Development of Advanced Carbon Face Seals for Aircraft Engines

Abstract

Modern aircraft gas turbine engines require the development of seals which can operate for a long time with low leakages. The basic type of seals applied for gas turbine engine rotor supports is face seal. To meet the modern requirements of reliability, leak-tightness and weight, low-leakage gas-static and hydrodynamic seals have to be developed. Dry gas seals use both gas-static and hydrodynamic principles. In dry gas seals microgrooves are often used, which ensure the reverse injection of leakages in the sealed cavity. Authors have developed a calculation technique including the concept of coupled hydrodynamic, thermal and structural calculations. This technique allows to calculate the seal performance taking into account the forces of inertia, rupture of the lubricant layer and the real form of the gap. Authors have compared the efficiency of seals with different forms of microgrooves. Results of calculations show that seal with rectangular form of microgrooves has a little gap leading to both the contact of seal surfaces and the wear. Reversible microgrooves have a higher oil mass flow rate, whereas HST micro-grooves have good performance, but they are difficult to produce. Spiral microgrooves have both an acceptable leakages and a high stiffness of liquid layer that is important in terms of ensuring of sealing performance at vibration conditions. Therefore, the spiral grooves were chosen for the developed seal. Based on calculation results, geometric dimensions were chosen to ensure the reliability of the seal operation by creating a guaranteed liquid film, which eliminates the wear of the sealing surfaces. Seals designed were tested both at the test rig and in the engine.