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<p>Fan blade out (FBO) events in aircraft engines pose a significant safety risk due to the high kinetic energy of rotating blades that fail the engine, leading to catastrophic danger to human life. Traditional metallic containment systems (Hard containment), while effective, contribute to significant weight penalties. This study explores a Ti–Kevlar-based fiber-metal laminate for a containment approach (soft containment) to achieve high impact resistance. A series of impact tests—both experimental and simulated—were conducted on laminates comprising of a 3.2&#xa0;mm thick Ti-6Al-4&#xa0;V alloy and 9 layers of Kevlar 29 (K-29) in [45, 0, 45, 0,45]s orientation. Results reveal that such laminates can withstand impact energies up to 515&#xa0;J and a velocity up to 4.85&#xa0;m/s. It is seen that the impact strength increases nearly threefold with the inclusion of K-29 in Ti-6Al-4&#xa0;V alloy. Finite element simulations accurately predicted deformation profiles and maximum indentation depths within ~ 10% of experimental measurements. 3D scanning and NURBS modeling confirmed residual displacements ranging from 14.6 to 17.8&#xa0;mm across impact energies, while radiographic analysis revealed progressive delamination and fiber fracture. The outcome highlights the high containment potential of the hybrid structure, making it a promising candidate for the next-generation soft-wall containment casing in gas turbine engines, thereby eliminating the threat to engines and subsequent loss of human lives.</p>

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Impact Performance of Ti–Kevlar Fiber-Metal Laminates for Jet Engine Fan Blade Containment: Experiments and Numerical Simulations

  • 期刊论文

  • 发表日期：

    2025年10月1日

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  • S. Sreemathi,
  • G. Jims John Wessley

摘要

Fan blade out (FBO) events in aircraft engines pose a significant safety risk due to the high kinetic energy of rotating blades that fail the engine, leading to catastrophic danger to human life. Traditional metallic containment systems (Hard containment), while effective, contribute to significant weight penalties. This study explores a Ti–Kevlar-based fiber-metal laminate for a containment approach (soft containment) to achieve high impact resistance. A series of impact tests—both experimental and simulated—were conducted on laminates comprising of a 3.2 mm thick Ti-6Al-4 V alloy and 9 layers of Kevlar 29 (K-29) in [45, 0, 45, 0,45]s orientation. Results reveal that such laminates can withstand impact energies up to 515 J and a velocity up to 4.85 m/s. It is seen that the impact strength increases nearly threefold with the inclusion of K-29 in Ti-6Al-4 V alloy. Finite element simulations accurately predicted deformation profiles and maximum indentation depths within ~ 10% of experimental measurements. 3D scanning and NURBS modeling confirmed residual displacements ranging from 14.6 to 17.8 mm across impact energies, while radiographic analysis revealed progressive delamination and fiber fracture. The outcome highlights the high containment potential of the hybrid structure, making it a promising candidate for the next-generation soft-wall containment casing in gas turbine engines, thereby eliminating the threat to engines and subsequent loss of human lives.