pps proceeding - Abstract Preview
pps proceeding
Symposium: S11 - Additive Manufacturing
Oral Presentation
 
 

3D printing of abradable polymer composite materials: Materials formulations and characterization

DERMANAKI FARAHANI Rouhollah (1)*, Hia Iee Lee (1), Brzeski David (1), Diouf Lewis Audrey (1), Piccierelli Nicola (2), Therriault Daniel (1)

(1) Polytechnique Montreal - Quebec - Canada, (2) Safran Composites - Itteville - France

Polymer-based abradable seal coatings are designed to minimize the clearance between the fan blade tips and the case in order to improve the performance of aircraft engines. Abradable seals are usually applied manually to the desired thickness to act as sacrificial layer between the blades and the case. In the present work, we investigate the direct deposition of a fine and porous acoustic structure made of commercially available aerospace-grade abradable material (i.e., epoxy resins with the addition of hollow glass microspheres) on flat glass substrates using an extrusion-based 3D printer. The abradable material composed of the resin and the hardener both filled with glass microspheres was fully characterized to assess its relevant properties for the new manufacturing process. First, the material (mixture of the resin and the hardener) was tested for its printability using printing nozzles of different inner diameters (IDs). Its high viscosity allowed materials deposition only with nozzles having relatively large IDs (>1 mm). As an indicator for the materials printability, viscosity measurements were performed by using a process-related capillary method and also in a standard rheometer. To find out their thermal properties, the materials (resin, hardener or their mixture) were tested in a Thermogravimetry Analysis (TGA) machine and in a modulated Differential Scanning Calorimetry (mDSC) equipment. The results obtained will further enable us to optimize the printing parameters for the deposition of finer filaments, not only to automatize the material applying process, but also to add other functionalities to the printed materials (e.g., acoustic) for aerospace applications.