doug ward - technische universität münchen · ge aviation 1 ge aviation doug ward chief...

GE Aviation

1 GE Aviation

Doug Ward Chief Consulting Engineer, Composites Chief Engineer’s Office

Symposium- TUM 5th Anniversary Institute for Carbon Composites Sept 11-12, 2014

2 TUM 5th Anniversary Composite Symposium

9/12/2014

Cleaner, quieter, faster, affordable

Fuel consumption

Emissions

Noise

Cost of ownership

Reliability

2 GE Aviation


9/12/2014

Composite fan blade … innovative technology changing the game

1988-UDF

1995-GE90

2004-GE90-115B 2011-GEnx


9/12/2014

Result of technology investment … dramatic improvements vs baseline

CF6-80C2 EIS: 1985

EIS: 2011

Fuel Burn NOx Noise D&C’s

15% 40% 13 db 50%

bett er SFC Lower CAEP 8 q u i e t e r f e w e r

Lean-burn combustor

23:1 HPC: highest pressure ratio in aviation

TiAL in LPT aft 2 stages

Composite fan case

Fewer, more efficient fan blades


9/12/2014

Engine Operating Conditions and Materials

Polymer Composites

Aluminum Alloys

Iron and Titanium Alloys

Nickel and Cobalt Alloys

Protective Coatings

Low Pressure Turbine 550 – 1025C

Fan & Compressor Ambient to 700C

Combustor 550 to 1100C

High Pressure Turbine 550 to 1150C

Ceramic Composites


9/12/2014

Engine Design Trends

Modern fans account for an increasing portion of total engine weight

Advances in cooling technology, improved hot section materials, and aerodynamic loading reduce the size of modern cores

Improving propulsive efficiency requires larger fans

CF6-80C2 Bypass Ratio = 5.3

Fan=21% of engine’s weight

GEnx-1B Bypass Ratio = 9.5

Fan=33% of engine’s weight

Larger fans are driving the need

for new lighter weight materials


9/12/2014

Composite Fan Design Considerations Fan blade weight drives propulsion system weight

• 1 kg weight increase on fan blade requires:

– 1kg increase in containment case weight

– ½ kg increase in rotor weight

– ½ kg increase in engine structure

– ¼ kg increase in aircraft structure

Carbon/epoxy material properties simultaneously reduce fan weight and improve durability over metalic structures

• Lighter weight (lower density)

• Increased specific stiffness

• Fatigue strength

• Damage & defect tolerance

Fan structural design requirements defined by rare “ultimate” events

• Fan blade out

• Large bird ingestion


9/12/2014

GEnx Composites

Fan Blade

Platform

Acoustic

Panels

Bonded Vanes

Ducts Fan Containment Case


9/12/2014

Composite technology advancement Improved performance and weight reduction

GE90-115B 777-200LR, -300ER, 777F

GE90-94B 777-200ER

GEnx 787, 747-8

• Swept aero

• 22 blades

• Wide chord design

• 22 blades

• Improved efficiency

• 18 blades

1995 2004 2011

LEAP 737 MAX, A320neo, C919

• 3D woven fiber and resin transfer mold

• 18 blades

2015 cert

Fan blade experience

Today: 30+ million flight hours

2016: 80+ million flight hours

Fan cases

• Integrated structure

• Saves 300+ kgs/aircraft

LEAP is a trademarks of CFM International, a 50/50 JV between Snecma and GE

Containment Analysis • GE Progressive Damage Material Model

Developed for Braided Composite material

Fan Blade Impact Analysis

Unique analytical capability is key to making the

composite fan a success

Predicted Vs. Actual Impact Strain

Time (sec)

Str

ain

Predicted Measured

Measured Radial Displacement

Predicted Radial Displacement

Composite Fan Module Simulation


9/12/2014

Containment Case Shell Material Wrap

Fan Case Manufacturing Processes

Resin Film Infusion process with braded pre-form

• Minimize labor & tooling costs

• Maximize performance

Case wrap & lay-up

Highly automated manufacturing processes

enable affordable manufacturing


9/12/2014

Strong Interrelationships

Fan case manufacturing

Wide variety of modern automated preform and cure technologies available to reduce manufacturing cost

Resin & fiber architecture combinations must be synergistic to obtain optimum performance

Long term supplier relationships defined by fundamental architecture decisions established early in program

Braid Twill Satin Non-Crimp Fabric

Resin System Fiber &

Arcitecture Process


9/12/2014

Process

Optimization

Resin

Wrapped Fabric

Tool

RFI (Resin Film Infusion)

Fan Case Processes Simulation

Highly automated manufacturing process minimizes hand labor

Process development requires multidisciplinary optimization

Thermal Model

Infusion Model

Cure Model

Resin Flow


9/12/2014

Material & Process Advancements … to solidify and expand the future of composite applications

High performance materials

• Toughened, processable resins

• Interface technology

• Higher modulus & strength fibers

• Higher temperature capability

• Coatings: erosion, thermal, etc.

Smart material design

• Multiple/hybrid materials

• Localized design

• Tailored architectures

Processing

• Automation

• Faster cycle time

• Process integration

Lower cost of introduction

• Structural analysis capabilities

• Modeling (ICME)

• Materials database(s) – Industrial collaboration

Increasing EHS regulations

Performance and cost are key drivers Must consider product life cycle


9/12/2014

Next generation composite technology …

80’s 00’s

Composite fan blades

(GE90)

10’s

Composite fan blades and case

(GEnx)

High temp composites

90’s

Unducted, composite fan blades

(UDF)

Expanded low-temp composites

Technology maturation and advancement

Moderate-temp composites

Core Nozzle

Turbine Blade

doug ward - technische universität münchen · ge aviation 1 ge aviation doug ward chief...

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