Revised_Atch_2_16T_C1_Compressor_Blades_Equipment_Specification.pdf

14424-17-003A

Distribution A - Public Release Distribution Unlimited

IRA-2620, PA-AEDC2016-195

SPEC NO. 14424-17-003A

21 April 2017

EQUIPMENT SPECIFICATION

FOR

16T C1 COMPRESSOR BLADES

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

Distribution A Public Release Distribution Unlimited

IRA-2620, PA-AEDC2016-195

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. Operating conditions

3.3. Non-Operating conditions

3.4. Design Loads

3.5. Blade and Cuff Physical Characteristics

3.6. Workmanship

3.7. Structural

3.8. Mechanical

3.9. Marking

4. VERIFICATION AND TESTING

4.1. Engineering Analysis

4.2. Testing

5. PACKAGE AND DELIVERY

6. NOTES

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1. SCOPE

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

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1 Drawings:

A. Contract Drawings:

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

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

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

4. Drawing number PU630917.01 – Blade Cuff Details

5. Drawing number SKRO6199 Blade Design Impact Panel – Details, Sheets 1 through 3

B. Reference Drawings:

1. Drawing number PG631713.01 – Blade Adapter Details Sheets 1 & 2 and associated .STEP file

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

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

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

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

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

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

8. 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 D2734-16 Standard Test Methods for Void Content of Reinforced Plastics.

B. ASTM D3171-15 Test Method for Fiber Content of Resin- Matrix Composites by Matrix Digestion.

C. ASTM D3800-16 Test Method for Density of High-Modulus Fibers.

D. ASTM D3039-14 Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials.

E. ASTM D6641-17 Standard Test Method for Determining the Compressive Properties of Polymer Matrix Composite Laminates Using a Combined Loading Compression (CLC) Test Fixture.

F. ASTM D5467-17 Standard Test Method for Compressive Properties of Unidirectional Polymer Matrix Composites Using a Sandwich Beam.

G. ASTM D2344-16 Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their Laminates.

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H. ASTM D5379-12 Standard Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method.

I. ASTM D5961-13 Standard Test Method for Bearing Response of Polymer Matrix Composite Laminates.

J. ASTM D953-10 Standard Test Method for Bearing Strength of Plastics.

K. ASTM C393- 16 Standard Test Method for Flexural Properties of Sandwich Constructions.

L. ASTM C297-15 Standard Test Method for Shear Properties of Sandwich Core Materials.

M. ASTM D3518-13 Standard Test Method for In-Plane Shear Response of Polymer Matrix Composite Materials by Tensile Test of a +/-45º Laminate.

N. ASTM D7078-12 Standard Test Method for Shear Properties of Composite Materials by V- Notched Rail Shear Method.

O. ASTM D6856-16 Standard Guide for Testing Fabric- Reinforced “Textile” Composite Materials.

P. ASTM D3479-12 Standard Test Method for Tension- Tension Fatigue of Polymer Matrix Composites Materials.

Q. ASTM D7028-15 Standard Test Method for Glass Transition Temperature (DMA Tg) of Polymer Matrix Composites by Dynamic Mechanical Analysis (DMA).

2.2.4. Composite Materials Handbook (CMH):

A. CMH-17G-12 Polymer Matrix Composites, Composite Materials Handbook (ITAR and non-ITAR Sections)

1. Volume 1 – Guidelines for Characterization of Structural Materials

2. Volume 2 – Material Properties

3. Volume 3 - Materials Usage, Design, and Analysis

4. Volume 6 – Structural Sandwich Panels

5. Sections 6.6.6 - Fiber Volume Fraction

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6. Section 6.6.7 - Void Volume Fraction

2.2.5. American Society of Mechanical Engineers (ASME)

A. ASME-Y14.5-09 Dimensioning and Tolerancing.

2.2.6. 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.)

2.2.7. Society of Automotive Engineers:

A. AS9100 - Quality Management Systems - Aerospace –Requirements

3. REQUIREMENTS

3.1. General:

3.1.1 Life of the blades and blade cuffs shall be 20 years minimum. Contractor shall demonstrate through a service life analysis, assuming an annual average of 1,500 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 2,000 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 In addition to start up/shut down cycling, the blades are subjected to dynamic loading of +/-35% of the static load at a frequency of 30 Hz.

3.1.3 The prototype blades which are received by AEDC 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.

3.1.4 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) to prevent hazardous material exposure.

3.1.5 The center of gravity of each blade assembly shall be analyzed in combination with the aerodynamic and centrifugal (CF) loading in the blade design. The “bumper” load (See Figure 1) in the cuff shall be supplied with the analysis for each load case.

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3.1.6 The Contractor performing composite manufacturing (including tooling) shall be AS9100 certified at the time of proposal.

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 320ºF.

3.2.2 Exposure to hydraulic fluid, lubricating oil, a high humidity environment, and occasional exposure to liquid water, gaseous nitrogen, carbon dioxide (fire protection systems), and rocket fuel, jet engine fuels (either burned or unburned), and their by-products.

3.2.3 Operational pressures from 0.4 psia to 29.2 psia. Due to pressure differentials in the blade, all internal cavities shall be vented. All internal cavities shall be cleaned of dust, loose fibers, resin particles, debris, and similar materials that may have accumulated.

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.

3.3.2 Exposure to hydraulic fluid, lubricating oil, a high humidity environment, and occasional exposure to liquid water, gaseous nitrogen, carbon dioxide (fire protection systems), and rocket fuel, jet engine fuels (either burned or unburned), and their by-products.

3.4 Design Loads: (all act simultaneously).

3.4.1 The maximum blade CF load occurs at a disc speed of 600 RPM (See Figure 1).

3.4.2 The maximum desired bumper load on the blade cuff shall be 5,000 lbf (See Figure 1). If the analysis shows that the blade design cannot limit the cuff load to 5,000 lbf, then the Government shall be consulted for approval of the increased load. The cuff load for each load case shall be supplied with Technical Design Review (TDR) documentation. The approximate stiffness of the spacer is 92,000 lbf/in.

3.4.3 Rotor blade aerodynamic loads have been generated using AEDC Computational Fluid Dynamics (CFD) tools and will be provided by the Government. These loads shall be used as the governing rotor blade aerodynamic loading. The load data will be provided by the Government in the form of comma delimited text files (.csv). Other formats may be available upon request. A total of seven static conditions shall be analyzed. The load cases will be given for each blade row.

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Figure 1- Load Definitions

3.5 Blade and Cuff Physical Characteristics:

3.5.1 The maximum weight for each blade (including blade, blade cuff, strongback (if applicable), tip cap, and blade pin bushing) without the blade pin and telemetry box shall not exceed 115 pounds (dry weight). A lighter blade is desirable but not required. The current blades are designed with an offset center of gravity intended to reduce the bending moment in the blade. Analysis shall be performed to show loads transferred to the adjacent blade spacers, blade cuff, blade adapter, and the rotor disc.

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3.5.2 If the cuff is integrated with the blade a cavity shall be provided 1” wide x 1.5” tall x 6” long on the leading and trailing ends which can support a 14-ounce package during compressor operation (including CF load from the telemetry package mass). The telemetry package shall be bonded such that the weight is supported in the radially outward direction (See Figure 1 for example)

3.5.3 Blade-to-blade weight deviation (including blade cuff and disc/blade interface bushings) shall not exceed 0.5 pounds.

3.5.4 The blade assembly shall include a removable tip cap (by grinding, the tip caps are not required to be re-usable) as shown on drawing 3202100.23.

3.5.5 Blade Geometry:

A. The aerodynamic surface shall fall within the bounds shown on AEDC drawings (Reference AEDC drawings 3202100.6 and 3202100.23).

Surface finish in the aerodynamic area of the blade shall adhere to the surface roughness callout of 32 micro-inches shown on the contract drawings.

B. For the integrated cuff trade study, it is acceptable to utilize the first 4” of the aerodynamic surface past the current cuff to create a smooth transition from the cuff to the aerodynamic surface (See Figure 2).

C. The blade attachment to the blade adapter shall be as shown in AEDC drawing 3202100.6.

D. The geometry of the blade cuff area which interfaces with the spacer and the blade cuff width shall fall within the boundaries set by AEDC drawing PU630917.01 (See Figure 3 for interface definition). If the cuff is integrated with the blade based on the trade then the Government shall approve all changes to the transition from the spacer interface area to the aerodynamic surface.

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Figure 2- Conceptual Integrated Cuff

Figure 3 - Cuff Interface Region

3.6. Workmanship: The blades shall be free of sharp edges that could pose an injury risk during their installation into the compressor. The blades shall be free from damage that induces stress concentrations in the structure.

Potential Integrated Cuff Existing Design

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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 based on progressive failure analysis 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 TDR and shall also be supported with established material property failure data from tests or recognized industry databases.

B. The blade leading or trailing edge maximum deflection at full load shall not exceed 0.07” in the radial direction and 2” in any other direction from the unloaded condition with the blade tip pointing radially outward from the center of the disc. The deflection limit shall include the maximum variation due to tolerances 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 or an alternate metal as opposed to low carbon steel. The final direction, will be approved by the Government at the TDR.

D. The blade operating natural frequency shall conform to the requirements in the Table 1 below.

Table 1 – Natural Frequency Requirements

Operating Speed

(RPM)

1st Bending Frequency (Hz)

2nd Bending Frequency (Hz)

600 3E : <28.5 Hz or >31.5 Hz 4E : <38 Hz or >42 Hz

7E : <66.7 Hz or >73.5 Hz 8E : <76.2 Hz or >84 Hz 9E: <85.7 Hz or >94.5 Hz

Known forcing functions exist at 3x rotation speed (3E), 4E, 7E, 8E, 9E, 41E and 43E. The current blades show dynamics for first bending at 3E and 4E, and second bending at 7E, 8E, and 9E.

For reference the current blade natural frequencies are:

1st Bending : 17.7 Hz

2nd Bending : 63.7 Hz

1st Torsion : 97 Hz

3rd Bending : 139 Hz

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2nd Torsion : 165 Hz

These numbers were measured with the blade mounted horizontally in a fixture with the cuff supporting the blade weight and no clamping on the opposite cuff surface.

E. The blade damping coefficient shall be 2% or higher for the 1st bending mode and 1% or higher for the 2nd bending mode.

F. Blade natural frequencies shall be calculated at operating loads in the compressor as well as the configuration in which the blade will be statically tested per section 4.1.5.

G. In the event of issues with natural frequency during in-tunnel prototype testing, the design shall allow for first and second bending frequencies to be adjusted by +/-2% without a major tooling or blade redesign. Metal weights shall not be used to tune the blade frequencies. Any additional material used to tune blade frequencies shall be polymer composite and integral to the blade structure.

H. The blade minimum torsional stiffness, based on twisting at the tip, shall be no less than 1,521 in-lbf/deg (current blade torsional stiffness). For reference, the measured bending stiffness of the current blade is 257 lbf/in as measured at the blade tip.

3.7.2. Blade Cuff

A. The blade design shall have a minimum Factor of Safety of 5.0 based on progressive failure analysis 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 TDR and shall also be supported with established material property failure data from tests or recognized industry databases.

B. A trade study shall be performed to show the advantages/disadvantages of integrating the cuff with the blade structure. The study shall be performed for the separate and integrated cuff to include cost of tooling and production, cost of spare cuffs, inspectability of the final structure, ease of repair, and damage tolerance. The final direction will be approved by the Government at the TDR.

3.7.3. Material Requirements

A. The blades, blade tip cap, and blade cuffs, with the exception of the disc/blade bushing and possibly the blade strongback (depending on the outcome of the strongback design trade study), 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)

Page-11 consistent with the structural requirements and surface roughness callout

B. The blade shall not contain fibrous or woven Kevlar™/Aramid, Quartz, Basalt, Boron, Pitch-based Carbon/Graphite, Aluminum, Ceramic, Silicon Carbide, Nylon, PBO, Polyethylene or Natural fibers unless approved by the Government.

C. The blade shall be split into 4 zones for installed visual inspectability as described herein and in Figure 4.

1. ZONE A: Not required to be translucent and is not required to have any surface layers of fiberglass unless required for galvanic corrosion.

2. ZONE B: Not required to be translucent, but shall have a minimum of 8 layers of fiberglass at the aerodynamic surface.

3. ZONE C: Shall be translucent. Shall have a minimum of 4 layers of fiberglass at the aerodynamic surface. The internal blade structure shall make no more than 15% of the blade surface opaque in zone 3.

4. ZONE D: Not required to be translucent, but shall have a minimum of 4 layers of fiberglass at the aerodynamic surface

Figure 4 - Blade Zones for visual inspectability

D. Exposed composite edges and interfaces shall be sealed to minimize moisture and fluid absorption. This sealant shall withstand the conditions in sections 3.2 and 3.3 without degradation of its sealing integrity.

E. Fiberglass shall be included at the surface of any carbon fiber composite which will interface with the blade adapter or disc/blade bushing to prevent

Page-12 galvanic corrosion. If these composite surfaces must be machined, the Contractor shall confirm that all fiberglass has not been removed.

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

3.7.4. Blade Tooling:

A. Sufficient blade tooling shall be fabricated such that 204 compressor blades can be manufactured within a two year period.

B. Sufficient tooling shall be supplied to the Government such that 100 compressor blades can be fabricated in addition to the two sets of 97 production units. If the tooling includes pieces that must be replaced after producing ten or fewer parts then detailed information about this hardware’s use and how to procure it shall be provided in lieu of the actual hardware.

3.8. Mechanical / Maintenance:

3.8.1. Blade Inspectability/Serviceability

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.

C. The blade design shall accommodate Non Destructive Inspection (NDI) after fabrication to the maximum extent possible with current state-of-the-art composite structure techniques. The Contractor shall submit a plan for NDI which gives best value for the Government based on their professional experience. This plan will be reviewed and approved by the Government at TDR.

D. During in-service inspections visual inspections only will be performed.

Any flaws from impact or other damage shall be visible or not service limiting.

E. The Contractor shall provide a procedure to repair the following blade damage (See Figure 5 and Table 2):

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Table 2 – Blade Damage

Blade Station (Distance from Pin) (in)

Chord Location

Size

Zone 1 (3”-11” from Pin) Any 0.5” diameter hole Zone 2 (11”-30” from Pin) Leading

Edge Slot 6”along span x 2” along chord

Zone 3 (11”-30” from Pin) Mid-chord 2” diameter hole Zone 4 (11”-30” from Pin) Trailing

Edge Slot 6” along span x 2” along chord

Zone 5 (30” from pin to Blade Tip)

Leading Edge

Slot 6” along span x 2” along chord

Zone 6 (30” from pin to Blade Tip)

Mid-chord 3” diameter hole

Zone 7 30” from pin to Blade Tip)

Trailing Edge

Slot 6”along span x 2” along chord

The blade shall survive any one of the damage levels (not all damage combined) shown in Table 2 for 16 hours of run time. A factor of safety of 2 on maximum strain is required for damage assessment and survivability of the design after damage is incurred.

Figure 5 - Damage Zones

3.9. Marking:

3.9.1. Each blade shall be weighed (weight shall include the blade, blade cuff, blade tip cap, blade strong-back (if applicable) and disc/blade interface bushings). Each blade shall be identified by a unique serial number. See Figure 6 for an example of blade marking. The blade shall be marked with ink or paint. The paint or ink shall not adversely affect the performance of the blade. The blade shall be marked with a 3-inch text height. If a 3-inch text height is not practical, other text

Page-14 height is permissible provided all information is present and legible. Use paint or ink capable of withstanding the conditions stated in sections 3.2 and 3.3. 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 6 - Blade Marking

4. VERIFICATION AND TESTING

4.1. Testing: All factory testing shall be performed at the Contractor’s (or their subcontractor’s) facility. The Government reserves the right to witness all tests.

All test plans shall be submitted 14 days prior to testing.

4.1.1. General Testing:

A. 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.

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B. All quality assurance and material testing performed by the Contractor shall be per the standards (when the standard is applicable to the test proposed) noted in Section 2.2.

C. 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.

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

E. The Contractor shall submit all test reports signed by personnel conducting the test and those approving the results. The Contractor shall not ship blade assemblies until test reports have been approved by the Contracting Officer.

4.1.2. Material Testing:

A. 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 320 F wet properties (or a higher temperature wet condition), material testing shall be performed using the AGATE methods for producing B-Basis design allowable. This testing shall include modulus and strength for tension, compression, and shear. Strain value shall be reported as necessary for any damage event assessment.

B. Multiple batch requirements normally associated with B-Basis testing are not required for assessment during this testing. Analysis based on the number of replicate sample at any given test condition coupled with the standard deviation of the test, and the associated kB factor (based on sample number tested) and will be sufficient.

C. The data is required at -20F (dry), 77F (dry), and 320F (dry and wet) condition for all B-Basis design allowable. If wet test data exists above 320F, that test information is acceptable if inclusive of tensile, compressive and shear loading conditions

D. The Contractor shall either perform void content testing on panels created for material characterization or shall report the void content from the industry data source from which B-basis allowables are taken. The Contractor shall run void content tests on as-built blade material during the manufacturing process development phase in order to assure that

Page-16 their process can produce parts that do not require further material property knockdowns due to excessive void content.

E. Sufficient bonded joint interface analyses shall be conducted at the 320F (dry) and -20F (dry) conditions necessary to assure bond interface strength at dominant, combined thermal and operational loading conditions. These bonded interfaces, particularly in the hub section of the blades do not lend themselves to representative testing since ASTM standards are not available or well-defined. Consequently, these bonded joint interface shall be assessed through a Finite Element Analysis (FEA) of the thermal and imposed operational loading at the temperature extremes.

4.1.3. Ballistic Impact Testing:

A. Structural panels representing the blade lay-up and internal structure shall undergo ballistic impact testing with a 0.06 lbm (420 grain) cylindrical steel projectile .5” in diameter at 500 +/-50 ft-lbf impact energy. The required impact trajectories are shown in drawing SKRO6199. The impact locations shall be submitted with the test plan a minimum of two weeks prior to testing and shall be approved by the Government. NDI shall be performed on the panels after testing to determine the extent of damage propagation. The panel shall represent the same layup and reinforcement spacing as the preliminary design specifies for the location of Section B- B in contract drawing 3202100.6 Sheet 1. The panel shall be fabricated with the same materials intended for use in the blade based on the TDR package. The panel shall be fabricated using the same process type (e.g.

prepreg, resin infusion, etc.) as envisioned in the TDR manufacturing concept. The panel shall conform to the dimensions and edge restraints shown in drawing SKRO6199. Note that the geometry shown in the drawing are examples of one possible design and are not intended to guide or explicitly infer the Contractor’s design. Panel shall be fabricated as shown in drawing SKRO6199. The test panel shall be fabricated such that additional material is available for void content testing. Void content testing of the panel shall be performed and included with the test report.

4.1.4. Fatigue Testing:

A. Sample (coupon) laminate testing shall be conducted at the “R-condition (stress cycle ratio)” and most realistic service operational temperature conditions used in the FEA.

B. ASTM D-3479 tension-tension laminates shall be tested to develop an operational laminate S-N curve at 320F (dry) temperature conditioning.

The S-N curve shall then be used to assess service life limitations of the conditions specified in section 3.1.1 and shall fatigue cycle a minimum of six (6) replicates at each stress level. The fatigue S-N curve shall be

Page-17 defined by testing at five (5) stress levels relative to B-Basis 320F (dry) maximum stress allowable determined from material testing. Fatigue test levels of 80%, 70%, 60%, 50% and 40% of the 320F (dry) maximum stress allowable (B-Basis) shall be used to define the S-N curve.

C. If representative S-N fatigue data exists from recognized data sources for the laminate material in tension-tension cycling at 320F (dry) or higher, that data may be used to establish the service life S-N curve.

D. Fatigue Testing is considered part of the material characterization plan.

4.1.5. Full Scale Structural and Thermal Testing:

A. Full scale structural and thermal testing shall be performed by the Contractor as follows:

1. All prototype and Low Rate Initial Production (LRIP) blades shall be tested in combined bending and torsion at maximum load at room temperature (70F+/-20F)

2. All prototype and Low Rate Initial Production (LRIP) blades shall be tested in combined bending and torsion at maximum load at maximum compressor temperature from of 320F.

B. The blade shall be loaded such that a distributed load is created along the length of the blade to prevent overstress due to the load application.

C. The blade root shall be subjected to CF, bending, and torsional combined loading at section E-E (the blade may be held past section E-E if required, but the load shall be transferred at this section) on drawing 320100.6 such that the root will see the maximum pin reactions given by the worst analysis load case. This root section test may be performed on a partial blade as opposed to a full blade.

D. The prototype blade not utilized for in-tunnel testing shall be statically tested in the same manner as the other prototype blades. For damage tolerance assessment this blade shall be subjected to damage as indicated in section 3.8.1. FEA analysis of the damage shall be performed for all zones. The blades shall be damaged and tested sequentially as shown below for zones 5, 6, and 7:

1. Damage blade at the worst case location for the given zone by removing material as shown in the specification table.

2. Statically/thermally test the blade (without CF root testing).

3. Repair the damage.

4. Statically/thermally test the blade (without CF root testing).

3. Conduct Modal Analysis test of the blade.

E. Successful structural/thermal testing is defined as follows:

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1. The blade shall show no permanent deformations which would put them out of geometric specification or create stress risers in the part.

2. No strain measurements show unacceptable factor of safety.

3. The strain measurements shall not exceed the FEA predictions by more than 15%.

4. The blades pass post-test NDI inspection with no new indications which are outside the accept/reject criteria created by the Contractor for continued blade service.

5. Test plans shall be submitted for approval by the Government two weeks prior to the test dates.

4.1.6. Non-destructive Inspection (NDI):

A. A baseline NDI inspection of each blade delivered shall be provided in electronic format, preferable in JPEG format for imaging NDI’s. The NDI inspection document shall be identified so it is traceable to the unique serial number marked on each blade as well as the date the NDI occurred.

Any indications outside the established accept/reject criteria and the Material Review Board (MRB) remediation for these indications shall be explained.

B. The Contractor shall provide additional NDI inspections of the prototype blades and LRIP blades which the Government will use for verification testing. This NDI inspection shall occur after acceptance testing (as performed by the Government) and following the repairs described section 3.8.1.E.

4.1.7. Modal testing:

A. Modal testing to identify all mode shapes up to 1000 HZ is required for all prototype and LRIP blades. The Contractor shall be responsible for creating the test procedure and choosing sufficient points along the blade to properly capture the mode shapes.

B. The Contractor shall be responsible for placing strain gages on the prototype and LRIP blades which will accurately identify vibration modes during in-tunnel testing at AEDC.

C. Production blades shall be tested using a simple tap test to show first natural frequency and damping ratio.

4.1.8. The Contractor shall be responsible for dimensional checks which will verify that the blade aerodynamic surface, all surfaces interfacing with surrounding parts, and the attachment point are within contract drawing tolerances for each blade delivered. An inspection report shall accompany all blades delivered.

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4.1.9. The Contractor shall supply a log recording, at a minimum, the blade serial number, weight, date of manufacture, lot number of all items used in that blade, geometric inspection report, blade natural frequency, and blade damping ratio.

In addition to this being supplied with each blade, a spreadsheet in Microsoft Excel format shall be submitted at the end of the production runs.

5. PACKAGING AND SHIPPING

5.1. The Contractor shall provide individual reusable packaging for each blade. The packaging shall be durable and accommodate stacking blades four 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 packed for long term storage in an enclosure that is capable of moving via forklift. These parts shall be protected for long-term storage in a manner based upon industry practice for the construction material type of the parts. All tooling required to build a further 100 blades following contract completion shall be shipped to AEDC.

5.3.1. Metal Tooling, Jigs and Fixtures: Steel, Aluminum, and Invar metal tooling, jigs, and fixtures should be protected appropriately from corrosion by spray coating with PVC film, applying grease to surfaces, using corrosion-resistant primers, or using corrosion resistant coatings.

5.3.2. Composite Tooling: Composite tooling parts should be protected from moisture ingestion by using spray coated PVC film and maintaining storage below 120°F, above 35°F, and at 50%RH+ conditions.

5.3.3. Contractor shall recommend maximum storage duration anticipated for the useful life of any metal or composite tooling, jigs and fixtures.

5.3.4. Contractor shall provide recommendations for periodic inspection procedures and steps to be taken regarding any tooling, jigs and fixtures remaining in storage after completion of the production blades.

5.4. No more than 10 blades shall be shipped in a single delivery to Arnold AFB, TN.

5.5. The Contractor shall provide individual reusable packaging for each blade. The packaging shall be durable and accommodate stacking blades four high by forklift.

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

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6. NOTES – Not Applicable

END OF SPECIFICATION