AIA Report On High Bypass Ratio Turbine Engine Uncontained Rotor Events And Small Fragment Threat Characterization Volume 1 AIA Project Report on High Bypass Ratio Turbine Engine Uncontained Rotor Events and Small Fragment Threat Characterization 1969-2006 Volume 1 January 2010 1969 –2006 HIGH BYPASS COMMERCIAL TURBOFANS 1 AIA Report On High Bypass Ratio Turbine Engine Uncontained Rotor Events And Small Fragment Threat Characterization Volume 1 Contributing Organizations and Individuals Ranee Carr AIA Hubert Parinaud Airbus Terrance Tritz Boeing Commercial Aircraft Van Winters Boeing Commercial Aircraft Thalerson Alves Embraer Sarah Knife (Chair) General Electric William Fletcher Rolls-Royce Michael Young Pratt & Whitney Douglas Zabawa Pratt & Whitney 1969 –2006 HIGH BYPASS COMMERCIAL TURBOFANS 2 AIA Report On High Bypass Ratio Turbine Engine Uncontained Rotor Events And Small Fragment Threat Characterization Volume 1 Table Of Contents Contributing Organizations and Individuals ................................................ 2 Table Of Contents ..................................................................................................... 3 Table of Figures ......................................................................................................... 6 List Of Tables .............................................................................................................. 8 Executive Summary ................................................................................................. 9 1. Introduction........................................................................................................... 15 2. Approach............................................................................................................... 18 2.1 Scope 18 2.2 Data collection process ....................................................................................... 19 2.3 Definitions........................................................................................................... 20 2.4 Analysis............................................................................................................... 22 3. Historical perspective on incidence of disk uncontainment ................................. 23 3.1 Results................................................................................................................. 23 3.2 Discussion........................................................................................................... 24 3.3 Experience in 2007-2008 ................................................................................... 26 4. Results................................................................................................................... 27 4.1 Number of Disk Uncontained events.................................................................. 28 4.2 Disk uncontained events by flight phase ............................................................ 28 4.3 Disk uncontainments by module......................................................................... 32 4.4 Engine speed at disk uncontainment................................................................... 33 4.5 Fires resulting from disk uncontainment ........................................................... 34 4.6 Small Fragment Impacts To Airplane Structure, from Disk Uncontainment..... 36 4.6.1 Number Of Holes Per Event- Results .............................................................. 37 4.6.2 Number Of Holes Per Event- Discussion ........................................................ 39 4.6.3 Effect Of Structure Impacted........................................................................... 40 4.6.4 Damage done inside the hole- Results............................................................. 44 4.7 Large Fragment Impacts To Airplane Structure, from Disk Uncontainment..... 47 4.8 Damage to airplane systems................................................................................ 49 4.8.1. Systems Damage- Results............................................................................... 52 4.8.2 Systems Damage - Discussion......................................................................... 52 4.9 Installation effects............................................................................................... 53 4.9.1 Results – small fragments ................................................................................ 53 4.9.2 Results – large fragments................................................................................. 53 4.9.3 Discussion........................................................................................................ 56 4.10 Small Fragment Masses .................................................................................... 57 4.10.1 Small Fragment Masses - Results.................................................................. 57 4.10.2 Small Fragment Masses -Discussion ............................................................. 58 4.11 Fragment release speeds ................................................................................... 59 4.11.1 Small Fragment Speeds - Previous work....................................................... 59 4.11.2 Large Disk Fragment speed -results ............................................................. 59 4.11.3 Discussion Of Large Fragment Estimated Speeds......................................... 60 5.0 Qualitative Discussion Of Small Fragment Energy................................................ 62 1969 –2006 HIGH BYPASS COMMERCIAL TURBOFANS 3 AIA Report On High Bypass Ratio Turbine Engine Uncontained Rotor Events And Small Fragment Threat Characterization Volume 1 5.1 Small Fragment Energies – Trajectories And Collected Masses....................... 62 5.2 Small fragment energies – penetrations of aircraft structure.............................. 63 5.3 Phase II............................................................................................................... 64 6.0 Discussion............................................................................................................... 66 6.1 Previous studies .................................................................................................. 66 6.1.2 Airplane-level consequence studies................................................................. 66 6.2 Probabilistic design goals ................................................................................... 69 6.3 Ricochets............................................................................................................ 71 6.4 Small Fragment Model ....................................................................................... 73 7.0 Conclusions............................................................................................................. 74 7.1 Disk uncontainment ............................................................................................ 74 7.2 Small Fragments Resulting From Disk Uncontainment ..................................... 75 7.3 Blade uncontainment .......................................................................................... 76 8.0 Recommendations................................................................................................... 77 9.0 References............................................................................................................... 79 Appendix 1 Disk Burst Event List................................................................................ 80 Appendix 2 Actions Taken To Prevent Disk Burst ...................................................... 81 Appendix 3 Blade Non-Containment ........................................................................... 90 Summary....................................................................................................................... 90 A3.1 Introduction.......................................................................................................... 90 A3.2 Forward Arc Discussion ....................................................................................... 91 A3.2.1 Event Rates ................................................................................................... 92 A3.2.2 Discussion Of Rates...................................................................................... 94 A3.2.3 Event Severity............................................................................................... 98 A3.2.4 Qualitative Fragment Damage – Forward Arc............................................ 110 A3.2.5 Forward Arc Events And Flight Phase ....................................................... 110 A3.2.6 Installation Effects .................................................................................. 111 A3.3 Casing Uncontainment Of Blades....................................................................... 112 A3.3.1 Event Rates ............................................................................................. 112 A3.3.2 Discussion Of Rates................................................................................ 114 A3.3.3 Event Severity........................................................................................ 114 A3.3.4 Qualitative Fragment Damage – Casing Uncontained................................ 120 A3.3.5 Casing Uncontained Events And Flight Phase ........................................... 121 A3.3.6 Installation Effects .....................................................................................