Reinforced High Temperature Titanium Metal Matrix Composite Systems For Impeller Applications In Advanced Army Turboshaft Engines

Superior high-temperature performance requirements for highly stressed rotating components of the compressor section in advanced Army turboshaft engines cannot be met by the existing materials and require sophisticated materials solution concepts. The objective of this SBIR program is to develop a reinforced high temperature titanium material system for impeller applications in advanced Army turboshaft engines to increase the performance, reduce the specific fuel consumption, and enhance the affordability. FMW, in collaboration with Honeywell Aerospace (aero engine original equipment manufacturer), proposed a nano-enhancement concept in Phase I and demonstrated the proof-of-concept via design trade studies, subscale article fabrication, and preliminary mechanical property evaluations. Nano-enhancement approach identified exceptional potential to meet the performance challenges in advanced turboshaft engine impellers. In Phase II, FMW-Honeywell team proposes to fully develop, optimize, scale-up, and mature the nano-enhanced titanium alloy impeller technology. A prototype impeller article, representative of the turboshaft engine, will be fabricated and machined into a fully-featured article for spin-pit testing. Manufacturability, machinability, and affordability aspects will be evaluated and risk reduction strategies will be developed. Detailed material characterization that includes microstructural quantifications, grain flow analysis, failure mechanisms, and microstructural variability analysis, will be conducted. Extensive testing on coupons extracted from various locations and orientations of the prototype article will be performed to generate material data under static and dynamic loading conditions at room and elevated temperatures relevant for the impeller. Impeller spin test data will be analyzed and compared with the baseline results to quantify the benefits. Phase II research and development effort will mature the nano-enhanced titanium impeller technology readiness to the level necessary for engine test demonstration.