Project number
26029
Organization
Honeywell Aerospace
Offering
ENGR498-F2025-S2026
The team will be expected to explore various materials and manufacturing methods for a hybrid composite/metallic stator for turbofan engines and evaluate the potential for real-world implementation. In this process, the team should be mindful of business considerations such as cost and weight. The team will need access to software to create 3D models and to execute computational fluid dynamics (CFD) and finite element (FEA) analyses. A preliminary statement of work includes:
1) Research current production standard composite stator manufacturing strategies to understand its advantages and disadvantages, including the necessity of a metallic reinforced leading edge to protect against erosion.
2) Research alternative composite manufacturing methods that could be applied in the context of turbofan engine stators, with special consideration for the metallic leading edge and possible alternatives.
3) Develop/choose at least one new composite/metallic manufacturing strategy that the team is capable of testing.
4) Perform mechanical analyses of stators for both the current and new manufacturing strategies; adjust the new strategy as needed.
a. If adjustments need to be made to the design/airfoil shape of the stator, or if the new strategy shows concern for geometric tolerances, model and evaluate the aerodynamic impact.
5) Manufacture or procure all necessary hardware (e.g., composite molds, mounting fixtures, metallic stator components, etc.) to develop stators with the new composite/metallic manufacturing strategy.
6) Conduct static loading tests and impact tests (if possible) to assess stator strength and compliance with foreign object debris (FOD) requirements.
7) Analyze the data and generate a final report that describes the program, the benefits, drawbacks, and risks for the new composite/metallic manufacturing strategy, and any recommendations based on lessons learned during the project.
The team is expected to prioritize the items in the statement of work above; however, the team may choose to explore additional relevant objectives if time permits. These optional objectives include:
1) Research considerations and limitations of sustained and repeated high temperature (200-800 deg. F) interactions for the composite/metallic stator.
2) Simulate and/or test sustained and repeated high temperature interactions for the current and/or new composite/metallic stator and evaluate the impact on the strength and geometric tolerances of the stator.
3) Develop one or more additional composite/metallic manufacturing strategies that would improve the thermal capabilities of the stator.
4) Simulate and/or test sustained and repeated high temperature interactions for the additional composite/metallic stator and evaluate the impact on the strength and geometric tolerances of the stator.
1) Research current production standard composite stator manufacturing strategies to understand its advantages and disadvantages, including the necessity of a metallic reinforced leading edge to protect against erosion.
2) Research alternative composite manufacturing methods that could be applied in the context of turbofan engine stators, with special consideration for the metallic leading edge and possible alternatives.
3) Develop/choose at least one new composite/metallic manufacturing strategy that the team is capable of testing.
4) Perform mechanical analyses of stators for both the current and new manufacturing strategies; adjust the new strategy as needed.
a. If adjustments need to be made to the design/airfoil shape of the stator, or if the new strategy shows concern for geometric tolerances, model and evaluate the aerodynamic impact.
5) Manufacture or procure all necessary hardware (e.g., composite molds, mounting fixtures, metallic stator components, etc.) to develop stators with the new composite/metallic manufacturing strategy.
6) Conduct static loading tests and impact tests (if possible) to assess stator strength and compliance with foreign object debris (FOD) requirements.
7) Analyze the data and generate a final report that describes the program, the benefits, drawbacks, and risks for the new composite/metallic manufacturing strategy, and any recommendations based on lessons learned during the project.
The team is expected to prioritize the items in the statement of work above; however, the team may choose to explore additional relevant objectives if time permits. These optional objectives include:
1) Research considerations and limitations of sustained and repeated high temperature (200-800 deg. F) interactions for the composite/metallic stator.
2) Simulate and/or test sustained and repeated high temperature interactions for the current and/or new composite/metallic stator and evaluate the impact on the strength and geometric tolerances of the stator.
3) Develop one or more additional composite/metallic manufacturing strategies that would improve the thermal capabilities of the stator.
4) Simulate and/or test sustained and repeated high temperature interactions for the additional composite/metallic stator and evaluate the impact on the strength and geometric tolerances of the stator.