CFM International Investment in 3-D Woven Composites Validated
Fan testing, rig testing successes keep the LEAP engine on track for certification in 2014.
In a press release dated November 14, 2012, CFM International announced an update on the testing of its advanced Leading Edge Aviation Propulsion (LEAP) engine. Notable for manufacturing engineers is its extensive use of advanced 3-D Woven Resin Transfer Molding (3-DW RTM.) The company recently completed its fan blade-out rig test with good results.
The LEAP engine is on track for certification in 2014, according to CFM International, and entry into service in 2016 on the Airbus A320neo and COMAC C919 in 2016. In 2017, it will enter into service on the Boeing 737 MAX. To date, CFM announced received orders and commitments for more than 2,450 LEAP engines to power these three aircraft types.
In addition to fan tests, CFM has conducted extensive rig testing of its ultra-high-efficiency LEAP low-pressure turbine. The rig, which included the full low-pressure turbine (LPT) and turbine rear frame, validated the technical innovations in the design, including the advanced three-dimensional designed airfoils and blade and vane alignment. Initial results confirmed high efficiency levels and matched results achieved in pre-test simulations. Testing has enabled CFM to assess acoustics and to validate corresponding LPT performance and airfoil mechanical behavior in a real operating environment.
Prior to testing in May, CFM completed a full-scale fan blade out rig test, simulating certification requirements for the proprietary 3-DW RTM technology. The company has also completed extensive full-scale component tests, including bird ingestion testing with the same very positive results.
"The fan blade-out test went beautifully," said Francois Bastin, director of the LEAP Program for CFM in the press release. "The fan experienced very low overall unbalance and behaved as we had predicted in pre-test simulations. We also included the composite fan case, which showed no cracks or stress defects and all parts were contained. This test was a total success and confirmed that the LEAP fan will meet all certification requirements."
In August, CFM completed endurance testing of the fan, with the hardware logging more than 5,000 cycles. The demanding test was designed to evaluate fan behavior within a real thermal and vibratory environment. The preliminary results have been outstanding, meeting or exceeding all pre-test predictions. “The endurance test is an important one for us because it addresses the conditions that our customers will eventually see in operation,” said Bastin. “We saw absolutely no change whatsoever on the fan blades and we couldn't be happier with the results.”
Source: CFM International. (CFM International is a 50/50 joint venture between GE Aviation and SNECMA.)
In earlier related reporting, AINOnline (10/22, Dubois) the testing is part of a larger “risk-abatement plan to ensure a smooth production transition from its CFM56 to the new Leap-1A, B and C engines… In Rochester, New Hampshire, and Commercy, France, two new factories will produce a combined 32,000 fan blades per year by 2019, according to CFM. Plans call for both to devote space to Albany Engineering Composites (AEC), SNECMA’s “preferred supplier” for carbon-fiber weaving and one of the few new providers for the Leap. Some 90% of the Leap’s 300-plus suppliers already provide parts for the CFM56 program.”