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Experimental study of the performance and endurance of carbon fiber brush seals for aero-engines bearing chambers

par Outirba, Bilal
Président du jury Degrez, Gérard
Promoteur Hendrick, Patrick
Publication Non publié, 2017-10-02

Thèse de doctorat

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Résumé :

Over the last decades, it has been progressively acknowledged that reducing the specific fuel consumption and the emission of pollutants as well as improving the thrust-to-weight ratio involves extensive research on advanced sealing technologies. Amongst these, brush seals are particularly well considered for their excellent leakage performance, their low friction properties, and their ability to cope with inevitable rotor excursions during flights. This thesis presents the experimental work that has been carried on in order to characterize carbon brush seals performance in function of the bristle pack geometry and the operating conditions. The analyzed parameters are the bristle free length, the density, and the inter-platedistance. The work, performed by the ULB in collaboration with French engine manufacturer Safran Aircraft Engines, provides first, a description of the test installation that reproduces accurately the severe working conditions encountered in a bearing chamber. A total of eight samples were submitted to extensive testing, and allowed to perform a qualitative analysis of the main performance indicators of a brush seal: the leakage flow, and the seal torque. Complex phenomena acting on the bristle pack were put in evidence under the effect of differential pressure androtation speed, and oil, which fundamentally deteriorate the leakage performance of a brush seal. Subsequently, performance models were developed through empirical correlations, based on the experimental data. They predict the leakage flow and the seal torque as a function of the geometrical parameters and operating conditions. In addition, hysteresis issues were also addressed, and an IR camera helped investigating the heat generation properties of a brush seal.Brush seal samples were submitted to endurance testing, in order to highlight wear mechanisms, and study the performance degradation with the operating time. Oil plays a major part in extending brush seals operating life, despite the leakage performance degradation. Finally, the correlations developed throughout the PhD thesis were used to develop an optimization process in function of the operating conditions of a modern aero-engine. Ultimately, large savings in air consumption were put in evidence when replacing labyrinth seals by brush seals.