Waterjet Techniques for Composite-Material Jet Engine Component Repair

This proposal addresses the development of a versatile, low-cost tool and techniques for its application to the repair of composite materials in jet engine components. This tool will consist of a waterjet, abrasive-waterjet, or an abrasive suspension jet. The repair process may include several functions, such as the removal of components to be repaired, performing a repair function, adding features such as holes or slots, or reconditioning surfaces. The versatility of the waterjet tool lies in its ability to perform all of the above repair functions on almost any material. Current methods of repair and their deficiencies will be surveyed, focusing on techniques used for composites in other aircraft structures and for metal cold- section blades and vanes. Waterjet machining techniques to replace or enhance these methods will be identified. Case studies will be selected with components supplied by General Electric Aircraft Engines. We will also perform a comparative analysis on cost of repair. The functional requirements of the waterjet tool will be determined for the applications to be identified in this project. These functional requirements will be used to identify future repair processes and machine development needs to be addressed in Phase II.