TF41 Engine Fan Disk Seeded Fault Crack Propagation Test

Uncontained engine failures, although rare in occurrence, can have a catastrophic effect on aircraft performance and safety. Engine disk cracks can eventually lead to these type of failures. A number of techniques to detect engine disk cracks have been developed in recent years. However, these technologies have only been validated by disk spin pit tests, not actual engine tests. Due to this, a project was established to perform seeded fault engine tests on a TF41 engine disk fan. A defect was machined in the first stage fan disk of a TF41 engine. The disk was run in a spin pit to initiate a crack. Once initiated, the disk was run in an actual engine test facility. The engine was cycled by a number of start and stops with the goal of propagating the crack to disk burst through low cycle fatigue. Various crack detection techniques were installed on the engine and run real-time during the test to validate their abilities to detect disk cracks. These techniques were based on methods such as change in mass imbalance using vibration or shaft displacement, change in blade position, acoustic emission, and torsional resonance. At the completion of 4474 test cycles, the crack in the TF41 disk was determined to have grown approximately 0.025 inches. This was far less the predicted crack growth based on a fracture mechanics analysis and finite element stress analysis.