Leveraging Additive Manufacturing in a Newly Designed and Commissioned Transonic Fan Research Facility

Despite the associated time, cost, and effort, experimental fan research remains necessary to validate computational models and physically develop new technologies. The need for a new fan research facility that would provide high quality experimental fan research at engine-representative speeds using detailed flow measurements was identified by the Office of Naval Research (ONR). The facility would be used to develop stall margin enhancement techniques, namely casing treatments to advance the field. In addition to support by ONR, Honeywell Aerospace donated a transonic fan rig and core exhaust plenum to make this project a reality.

The new research facility was designed and built around this new fan rig for investigations into casing treatments, inlet distortion, and aeromechanics research, as well as future projects that would make use of the new space. The funding package included a renovation of the build room in ZL1 and two brand new test cells constructed in previously empty space. All necessary equipment was designed, procured, and placed in the correct positions to ensure operability of the fan. The new space necessitated a mechanical checkout and commissioning process before conducting research projects.

In parallel to the development of the facility, a novel fan casing was designed to make use of rapid prototyping to experimentally test casing treatments. The fan casing assembly is made up of three metal components that remained fixed and six individual 3D printed plastic inserts that make up the flowpath surrounding the rotor. The geometry of each component was developed according to best-practices and computational structural analysis. Following commissioning of the fan test cell, the new fan casing was successfully implemented and tested over the full operating range of the fan.