operation. The reject/repair criteria shall consider the location, type of damage incurred, and the reparability for maintaining the required Factor of Safety of 5.0 for operational conditions (ref section 3.2 and 3.4).

C. The blade design shall accommodate NDI to the maximum extent possible with current state-of-the-art composite structure techniques at any time prior to installation in the compressor and during in-service inspections. In service inspections will consist of a (in-service inspections require the inspection to be performed inside the compressor; the blade will be removed and sent to the inspection/repair facility if visual indications are detected).

D. The proposed NDI method shall be capable of determining service limiting defects during fabrication and in-service inspections.

E. The contractor shall provide an estimate and procedure to repair the following blade damage:

Blade Station (Distance from Pin) (in)

Span Location Size

3-11” Any .5” diameter hole 11-30” Leading Edge 6”along length x 2” along span 11-30” Mid-span 2” diameter hole 11-30” Trailing Edge 6” along length x 2” along span 30” to Blade Tip Leading Edge 6” along length x 2” along span 30” to Blade Tip Mid-Span 3” diameter hole 30” to Blade Tip Trailing Edge 6”along length x 2” along span

The blade must also survive this level of damage for 16 hours of run time.

A factor of safety of 2 on maximum strain is required for this case.

3.9. Marking:

3.9.1. Each blade shall be identified by a unique serial number marked with ink or paint (the paint or ink shall not adversely affect the performance of the blade and located as shown in Figure 2 with a 3” text height where practical. If a 3 inch text height is not practical other text height is permissible provided all information is

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Use paint or ink capable of withstanding the conditions stated in sections 3.3 and

3.4. The format shall be in accordance with the following:

C1 - X - ###

Designates the sequence number in which the blades were fabricated, sequence shall start at 401 for each row.

Designates Row in which blade will be used (blade shall be marked with A, B, or C)

Designates compressor C1. This designation will be the same for all blades.

FIGURE 2- BLADE MARKING

4. VERIFICATION AND TESTING

4.1. Engineering Analysis: The Contractor shall perform Finite Element Analysis (FEA) of the blade structure. The contractor shall also perform traditional hand calculations as backup to their FEA results. Analysis shall be submitted in accordance with statement of work 14424-001-16 section 3.3.2.C.

4.2. Testing: All factory testing shall be performed at the Contractor’s facility.

Government reserves the right to witness all tests.

4.2.1. The contractor shall perform, document and provide reports for all testing that establishes material allowables and process parameters that would be necessary to ensure the blades and blade cuffs consistently meet the requirements set forth in this specification.

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4.2.2. With prior Government approval lamina material properties which are available from commercial or military databases (e.g. CMH-17, AGATE, NCAMP) may be used in lieu of material testing for room temperature dry properties. Unless the database also includes 300F wet properties material testing shall be performed using the AGATE method for producing B-Basis design allowables. At a minimum this testing shall include modulus and strength for tension, compression, and shear.

4.2.3. Test information shall in all cases represent the actual materials chosen for the components as well as represent the selected manufacturing process as verified by “as-built” properties.

4.2.4. All quality assurance testing performed by the contractor should be per the standards (when the standard is applicable to the test proposed) noted in Section 2.

4.2.5. Quality assurance test information shall document and supply reports for any variances between lots, batches and raw material production runs that may affect the performance of the end product.

4.2.6. Government performed tests

A. The Government plans to perform acceptance testing of the 10 LRIP blades at AEDC. A contractor representative may witness the LRIP testing and shall comply with all security and safety requirements at the installation.

5. Packaging

5.1. The contractor shall provide individual reusable packaging for each blade. The packaging shall be durable and accommodate stacking blades 4 high by forklift.

5.2. The packaging shall be marked on the exterior with the corresponding blade serial number.

5.3. All tooling, jigs, and fixtures shall be packaged for long term storage in an enclosure that is capable of moving via forklift. These parts shall be coated and shrink wrapped to prevent corrosion.

6. NOTES – Not Applicable

END OF SPECIFICATION

16T C-1 COMPRESSOR BLADE STRUCTURAL DESIGN/ANALYSIS, TOOLING TESTING UNITS, AND MANUFACTURING