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A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing, Part II: Additive Manufacturing and Characterization of Polymer CompositesThis publication is the second part of the three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides-Ultem 9085 and experimental Ultem 1000 mixed with 10% chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25 to 31%. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties. A preliminary modeling was also initiated to predict the mechanical properties of FDM-printed Ultem 9085 coupons in relation to varied raster angles and void contents, using the GRC-developed MAC/GMC program.
Document ID
20150011644
Acquisition Source
Glenn Research Center
Document Type
Technical Memorandum (TM)
Authors
Chuang, Kathy C.
(NASA Glenn Research Center Cleveland, OH United States)
Grady, Joseph E.
(NASA Glenn Research Center Cleveland, OH United States)
Arnold, Steven M.
(NASA Glenn Research Center Cleveland, OH United States)
Draper, Robert D.
(NASA Glenn Research Center Cleveland, OH United States)
Shin, Eugene
(Ohio Aerospace Inst. Brook Park, OH, United States)
Patterson, Clark
(rp+m (Rapid Prototyping+Manufacturing) Avon Lake, OH, United States)
Santelle, Tom
(rp+m (Rapid Prototyping+Manufacturing) Avon Lake, OH, United States)
Lao, Chao
(NASA Glenn Research Center Cleveland, OH United States)
Rhein, Morgan
(NASA Glenn Research Center Cleveland, OH United States)
Mehl, Jeremy
(NASA Glenn Research Center Cleveland, OH United States)
Date Acquired
June 26, 2015
Publication Date
June 1, 2015
Subject Category
Instrumentation And Photography
Nonmetallic Materials
Report/Patent Number
NASA/TM-2015-218749
E-19075
GRC-E-DAA-TN21324
Funding Number(s)
WBS: WBS 694478.02.93.02.14.64.22
CONTRACT_GRANT: NNC13BA10B
Distribution Limits
Public
Copyright
Public Use Permitted.
Keywords
Polymer
Additive Manufacturing
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