GE Aviation. Titanium Utilization & An Aircraft Engine OEM Perspective. David Linger

Transcription

1 GE Aviation Titanium Utilization & Vision For The Next Decade: An Aircraft Engine OEM Perspective David Linger September 16, 2009 Aviation Ti-Team Jon Blank Mike Peretti David Linger Andy Woodfield Eric Ott

2 Agenda Business Update Material Trends & Case Study Novel Ti Manufacturing Additive Manufacturing A Perfect Storm Supply Chain 2

3 A global provider of engines, systems and services Segments Commercial Military Business & General Aviation 3

4 GE Aviation portfolio $19.2B ($ in bilions) Commercial engines Commercial engine services Military engines & services 08 Revenue a) $5.2 $6.8 $4.2 Systems Business & General Aviation Unison Engine Components 08 Revenue $2.2 $0.4 $0.4 A leading aviation technology business (a-includes GE s 50% ofcfm I& EA CFM Iis a 50/50 JV betw een GE and Snecm a EA is a 50/50 JV GE and Pratt& W hitney 4

5 Commercial outlook strong Commercial engines Commercial installed base Most popular on regional 1,230 engine backlog Most popular on single-aisle 5,850 22,400 engine backlog 22,400 CFM Most popular on Boeing engine backlog 13, Most popular on 5,200 14,000 wide-bodies ,300 2,300 engine 4,500 backlog F GE EA Fleetin active com m ercialservice Source:CASE,GE internalstudies GP7000 developed by GE/P&W Engine A liance CFM Iis a 50/50 jointcom pany betw een GE and Snecm a 5

6 Material Trends -Composites -Titanium

7 Composites Acoustic Panels Fan Blade Platform Bonded Vanes Fan Containment Case Ducts 7

8 Gamma TiAl Turbine Blades World s First Certified Intermetallic Material Application TiAl 8

9 Material Options fic Streng gth a/(mg/m 3 )) Speci (MP Titanium Alloys Gamma TiAl ~ 50/50 Ti and Al Ti good to ~ 550C Al good to ~ 250C Gamma TiAl good to ~ 800C It s a miracle!!! TiAl Alloys Single Crystal Superalloys 50 Mg Al Superalloys CMC Refractory Metals and Intermetallics Temperature (ºC) REF.Advanced M eta lic M aterials,da lis Hardw ick,afrl

10 LPT Blade Manufacturing Sequence Casting Ingot Production Melt and cast parts Pre HIP Solution HIP Post HIP Heat Treat Xray/FPI (repair as necessary) Machining and coating LPT Assembly 10

11 Pre Introduction Test Components All three cast gamma components successfully machined and engine tested. 11

12 Novel Manufacturing

13 BlueArc ECDM Rapid Roughing A new high speed electro-erosion process: Simultaneous Discharge/arcing High Current Abundant Flushing Added relative interelectrode surface motion for process stability improvement Sparks & Globules Fast Feed Electrode wheel (Steel, copper, brass, etc) Electrolytic coolant fills gap Grinding Application Surface finish on Ti64 Achieved 4X cycle time/75% tooling cost reduction as compared with the mechanical milling Rapid material removal rates, 5-15 in 3 /min, with low HAZ, 0-5 mil. 13

14 Projection Welding of Bosses Solid state fabrication process for hollow bosses/ports Pneumatic Cylinder Spring Independent Fixture Block Hard Stop Moveable Machine Platen Upper Part Clamp Lower Part Clamp Fixed Machine Platen 14

15 Additive M anufacturing

16 Bulk Deposition Technologies Spray Casting- Cold Spray- Metal Injection Molding- Metal Powder Laser Sintering- Electron Beam Melting- 16

17 Feature Deposition Technologies Plasma Transferred Arc Solid Free Form Fabrication- Electron Beam Free Form Fabrication- Laser Net Shaped Manufacturing- 17

18 History Tells Us

19 Em ergence ofalum inum in the Market (2006$/lb) >10,000 $/lb 350 $/lb 1852 Hal-H eroult& Bayer Processes Revolutionized Alum inum Transitioning itfrom a Precious Pre Metalto a Common Material Ave erage Price 1 $/lb 1886 Hall-Heroult Process -Alum inum Sm elting 1888 Bayer Process -Alum ina extraction from ore st all-alplane $/lb $/lb Demand (Metric Tonnes) 19

20 The PerfectStorm Additive M anufacturing Converges with Meltless TiPow der

21 Meltless Ti Alloy Powder is Alternative ti to Ti sponge - lower cost, higher h quality, and more versatile New breakthrough chemical and electrochemical powder synthesis Vital for more efficient i downstream processing Enables new novel Ti alloys Accelerates & broadens use of direct metal powder consolidation The Vision for Meltless Ti OR Pow der Pow der Consolidation MilProduct Near NetShape 21

22 Meltless Ti Alloy Eco Benefits 2/3 Less Energy Consumption 50% Less CO 2 emissions Processing infrastructure Transportation energy 2 GE Aviation Annual Energy Savings Material Synthesis >341 billion BTU/yr. * benefit vs. Kroll thru billet Component Processing >55 billion BTU/yr. *Assuming only 20% yield Product Use % Specific Fuel Consumption 22

23 NovelA loys

24 NovelMeltless A loys Meltless Ti Alloy Cap pability Strength / Temp. Kroll Ti + Melting Meltless Ti approach enables revolutionary new alloys and capabilities 24

25 Novel Titanium Alloys New Capabilities Strength Modulus Corrosion Current Fatigue New Temperature Wear New Capabilities = Market Growth 25

26 Applications Booster spool and blades HPC spool disks/blades Outer duct (Military) Ti HPC case / vanes Engine mount Outer turbine static parts (Military) MLE Tip cap Trailing edge Tail cone (not visible) Afterburner case (Military) Fan disks (not visible) Fan case (Military) Fan frame (not visible) Bearing housing (not visible) Heat shield HPC disks/blades further back in compressor Nozzle case (Military) Alloy Tubing/Ducts (Military) CP Ti Ti-64 Ti-64/Ti Novel 26

27 Novel Ti Alloy Enables Expanded Use Weight Ti Cases -Replace steel cases Lower stator weight Improved clearances Temperature Ti Disks/Shafts - Replace Ni/steel components Lower rotating weight Lighter stator weight Improved designs Temperature Ti Airfoils - Replace Ni/steel blades/vanes Lower rotating weight Lighter stator weight Engine levelbenefit Up to75lbs 3-5m ilclearance % SFC % Fuelburn 27

28 Supply Chain

29 Develop Supply Chain Powder Supplier Consolidator Processing Mill Product Ti Alloy Powder Producer Consolidation Ti Alloy GFM Billetizing Ti Alloy Bar Roll Novel Manufacturing Chemical Industry PM Industry Metals Industry Mtl Metals Industry Id Manufacturing Packaging PM Additive Manufacturing Part 29

30 Meltless Ti Alloy Technology A New Titanium Supply Chain Ti Alloy Powder Meltless Ti Powder Metallurgy Material Synthesis Efficient chemical processing Direct alloying Component Processing 40% improvement in material yield 50% reduction in process steps Novel Alloys Near Net Shape Substitute mill products 50% less mfg cost Technology Net shape processing 75% less mfg cost Novel alloys enhanced properties 30

31 Thank you!