NCMS Project #: 140724
Problem: The T700-GE-401C engine are jointly operated in all military services, powering H-60, AH-64 and AH1 aircraft. These types of aircraft are operated in both erosive and maritime environments. These austere operating environments degrade compressor airfoil condition and performance. When gas turbine engines degrade due to erosion of compressor airfoils, the resultant is higher fuel consumption, greater environmental engine emissions, greatly reduced engine reliability. Additionally, compressor airfoil corrosion is a leading cause of scrap during engine repair and overhaul. Each of these negative outcomes has a direct effect on increasing the cost of operating commercial and military aircraft.
Benefit: The overall benefits of the application of an EC/RC on compressor blades are significant such as: increase time-on-wing, retain engine power, increase engine compressor life, decrease amount of infield compressor washes, decrease maintenance actions, and reduce environmental impact per each engine repair & overhaul. This coating will also decrease overall maintenance costs and reduce compressor replacement, and spares reduction. Due to overall compressor efficiencies fuel savings would also be achieved. Lastly, the coating on the compressor blades would reduce manufacturing of critical materials such as titanium and ultimately decrease spare parts procurements.
Solution/Approach: This collaborative initiative will assess the benefits of applying a protective coating to gas turbine engine airfoils and will begin to conduct the required testing necessary to qualify the coating for flight. In order to properly assess the coatings potential this collaborative endeavor will leverage the U.S. Military T700 engine, whose commercial counterpart is the CT7. It is important to understand how the fatigue life is impacted prior to applying coatings to critical rotating components so that transition of these capabilities is possible and a certificate of flight worthiness can be obtained. This project will leverage ongoing joint initiatives currently evaluating engine compressor Erosion/Corrosion Resistance Coating (EC/RC) for increased durability, with extensions to field testing and evaluations. This effort complements NAVAIR’s activity as joint service lead to explore the benefits of ER/CR on the H-60 helicopter and to qualify this coating on T700 engine components used by the services.
Impact on Warfighter:
- Reduce logistics footprint
- Reduce demand for expensive long lead time of compressor components
- Improve maintenance capacity
- Increase aircraft readiness and throughput
- U.S. Navy, NAVAIR, Patuxent River
- MDS Coating Technologies
- General Electric Aviation
- Cost savings
- Repair turn-around time
- Maintenance avoidance and reliability
- Improved readiness
- Coatings/corrosion prevention