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Old 01-25-2007 | 01:14 PM
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Harley Condra
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From: Longwood , FL
Default RE: Bypass material

I have had not one, but two turbine wheel failures caused by bearing failure way back when, with RAM 750 PLUS engines.
In one case, the exhaust nozzle was blown off the engine, and in the other, it managed to stay on. In both cases, the turbine wheel shed multiple blades when the wheel contacted the NGV, puncturing the engine case and nozzle.
The BVM bypass tube contained all of the fragments, (except the departed nozzle), exhibiting no signs of internal damage. The RAM engine has a stainless steel containment ring around the wheel which is supposed to slow down or stop fragments to minimize the damage as the carbon bypass tube isn't designed to contain a turbine wheel explosion.

The airframe was not damaged in either case.....I guess the containment ring did it's job. BTW, it had the exterior BVM Kevlar containment ring installed also.

Darryl, here's the reason:
It's not for fashion; The BVM bypass tube is made from a high temperature epoxy resin and carbon cloth in order to have more stiffness and higher heat resistance and than any comparable thickness E-glass or S-glass low temperature epoxy resin laminate can offer. It will retain it's shape at the operating temperatures that heat soak it, especially during ground opeations.
The high temperature resin and the carbon cloth will also allow you a few more seconds to get a fire put out, which I view as insurance in an expensive airframe.
There is a laminate of 2 oz. glass skin to help "compact" the carbon cloth and make the exterior smoother, (Many of us like to paint them). After the wet layup and room temperature cure is complete, high temperature resins receive a "post cure" (about 450 F oven) which cures the resin further, allowing the resin system to withstand much higher temperatures than it will hopefully ever see.
Normal epoxy resins (low temp) soften with temperature increases. That's why Burt Rutan (and other knowledgeable composite engineers) always recommends painting composite airplanes white.

Bypass tubes made from low temp resins and boat cloth are much cheaper to produce, but are very old tech.
But, as you have so eliquently stated, you can charge more for a carbon bypass tube. I'll bet that you would have to, as basic market economics would dictate.

Harley Condra
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