Lowering Integrally Bladed Rotor Sustainment Costs Through Mistuning Characterization of Intentionally Mistuned Blades

The objective of the proposed work is to develop measurement equipment and analysis methods that are required to characterize mistuning in Integrally Bladed Rotors (IBRs) that have intentionally mistuned blades for the purpose of supporting airfoil Foreign Object Damage (FOD) and repair limit expansion. The proposed work will expand IBR mistuning bench characterization technology to newer engine designs. New engines utilize two additional design technologies that make vibration testing and analysis more challenging: blades have intentional (A/B) mistuning and blade vibratory response is excited by asymmetric vane spacing. Blade Diagnostics Corporation (BDC) develops systems for measuring and analyzing the geometry and vibratory response of integrally bladed rotors (IBRs). Their product, SmartBlend« Systems (SBS), incorporates next generation testing and analytics for active propulsion fleet maintenance. SmartBlend uses specific information about each part to safely repair more IBRs and quickly return them to service, thus, reducing maintenance costs and improving fleet readiness. The SBS IBR data becomes part of a database which can be used to inform decision makers for improved workflow, repair strategies, and IBR asset management. BDC worked with AFRL (Dayton) and ALC (Oklahoma City) to build and install a SmartBlend System for evaluating F119 IBRs at the ALC where it has been fully integrated into the F119 repair workflow. Based on F119 damage rates it has been estimated that fully implementing SmartBlend technology for the F135 would provide an ROI of more than 30 to 1. The purpose of the proposed work is to compliment BDCs 19.2 and X21.1 SBIR projects by developing an Adapter Kit for the F135 2nd Fan IBR and technology enhancements to address A/B mistuning and A/V excitation. If BDC is awarded a Phase II, then ALC has committed to use the project deliverables to evaluate F135 2nd Fan IBRs in the ALC-OC repair depot.