Composites: A Multi-industry Perspective LCC 5th Anniversary Symposium September 11, 2014 Dr. Matthew Beaumont Imagination at work.
GE a heritage of innovation 1892 300,000 $150 1 FOUNDED EMPLOYEES WORLDWIDE BILLION IN ANNUAL REVENUE COMPANY IN DOW JONES INDEX ORIGINALLY LISTED IN 1896 2
GE today Power & Water Energy Management Oil & Gas GE Capital Healthcare Aviation Transportation Home & Business Solutions Aligned for growth 3
Expanding our global presence 1900-1999 2000-2009 2010+ Advanced Manufacturing and Software Technology Center Detroit, MI Global Research Headquarters Niskayuna, NY O&G Tech Center Oklahoma Global Research Europe Munich, Germany 2X Size + Customer Innovation Center Israel Russia Japan Software CoE San Ramon, CA Welch Technology Center Bangalore, India China Technology Center Shanghai, China + 3 Customer Innovation Centers Brazil Technology Center Customer focused R&D Rio de Janeiro, Brazil 4
Specific Modulus Specific Strength GRC Composites Technologies Simulation Damage Tolerance Design Testing Fan Blade Materials Niskayuna, New York Munich, Germany Bangalore, India Manufacturing Composite Properties (60% Fiber Volume) Relative to Metal 7 6 5 4 Specific Modulus Specific Strength 35 30 25 20 Inspection Processing 3 15 2 10 1 5 0 0 Stainless Steel Aluminum 7075 Titanium 6-4 E-Glass S-Glass Kevlar 49 Nextel 610 T700S AS4 IM7-6000 Carbon Fibers T800S IM10 5
Evolution of composites use in GE Nacelles Thrust Reverser Off-shore Riser Pipes Fan Blade Fan Case Ducts Aviation Aviation Wind Aviation Wind Oil and Gas Wind Turbine Blades 6
Aviation
GEnx composites use Acoustic Panels Fan Blade Platform Bonded Vanes Fan Containment Case Ducts 8
GE Aviation composite manufacturing Batesville, MS, USA Second composites plant announced for Ellisville, MS, USA Middle River, MD, USA Hamble, UK Gloucester, UK San Marcos, TX, USA 9
Wind Energy
Wind blade shell production Outer Shell Layers Positioning of Prefabs Core Material Inner Shell Layers Shell Infusion 11
High volume serial production Managing the supply chain for wind turbine blades Making improvements to manufacturing processes Increasing quality while decreasing cost Maximizing the effectiveness of glass fibers 12
Oil & Gas
What are flexible pipes used for? Transfer Lines Tend to be large diameter pipelines connecting two structures which are often dynamic Jumpers Short lengths of pipe connecting two fixed structures either above or below water Risers Pipes suspended in the water column connecting FPSOs to subsea infrastructure Flowlines Static pipelines used to carry fluids on the sea bed Designed to have the strength and durability associated with rigid steel pipes, flexible systems are often the only solution for risers in dynamic environments 14
Hybrid flexible pipe design concept Composite Armor Optimized fiber angles and thicknesses to meet design requirements with minimum mass; fewer layers for easier inspection Thermoplastic Matrix PVDF - qualified pipe material Carbon Fiber Not susceptible to environmental stress corrosion; chemically resistant Smooth Bore Option For smaller diameter / lower temperature applications low pressure drop & improved flow assurance Metallic Carcass High temperature collapse resistance; well characterized performance Bonded Liner/Barrier PVDF - with high chemical resistance; reduced permeated gas risks; easier inspection Metallic Tensile Armor Straightforward means to attach mature end fitting technologies; stable dynamics; industry experience; impact damage tolerance 15
Replacing the tensile armour layer with thermoset composite profile Tensile Test Bend Test 16
Gas turbine inlet plenum 17
Composite inlet system initiative Advantages of replacing a welded stainless steel inlet plenum with a glass fiber composite structure: Weight reduction Cost reduction Volume reduction Improved airflow Anti oxidation material 18
The Brilliant Factory
Process informatics 6 sigma tools Data Information Knowledge Faster Process Development Traceability Increase capacity Improved quality and process capability Cost reduction opportunities Faster Root Cause Analysis Robust Process Designs Knowledge fusion across time-scales Yield and Process Control Yield Maintenance Cost Reduction 20
The brilliant factory Supply Chain Network digital thread forms 21 st century Self-improving Manufacturing ecosystem Smart Factory Virtual Product Design Virtual Manufacturing Service/Repair Shop 21
GE-TU Munich Collaboration GE-GRC and the TUM - LCC began a general agreement for research collaboration in 2010 with a pledge of 5M. With this money, GRC has been sponsoring 6 doctoral theses with advisors from GE: Fiber placement Textile draping Removable mandrel materials Thermoplastic forming Curing simulation Composite-metal hybrid structures 22