Overview
The COMPOCOAT project developed a new surface protection system for the development of composite aero-engine aerofoil structures with metallic leading edge. The surface protection system was based on TWI’s CompoSurfTM family of coating technologies and provide erosion protection for the metallic leading edge and thermal protection for the composite body. In addition to the surface protection system, the Comeld® joining process was utilised for achieving high strength bonding in the metal-composite interface. The leading edge itself comprised of two fishbone shaped parts that facilitated further strength to the bond. The two parts were welded together by laser, ensuring aerodynamic surface at the edge tip.
The operating temperature for the new aerofoil structure was in excess of 360°C. Out-of-Autoclave (OoA) processing enabled the rate manufacture of the demonstration parts, thus improving the cost effectiveness of the production.
Funding
Results
Executive Summary:
The COMPOCOAT project had developed a new surface protection system for composite aero-engine aerofoil structures with metallic leading edge. The surface protection system was based on TWI’s CompoSurf family of coating technologies. It provided erosion protection for the metallic leading edge and thermal protection for the composite body. In addition to the surface protection system, the Comeld® joining process had been utilised for achieving high strength bonding in the metal-composite interface at the leading edge. Laser welding had been tested as potential welding method for joining the leading edge without any thermal impact on the composite.
The operating temperature for the new aerofoil structure was in excess of 250°C.