GE Aviation Doug Ward Chief Consulting Engineer, Composites Chief Engineer s Office Symposium- TUM 5th Anniversary Institute for Carbon Composites Sept 11-12, 2014 1 GE Aviation
Cleaner, quieter, faster, affordable Fuel consumption Emissions Noise Cost of ownership Reliability 2 GE Aviation
Composite fan blade innovative technology changing the game 2004-GE90-115B 2011-GEnx 1995-GE90 1988-UDF 3
Result of technology investment dramatic improvements vs baseline Composite fan case Fewer, more efficient fan blades Lean-burn combustor TiAL in LPT aft 2 stages CF6-80C2 EIS: 1985 23:1 HPC: highest pressure ratio in aviation EIS: 2011 Fuel Burn NOx Noise D&C s 15 % 40 % 13 db 50 % better SFC Lower CAEP 8 q u i e t e r f e w e r 4
Engine Operating Conditions and Materials Fan & Compressor Ambient to 700C Combustor 550 to 1100C High Pressure Turbine 550 to 1150C Low Pressure Turbine 550 1025C Polymer Composites Aluminum Alloys Iron and Titanium Alloys Nickel and Cobalt Alloys Protective Coatings Ceramic Composites 5
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 Larger fans are driving the need for new lighter weight materials GEnx-1B Bypass Ratio = 9.5 Fan=33% of engine s weight 6
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 7
GEnx Composites Acoustic Panels Fan Blade Platform Bonded Vanes Fan Containment Case Ducts 8
Composite technology advancement Improved performance and weight reduction GE90-94B 777-200ER GE90-115B 777-200LR, -300ER, 777F GEnx 787, 747-8 LEAP 737 MAX, A320neo, C919 1995 2004 2011 2015 cert Wide chord design 22 blades Swept aero 22 blades Improved efficiency 18 blades 3D woven fiber and resin transfer mold 18 blades 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 9
Strain Composite Fan Module Simulation Fan Blade Impact Analysis Containment Analysis GE Progressive Damage Material Model Developed for Braided Composite material Predicted Vs. Actual Impact Strain Predicted Measured Time (sec) Measured Radial Displacement Predicted Radial Displacement Unique analytical capability is key to making the composite fan a success
Fan Case Manufacturing Processes Case wrap & lay-up Containment Case Shell Material Wrap Resin Film Infusion process with braded pre-form Minimize labor & tooling costs Maximize performance Highly automated manufacturing processes enable affordable manufacturing 11
Fan case manufacturing Braid Twill Satin Non-Crimp Fabric 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 Resin System Fiber & Arcitecture Strong Interrelationships Process 12
Fan Case Processes Simulation Highly automated manufacturing process minimizes hand labor Process development requires multidisciplinary optimization RFI (Resin Film Infusion) Thermal Model Infusion Model Cure Model Resin Flow Process Optimization Wrapped Fabric Resin Tool 13
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 14
Next generation composite technology Technology maturation and advancement Unducted, composite fan blades (UDF) Composite fan blades (GE90) Composite fan blades and case (GEnx) High temp composites Moderate-temp composites Expanded low-temp composites Turbine Blade Core Nozzle 80 s 90 s 00 s 10 s 15