behind the curtain: design and manufacturing technology ... · –evolution and refinement verses...
TRANSCRIPT
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The 12th Israeli Symposium on Jet Engines and Gas Turbines Haifa, November 2013
Behind the Curtain:
Design and Manufacturing
Technology For 21st Century
Commercial Propulsion
Alan Epstein
Vice President, Technology & Environment
Pratt & Whitney
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Outline of this Talk
• Why commercial aviation is important
• Aircraft propulsion in the 21st century
– Evolution and refinement verses revolution
• Aero engines are a great home for advanced
technology
– Historically, most technology focused on product design
– Manufacturing technology now offers new opportunities
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Commercial Aviation In One Year…
Source: ATAG
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Aviation: World Trade
Source: ATAG
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Deliveries Going Forward: 2012-2031
68,000 New Aircraft Across a Range of Sizes
$4.75 trillion worth of new aircraft
Source: ATAG
$0.85 trillion engine supplier share
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Deliveries Going Forward: 2012-2031
68,000 New Aircraft Across a Range of Sizes
$2.8 trillion engine lifetime revenue
$4.75 trillion worth of new aircraft
Source: ATAG
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What’s New?
“There is nothing new in the world except the history you do not know.”
Harry S. Truman
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0
1
2
3
4
5
6
1990 1995 2000 2005 2010
Fuel at $0.50/gal
22% Operating Costs
Fuel at $4.00/gal
60% Operating Costs
Daily
Spot
Pri
ce,
US
D/g
al
Year
Fuel
Engine
Airframe
Crew
Fees
External Driver Spurs Innovation – Cost of Fuel Twin Aisle Aircraft Costs (excludes capital)
*Then Year $USD
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Meeting the Climate Change Challenge
“The world cannot regulate its way out of global warming; it must innovate.”
Tom Friedman,
Columnist, New York Times
Author, The World Is Flat
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Innovation vs. Novelty
• Innovation
– “The alteration of what is established by the introduction of new elements or forms”*
• Novelty:
– “An…amusing object…relying for its appeal on the newness of its design”*
*Source: OED
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Reducing the Cost of Fuel These Aircraft Fly Well, but…
Solar Power Human Power
Novelty verses innovation
Is there economic value?
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Airplanes of the Future? Future Airplane is Unclear, Future Motor is Not
Source: ATAG
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Energy Onboard, MJ
Max P
ow
er,
kW
Vehicle Maximum Energy and Power
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Evolution of Motor Efficiency Shaft Power Delivered per Unit of Power In
~0.4pts/yr
Moto
r E
ffic
iency
Entry Into Service, Year
30%
40%
50%
60%
1960 1970 1980 1990 2000 2010 2020
50MW Diesel
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25 MW of Shaft Power
(photo courtesy Wärtsilä)
680 tonnes 1.6 tonnes
= Same
Power
Better Efficiency
Lower Emissions
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Aero Engine Demands Push Engineering Limits Power to Weight Requires Very Expensive Material
Wright Flyer Wrights’ engine used aluminum,
then 100 times the cost of steel
Wikimedia Commons Wright-Brothers.org
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Advanced Materials are at the Heart of Propulsion Enabling Performance, Weight, and Life
Microcircuit Casting / Cooling Technology
6th Generation Powder Metal Materials
5th Generation Turbine Coating Technology
6th Generation Oxidation Resistant Single Crystal Airfoil
Alloys
High Strength Forged TiAl Airfoil Alloys
Cathodic Arc Bond Coat
TiAl LPT Blades
Electron Beam TBC
Advanced PM HPT disk Suspension Plasma TBC
Advanced Single Crystal Casting
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Evolution of Bypass Ratio and Efficiency
In Service BPR = 5
Fuel Burn Reference
2013-16 BPR ~ 12
-15%
Longer Term BPR ~ 15-18
-20-30%
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How We Make Engines Today
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Manufacturing a Jet Engine Processes Much the Same Then and Now
State-of-the-Art 1937 State-of-the-Art 2013
• Forging
• Machining
• Casting
• Welding
Jet engines have
been largely
made by…
aircraftenginedesign.com
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Forging Enhances Metal Properties Refining the Process Over Time
500-350 B.C. Bronze Laminated Swords
Iron and Steel Swords
Dual Alloy Swords
(Warring States Period, China)
1860 A.D.
2000
Modern Forging
2200 B.C.
Iron Dagger at
Alaca Hoyuk
(Turkey)
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Engine Disks are Unique in Aviation Always Forged for Strength, Machined for Shape
1970
1990
Whittle Engine
Metal Powder 1937
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Billet Extrusion
Alloy Powder
Atomization
Rotor Isothermal
Forging
Powder Metallurgy Manufacturing Process P&W’s Vertically Integrated Supply Chain
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Casting for Shape
3200 B.C.
Cast crucible
steel in India
Popularization of
Investment Casting
Cast Copper
Mesopotamia*
* Image courtesy of the American Foundry Society
300-500 A.D.
1900
1960
Turbine
Blades
200 B.C-200 A.D.
~450 B.C.
Cast Iron Plowshare
Han Dynasty, China
Earliest Cast Iron
Jiangsu, China
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Turbine Blades – From Wrought to Cast
1980
Whittle Engine
1st single crystal
research blade
1940
1970
1960
Improved single
crystal
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Machining for Shape Computations Drove More Complex Geometries
Traditional
2-D Airfoils
Recent
3-D Airfoils
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Machining for Shape
Reducing Part Count and Cost, Improving Performance
Separate Disk, Airfoils
57 pieces
Integrally Bladed Rotor (IBR)
One piece
Preferred Approach Traditional Approach
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New 20th Century Manufacturing Technology Cutting and Hole Drilling Tough Material
[Siemens press picture] [Courtesy LAI International]
Electrical
Discharge
Machining
(EDM)
Laser Drilling
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Stereolithography – Shape, but not Properties New Tech of the 1980s
Compressor Rear Case
Master and Wax Patterns
Seal Model
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New Manufacturing Technologies Emerging Opportunities
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Manufacturing Technology to Create Value A Few 21st Century Advances
Direct Metal Laser Sintering
Electron Beam Melting
Intelligent Cells
Thermoplastics
Advanced processes reduce cost and weight
Automation Machine
Monitoring
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Direct Metal Laser Sintering (DMLS) An Emerging Technology
Part Laser or E-Beam
Sintering
Metal Powder
[Images courtesy of Morris Technologies]
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Manufacturing by Adding One Layer at a Time Both 2-D and 3-D Shapes Possible
[Image courtesy of Morris Technologies]
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DMLS Demonstration
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Near Term Applications of DMLS
Low Stress, Geometrically Complex
[Images courtesy of Morris Technologies]
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Process Dependent Design and Materials Different Outcomes by Process and Properties
Design for the cold
spray process
Design for direct metal
laser sintering (DMLS)
[El-Wardany et al, 2nd World Congress on Integrated Computational Materials Engineering]
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Challenges for Additive Manufacturing Jet Engines Care About Shape and Properties
Shape accuracy not yet adequate
Finish processing needed
Product properties can be improved
Strength at temperature
Corrosion
Fracture toughness, etc.
Ensuring Quality
Material systems available
Powder quality and availability
[Image courtesy of EOS]
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Summary
• Gas turbines are the future of commercial aviation
• Most efficient engines on the planet
• Lowest emissions
• Lowest cost of ownership
• Jet engines manufactured with legacy approaches
• Innovation is opening new manufacturing opportunities
• Manufacturing technology is an exciting investment area
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