FAA T53-L-13L Turbine Fragment Containment Test

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of the FAA T53-L-13L engine turbine disk fragment containment test is presented in this report. A containment ring was designed and fabricated by Pepin Associates, Inc. and provided to the Naval Air Warfare Center, Weapons Division by the William J. Hughes Technical Center. his ring was fabricated with a 0.014-inch titanium inner and outer sleeve. One- inch-thick Kevlar 29 ballistic fabric made up the primary structure of the containment ring. The ring was reinforced with titanium rods inserted through the fabric and laser welded to the inner and outer sleeves. The engine and containment ring were installed in an UH-1 Huey helicopter. The second stage power turbine disk was notched so that the disk would rupture at approximately 20,400 rpm. The engine was started and immediately accelerated to minimize the chance of a premature rupture. he event was recorded on high-speed film at 4000 pictures per second. The disk ruptured as the engine accelerated through 19,629 rpm. The disk ruptured into three equal sections (approximately 3.6 lbs. each). The result was a contained tri-hub burst with minor bulging of the containment ring and little sign of distress to the airframe. his test demonstrated the capability to contain a tri-hub burst on a medium sized turboshaft helicopter engine. 17. Turbine fragment, Containment ring, Tri-hub burst, Kevlar, T53 rotor, Huey helicopter, Full-size T53 rotor fragments 18. Statement Document is available to the public through the National Technical Information Service (NTIS), Springfield, Virginia 22161. 19. assif. (of this report) Unclassified 20. assif. (of this page) Unclassified 21. s 16 22. Report No. Recipient's Cat Title and Subt Report Date Performing O Author(s) Performing O Performing O Work Unit No Contract or Sponsoring Type of Rep Sponsoring Supplement Abstract T T T Key Words Distribution Security Cl Security Cl No. of Page Price Form DOT F1700.7 (8-72) Reproduction of completed page authorized ACKNOWLEDGEMENTS The FAA William J. Hughes Technical Center, Atlantic City International Airport, New Jersey, and the Naval Air Warfare Center, Weapons Division, China Lake, California, would like to thank the agencies that had assisted and significantly contributed to the success of this test program. These agencies include the Naval Air Warfare Center, Aircraft Division, Trenton, New Jersey; Corpus Christi Army Depot, Corpus Christi, Texas; and the New Jersey Army National Guard, Trenton, New Jersey. iii/iv TABLE OF CONTENTS Page EXECUTIVE SUMMARY vii INTRODUCTION 1 TEST OBJECTIVES 1 TEST SETUP 1 HIGH-SPEED CAMERA TIMING 3 TEST PROCEDURE 4 TEST RESULTS 4 CONCLUSIONS 9 v 1 2 3 4 5 6 7 8 9 10 11 LIST OF FIGURES Figure Page Containment Ring Section 2 Pretest Installation 2 Test Setup 3 Engine Acceleration Calibration 3 Power Turbine Speed and Break Paper Voltage Versus Time Test Data 5 Power Turbine Speed and Compressor Discharge Pressure Versus Time Test Data 6 Power Turbine Speed and Turbine Gas Temperature Versus Time Test Data 6 Posttest Engine 7 Posttest Left Side of Engine 7 Posttest Right Side of Engine 8 Disk Fragments 8 LIST OF TABLE Table Page 1 Weight of Disk Fragments After Burst 5 vi EXECUTIVE SUMMARY As a part of the Federal Aviation Administration 9s Aircraft Catastrophic Failure Prevention Program, the Naval Air Warfare Center Weapons Division under contract to the FAA William J. Hughes Technical Center conducted a turbine disk containment test. The purpose was to demonstrate the containment capability of the Kevlar ring against full-size T53 engine rotor fragments. A containment ring was designed and fabricated by Pepin Associates, Inc. and provided to the Naval Air Warfare Center, Weapons Division by the William J. Hughes Technical Center. The engine and containment ring were installed in an UH-1 Huey helicopter. The second stage power turbine disk was notched so that the disk would rupture at approximately 20,400 rpm. The engine was started and immediately accelerated to minimize the chance of a premature rupture. The event was recorded on high-speed film at 4000 pictures per second. The disk ruptured as the engine accelerated through 19,629 rpm. The disk ruptured into three equal sections (approximately 3.6 lbs. each). The result was a contained tri-hub burst with minor bulging of the containment ring and little sign of distress to the airframe. vii/viii INTRODUCTION This test was conducted as the final phase of the cDevelopment of Lightweight Containment Structures d project sponsored by the FAA William J. Hughes Technical Center under the Aircraft Catastrophic Failure Prevention Program. The objective of this effort was to develop and evaluate the aircraft rotor fragment containment materials and structures against a fully bladed T53 turboshaft engine second stage power turbine. The turbine disk was modified to burst at approximately 20,400 rpm to produce 1 x 10 6 in-lbs of kinetic energy. The T53 engine was selected to represent the medium turboshaft engines. Previous burst tests using modified T53 second stage power turbine disks were conducted in a vacuum spin chamber located at the Naval Air Warfare Center Aircraft Division in Trenton (NAWCAD-TRN), New Jersey. This test, as the final phase, was conducted at the outdoor test site at the Naval Air Warfare Center Weapons Division at China Lake, California. Kevlar, S-2 fiberglass, and polybenzbisoxazole (PBO) fabrics and cylindrical structures with reinforcements were evaluated and spin tested for disk fragment containment during the early phase of the program. Some of the tests were configured with the engine case and combustor as installed in the actual engine. The most promising material was PBO followed by Kevlar. Due to the time and funding constraints, the Kevlar material was used for the final phase. Pepin Associates, Inc. (PAI) fabricated the containment rings described in this report. TEST OBJECTIVES The primary objective of the test was to demonstrate the containment capability of the Kevlar ring that was designed and fabricated by PAI to contain the full-size T53 engine rotor fragments. A secondary objective was to study the effect of absorbing the rotor fragment energy on the aircraft during the containment event. This includes the interaction of the impacted containment ring, rotor fragments, and the engine accessories such as the combustor, vane, and case. TEST SETUP NAWCAD-TRN personnel modified the second power turbine and used the New Jersey Army National Guard facility for engine disassembly and installation of the disk. The second stage power turbine disk was weakened by removing three turbine blades, 120 ° apart. Then radial slots were machined from the blade firtree groove down into the disk. The tri-hub burst design and procedure are explained in detail in cEvaluation of Lightweight Material Concepts for Aircraft Turbine Engine Rotor Failure Protection d FAA Report DOT/FAA/AR-96/110. The notch created a stress concentration in the disk sufficient to cause an overload failure at normal operating speed. The containment ring was developed and fabricated by Pepin Associates Inc. The ring was fabricated with a 0.014-inch titanium inner and outer sleeve. One-inch-thick Kevlar 29 ballistic fabric made up the primary structure of the containment ring. The ring was strengthened with titanium rods which were inserted through the fabric and laser welded to the inner and outer sleeves (figure 1). The ring weighed approximately 25 lbs. The containment ring was installed on the test engine and loosely connected to the engine case. The ring was centered on the second stage power turbine. 1 FIGURE 1. CONTAINMENT RING SECTION The T53 engine was then installed in an UH-1 Huey helicopter (figure 2). The helicopter was mounted on two 2-foot-thick cement blocks and cabled down to three 1-foot-thick cement blocks (figure 3). The rotor head was removed to simplify the test setup and preparation. The engine was remotely started and operated. An emergency shutoff valve was located near the engine interface. FIGURE 2. PRETEST INSTALLATION 2 3 FIGURE 3. HIGH-SPEED CAMERA TIMING Even though the disk was notched, there was no way of determining exactly when or at what speed the disk would fail. apture the event on high-speed film, a speed trigger circuit was used. were approximately 8 seconds of film at a camera speed of 4000 pictures per second, 2.5 seconds of which were used as the cameras came up to speed. the test engine, a second engine was tested to determine the power turbine acceleration time from idle to maximum (figure 4). e conducted, and it was determined that the acceleration from idle to maximum was approximately 10 seconds. Idle speed was approximately 10,400 rpm and maximum was 22,500 rpm. ased on the engine acceleration times and the target rupture speed (20,400 rpm) and considering the camera time required to come to speed, a trigger speed of 14,000 rpm was chosen. 0 20 40 60 80 100 120 0 5000 10000 15000 20000 25000 1110 1115 1120 1125 1130 1135 1140 1145 1150 Time (sec) 10 Sec Accel Trigger Speed Cameras @ Speed Power Level Angle 3 PLA (deg) Power Turbine Speed - Np (rpm) FIGURE 4. INE ACCELERATION CALIBRATION TEST SETUP To c There Prior to installing Multiple runs wer B ENG TEST PROCEDURE The test was successfully conducted per the following checklist and procedure. Pretest Checklist 1. Install break-paper 2. Check fuel valve operation 3. Check camera views 4. Fuel system checkout. Reroute and protect fuel line 3 shutoff valve 5. Ignitor checks 6. Camera line checkout 7. Define the power turbine speed (Np) trigger speed 14,000 rpm 8. Load cameras Test Procedure 1. Open fuel valve 2. Verify cameras ready 3. Verify camera lines are unarmed 4. Begin data collection 5. Starter power ON and ignitors ON 6. Power level angle (PLA) to 25 deg 7. Disengage starter and ignitors at N2 = 50 % 8. Reset trigger system 9. Arm camera lines 10. Verify good start 11. Advance PLA to 100 deg 12. Ensure trigger is activated as Np passes 14,000 rpm 13. Ensure Np is accelerating to 20,000 at approximately 1500 rpm/sec Should take approximately 4 seconds 14. If Np reaches overspeed limit 22,000 rpm, continue engine running until disk ruptures. 15. After event close fuel valve. 16. Secure the pad; allow firefighters access to the pad as needed. TEST RESULTS The test was completed as planned. The cameras were triggered as Np passed through 14,000 rpm. The disk released at 19,629 rpm. Test data are provided in figures 5 through 7. The disk ruptured into three nearly equal sections that were contained by the containment ring. The outer titanium shell split due to the tensile load resulting from the disk fragments pulling the Kevlar into a triangular shape. All three disk fragments penetrated the engine combustor case. The fuel lines located between the containment ring and combustor case were penetrated, resulting in a small fire. Secondary blade fragments exited the engine exhaust nozzle and a few fragments 4 5 appeared to exit through the holes created by the disk fragments. fragments were low- energy releases. re provided in figures 8 through 11. The engine stayed within its mounts, with little apparent duress caused from the disk fragment energy being absorbed. The only noticeable sign of high vibration or loading was a broken throttle linkage. The disk fragments were recovered and weighed (table 1). riginal weight of 10.8 lbs included blades which were broken off during impact. roximately 2.65 lbs of debris was released. TABLE 1. EIGHT OF DISK FRAGMENTS AFTER BURST Disk Fragment Number Fragment Weight After Burst (lbs) 1 2.66 2 2.70 3 2.79 Total Large Disk Fragments 8.15 18000 18500 19000 19500 20000 20500 21000 21500 22000 -2 0 2 4 6 8 -4 -2 0 2 4 Power Turbine Speed - Np (rpm) Break Paper Voltage (V) Time (sec) FIGURE 5. OWER TURBINE SPEED AND BREAK PAPER VOLTAGE VERSUS TIME TEST DATA These Post event pictures a The o App W P 6 18000 18500 19000 19500 20000 20500 21000 21500 22000 -10 0 10 20 30 40 -4 -2 0 2 4 Power Turbine Speed - Np (rpm) Compressor Discharge Pressure - Ps3 (psig) Time (sec) FIGURE 6. OWER TURBINE SPEED AND COMPRESSOR DISCHARGE PRESSURE VERSUS TIME TEST DATA 10000 12000 14000 16000 18000 20000 22000 0 100 200 300 400 500 600 700 800 -5 -4 -3 -2 -1 0 1 Power Turbine Speed - Np (rpm) Turbine Gas Temperature - TGT ( 0 C) Time (sec) TGT ( 0 C) FIGURE 7. OWER TURBINE SPEED AND TURBINE GAS TEMPERATURE VERSUS TIME TEST DATA P P Frag. #2 Frag. #3 Frag. #1 FIGURE 8. POSTTEST ENGINE FIGURE 9. POSTTEST LEFT SIDE OF ENGINE 7 FIGURE 10. POSTTEST RIGHT SIDE OF ENGINE FIGURE 11. DISK FRAGMENTS 8 CONCLUSIONS The Pepin containment ring successfully contained the T53 second stage power turbine fragments. This fiber material, Kevlar 29 reinforced with titanium rods at 45 ° angles, is a good baseline ballistic fabric for containment structures. This is based on the specific containment fragment energy of the containment ring. All three fragments penetrated through the combustor case and were embedded inside the containment ring. Minimum interactions between the immediate engine components and fragments were observed. This test demonstrated the capability to contain a tri-hub burst on a medium sized turboshaft helicopter engine. Practical issues related to clearance for maintenance on a day to day basis as well as design for ring expansion during the failure are difficult challenges that must be considered for production of this type of a system. 9/10 Appendix 3 List of FAA Technical Reports Published in FY98 Report Number Title R&D Highlights 1998 Highlights of the major accomplishments and applications. DOT/FAA/AR-TN97/50 Comparison of Radial and Bias-Ply Tire Heating on a B-727 Aircraft DOT/FAA/AR-97/99 Fire-Resistant Materials: Research Overview DOT/FAA/AR-95/18 User 9s Manual for the FAA Research and Development Electromagnetic Database (FRED) DOT/FAA/AR-97/7 Advanced Pavement Design: Finite Element Modeling for Rigid Pavement Joints, Report II: Model Development DOT/FAA/AR-97/26 Impact of New Large Aircraft on Airport Design DOT/FAA/AR-97/64 Operational Evaluation of a Health and Usage Monitoring Systems (HUMS) DOT/FAA/AR-TN98/15 Fire Testing of Ethanol-Based Hand Cleaner DOT/FAA/AR-95/111 Stress-Intensity Factors for Elliptical Cracks Emanating from Countersunk Rivet Holes DOT/FAA/AR-97/9 An Acoustic Emission Test for Aircraft Halon 1301 Fire Extinguisher Bottles DOT/FAA/AR-97/37 Development of an Improved Magneto-Optic/Eddy-Current Imager DOT/FAA/AR-97/69 Automated Inspection of Aircraft DOT/FAA/AR-97/5 Marginal Aggregates in Flexible Pavements: Field Evaluation DOT/FAA/AR-97/87 A Predictive Methodology for Delamination Growth in Laminated Composites, Part I: Theoretical Development and Preliminary Experimental Results DOT/FAA/AR-TN97/103 Initial Development of an Exploding Aerosol Can Simulator DOT/FAA/AR-97/56 Applications of Fracture Mechanics to the Durability of Bonded Composite Joints A-1 Report Number Title DOT/FAA/AR-96/97 Stress-Intensity Factors Along Three-Dimensional Elliptical Crack Fronts DOT/FAA/AR96/119 Vertical Drop Test of a Beechcraft 1900C Airliner DOT/FAA/AR-98/22 FAA T53-L-13L Turbine Fragment Containment Test DOT/FAA/AR-97/85 Response and Failure of Composite Plates with a Bolt-Filled Hole DOT/FAA/AR-98/26 A Review of the Flammability Hazard of Jet A Fuel Vapor in Civil Transport Aircraft Fuel Tanks DOT/FAA/AR-TN97/108 Effects of Concentrated Hydrochloric Acid Spills on Aircraft Aluminum Skin DOT/FAA/AR-TN98/32 Cargo Compartment Fire Protection in Large Commercial Transport Aircraft DOT/FAA/AR-98/28 Statistical Loads Data for Boeing 737-400 Aircraft in Commercial Operations DOT/FAA/AR-97/47 Development of Advanced Computational Models for Airport Pavement Design DOT/FAA/AR-98/34 Health Hazards of Combustion Products From Aircraft Composite Materials DOT/FAA/AR-97/81 Bioremediation of Aircraft Deicing Fluids (Glycol) at Airports DOT/FAA/AR-TN97/8 Heats of Combustion of High-Temperature Polymers DOT/FAA/AR-95/29 FACT SHEETS Fiber Composite Analysis and Design: Composite Materials and Laminates, Volume I Note: This document 9s PDF is unique from the above documents in that some of the Adobe navigational tools cannot be used such as searching and bookmarking. To navigate in this document, page down to the Table of Contents, List of Figures, and List of Tables where the entries are linked to the body of the document. A-2

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