Additive manufacturing of high-performance polymer parts for aerospace application

Additive manufacturing (AM), 3D printing, offers flexibility in manufacturing and can process a wide range of materials. In this project, polymers and composites are investigated to increase mechanical performance, and to reduce weight, cost, and lead time of candidate parts. Pratt & Whitney Canada (P&WC) can greatly benefit from AM processes in aircraft engine components. In addition, AM can shorten the engine design cycle, and Research and Development (R&D) activities. This requires investigation of 3D printed parts and the impact of manufacturing parameters on final part properties, e.g.

Hard Anodising of A205 Aluminum Alloy

The future of aerospace technology relies on us investing in lighter, more fuel-efficient materials that can operate at hotter temperature with greater corrosion resistance. One such alloy that has the potential to meet these needs is the new aluminum alloy A205. In this work we aim to develop a hard anodising process for the A205 alloy, enabling it to perform in more demanding environments. The hard anodising surface treatment will combine corrosion resistance with wear resistance opening up new avenues of applications for the A205 material.

Identification of a constitutive material model for an aircraft engine abradable rub strip material

This research project between the University of Windsor and Pratt & Whitney Canada (P&WC) is focused on a porous composite material used by aircraft engine manufacturers in the design of fancases of turbofan engines. The objective of the project is two-fold and includes 1) experimentally investigating the behavior of the composite material at different loading conditions; and 2) identifying a model that can be used to represent this material in fan blade-off simulations.

CFD methodology for analysis of multiphase flow process

Oil that has passed through the bearings and gearboxes of aircraft engines is recycled by a specialized oil scavenging system that separates droplets dispersed from the shaft from air and particulate matter. This process helps to mitigate the emissions of aircraft engines, greatly improves oil consumption and Improves working life by improving the cooling capabilities of the lubrication system.

Pratt & Whitney Canada Pre-Detailed Design System for Turbines

The aero-engine design process is highly iterative, multidisciplinary and complex in nature. The success of an engine depends on a carefully balanced design that best exploits the interactions between numerous traditional engineering disciplines such as aerodynamics and structures as well as lifecycle analysis of cost, manufacturability, serviceability and supportability. Pratt & Whitney Canada (P&WC) is the world leader in the design and manufacturing of small aero-engines.

Service Life Predictions for Machined Components of Nickel-based Superalloys

Nowadays in aerospace industry, the main concern is to reach an optimum, reliable, and reproducible manufacturing process with a high predictability of the components’ service life and the lowest production cost. Machining is one of the main manufacturing processes for industrial parts which can change the surface characteristics of materials. The main aspects of these alterations are metallurgical, topographical, mechanical, and thermal which could affect microstructure, roughness, and residual stresses at the surface and near the surface of machined components, respectively.

Polymer Composites and Thermoformed Thermoplastics for Engine Fire Zones

This project is intended to develop the technology to form high performance plastics reinforced with carbon fibre (polymer composites) in order to produce lighter parts to replace conventional metallic parts. As the parts may be exposed to fire during use, a comparison between different material systems under fire exposure is also required to have a better understanding of those materials in this condition and if they would withstand the necessary requirements.

Human Errors Analysis in an Aircraft Engine Assembly Center

Human operators show significant variability in performance when operating in complex manufacturing systems that are usually referred to human errors. Such errors are identified as the failure to perform an action within the safe operating limit and often lead to product quality defects. Approximately 50%-80% of the incidents and accidents in safety-critical systems have been associated with human error.

Nonlinear Dynamic Analysis of Aero-Engines

Aero-engines are lightweight structures which are assembled of several thin walled cylindrical components (casings). Casings are joined by bolted flanges, and must withstand high forces. To accurately predict the response of casings assembly, the non-linear behavior of the casing joints must be considered. Currently, aero-engine manufacturers (i.e PWC) are facing serious limitations in matching the experimental results with FE models prediction tools of the aero-engine.

Validation and calibration of Squeeze Film Damper Model with Experiment

This research project studies a specific component in the commercial aircraft engine called the squeezed film damper, or SFD. The SFD is applied to reduce the vibration of the engine rotor, which in turn reduces the noise and brings comfort to the passengers. The expected delivery from this project includes an advanced SFD model which will be used by P&WC for the simulation of engine vibration. The developed model can also be studied as the guideline for an upgraded level of SFD design.