volvo aero corporation proprietary information. this information is subject to restrictions on first...
TRANSCRIPT
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 1
Flygteknik 2010
18 - 19 Oktober 2010
NEW MATERIALS IN THE DESIGN AND MANUFACTURING OF HOT STRUCTURES
FOR AIRCRAFT ENGINES ALLVAC 718PLUS
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 2
1. Volvo Aero Engine Components
– ’Make it Light Strategy’
2. Present and Future Material Demands
3. Alloy 718
4. Efforts with Existing Alloys
– René 220 and IN939
5. Evolution of Alloy 718 type materials
– Allvac 718Plus
6. Summary
Flygteknik 2010
18 - 19 Oktober 2010
Outline
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 3
Volvo Aircraft Engine Components
Flygteknik 2010
18 - 19 Oktober 2010
’HOT Parts’
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 4
IN718
Fabrication for low weight
Pressure for higher temperatures
Lower weight
Lower cost
Flygteknik 2010
18 - 19 Oktober 2010
State of the Art for Hot Structures
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 5
Temperature – HOTTER
Mechanical properties - BETTER
Cost – LOWER
Available in all material forms – wrought, sheet, cast – OF COURSE
Joining, forming, machining, repair – NO PROBLEM
Risk – NONE
Flygteknik 2010
18 - 19 Oktober 2010
The Hot Structure Designers Dream of New Materials
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 6
Stable alloy and processing specs!
Durability (fatigue, crack prop, thermodynamic stability)
Defect control methods available
Environmental resistance
Environmentally friendly
Available from several suppliers
Available for decades to come
Flygteknik 2010
18 - 19 Oktober 2010
… and of course!
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 7
Compressor Rear Frame - CF6 80C
Temperature 650℃
Cast central body
Front, rear wrought rings joined by EB-welding
Alloy 718 – ”excellent” weldability
Flygteknik 2010
18 - 19 Oktober 2010
Good ’Old’ Alloy 718(Since 1959)
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 8
Flygteknik 2010
18 - 19 Oktober 2010
Effort with a New (1990) Alloy René 220
Compressor Rear Frame - CF6 80E
80E to run close to 700 ℃
Cast central body cast René 220 (max 700 )℃
Wrought Alloy 718 front and skirt parts joined to casting by EB-welding
Two different materials – 718 + René 220 - joined!
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 9
Flygteknik 2010
18 - 19 Oktober 2010
IN 939 Temptation
Compare alloy 718 High temperature
200 ºC over alloy 718
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 10
Flygteknik 2010
18 - 19 Oktober 2010
CLEAN IN 939 Development Effort
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 11
There are no perfect castings!
Flygteknik 2010
18 - 19 Oktober 2010
IN 939 Parts Can Only be Cast…
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 12
Flygteknik 2010
18 - 19 Oktober 2010
IN 939 Weld Repair Draw Back
’Soft’ filler material, C263
Grind outGrinding
Overaged material
The art of avoiding new cracks!
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 13
No casting without weld repair!
Flygteknik 2010
18 - 19 Oktober 2010
and
Again!
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 14
Alloy 718 Max 650℃
Allvac 718Plus 700℃
Waspaloy Max 750℃
Flygteknik 2010
18 - 19 Oktober 2010
New promises!
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 15
Early work 1990’th Allvac
MAI (Materials Affordability Initiative) program
– US Air Force funding
Joint effort
– GE, Honeywell and P & W
– Firth-Rixson and Ladish Co (forgers)
– Primary metal producers Allvac and Carpenter Technology
– Air Force Research Laboratory
Flygteknik 2010
18 - 19 Oktober 2010
718Plus
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 16
Since 2002
All OEM’s do individual work
Joint Assessment Program for materials data base
Vital program – Volvo Aero + ITP
Flygteknik 2010
18 - 19 Oktober 2010
718Plus European Work
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 17
Wrought parts
Sheet metal
Cast material
and
WELDABILITY
Flygteknik 2010
18 - 19 Oktober 2010
Remember!For Volvo low weight assembly parts we need
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 18
Flygteknik 2010
18 - 19 Oktober 2010
718Plus Wrought Material’All in Place’
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 19
• AMS specification
• Material data bases
• Approved for flying application
• GE 90 LPT
• Still – the alloy is sensitive to heat treatment variations
Flygteknik 2010
18 - 19 Oktober 2010
718Plus Wrought Material’All in Place’
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 20
Flygteknik 2010
18 - 19 Oktober 2010
718Plus Sheet Material
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 21
But!
– No AMS spec.
– Sensitive to processing
Still
– Allvac tunes the processing
– Spec. in one year
Flygteknik 2010
18 - 19 Oktober 2010
718Plus Sheet Material
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 22
Flygteknik 2010
18 - 19 Oktober 2010
718Plus Cast MaterialThe VITAL program
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 23
Part of the MAI program
– Some draw backs
VITAL
– Confirms results from the MAI program
New MAI program
– Spec. in two years?
Flygteknik 2010
18 - 19 Oktober 2010
718Plus Cast Material
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 24
Weldability!
Flygteknik 2010
18 - 19 Oktober 2010
The key issue
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 25
No cracking!
– Not when the weld solidifies
– Not in the heat affected zone during cooling down
– Not in the heat treatment afterwards
Flygteknik 2010
18 - 19 Oktober 2010
Weldability?
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 26
No cracking during EB welding.
At par with Alloy 718 at weldabiltiy testing (Varestraint, TransVarestraint and Gleeble testing).
Improved understanding of homogenization and weld repair of cast material!
Flygteknik 2010
18 - 19 Oktober 2010
Weldability
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 27
• A ”sucessful” alloy > 650 for structures ℃ must meet
– Strength performance
– Cost performance
– All – wrought, sheet and cast – product forms
– Excellent weldability – on par with Alloy 718
• 718Plus offers 700℃– Wrought OK
– Sheet in one year
– Cast in two years
– Weldability is the strongest point
Flygteknik 2010
18 - 19 Oktober 2010
Summary
Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.
Joel Andersson
10110 Utg. 12
Slide 28
Flygteknik 2010
18 - 19 Oktober 2010
Thank You for your attention!