leap brochure 2015
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The LEAP engine represents the optimum combination of CFM International’s unrivaled experience as the preferred engine supplier for single-aisle aircraft coupled with strong expertise and constant investment in research & technology development.
CFM commitments: • Proven performance • Lowest execution risk • Best technology
The new LEAP engine is paving the way for tomorrow’s aircraft by incorporating some of the industry’s most advanced technologies developed by Snecma (Safran) and GE.
As a worthy successor to the CFM56 family, the world’s best-selling aircraft engines, the LEAP engine combines the expertise of its parent companies to meet customers’ increasingly demanding economic and environmental requirements.
The LEAP product line incorporates a number of innovative technologies developed over 40 years of research and development, including optimized thermodynamic design, higher bypass and compression ratios, advanced 3-D aerodynamic design and greater use of advanced materials.
All to deliver world class performance, greater reliability, improved environmental footprint and optimized cost of ownership to airlines around the globe.
LEAP OVERVIEW
Single western powerplant (LEAP-1C)
(*) Data as of April 30, 2015
Boeing 737 MAX
COMACC919
AirbusA320neo
Other aircraft
CFM
COMMERCIAL SUCCESS
A320neo
737 MAX
C919
Dual-source (LEAP-1A)
Single-source (LEAP-1B)
of orders share for the single aisle market75%CF
M
LEAP-1C (COMAC C919)
LEAP-1A(Airbus A320neo)
LEAP-1B(Boeing 737 MAX)
Other engines
To date*, CFM has received more than 8,900 LEAP engines orders and commitments across all three models.
These aircraft account for
of new single aisle orders˜90%
0 100
The first LEAP-1A powered A320 neo.
CFM is pushing the limits with the new LEAP engine to meet the performance and reliability expectations made to its customers. All in all, CFM will have a total of 60 engines builds to execute the most extensive ground and flight test certification program in the company’s history. These engines will accumulate approximately 40,000 cycles of testing before entry into service, the equivalent of 15 years of airline service.
Like all new engines, the LEAP family will complete challenging tests on its way to certification. Among them: Fan Blade Out: The engine must be able to contain a fan blade breaking off, without suffering critical damage. The test
requires a special fan blade with an small embedded explosive charge, to separate it on command during the test.
Bird ingestion test: To demonstrate that the engine maintains 75% of its thrust for 20 minutes following a bird ingestion.
Block test: Extreme endurance tests to check the operability of the engine, running it at triple redline (maximum fan speed; maximum core speed; and maximum exhaust gas temperature) over 5,000 simulated cycles.
Icing Tests: To demonstrate that the ingestion of a block of ice does not affect engine performance
EXTENSIVE TESTING
MULTIPLE PROVEN CUTTING EDGE TECHNOLOGIES
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High bypass ratioOptimum propulsive efficiency
3-D woven carbon fiber compositesLightweight, increased durability
Debris rejection systemAirfoil protection against erosion
High tech compressorOptimum thermal efficiency
New generation combustorLean burn, low emissions
Ceramic composites, new cooling & 3-D aerodynamicsReduced weight, cooling optimization
Lightweight materials & 3-D aerodynamicsReduced weight, increased efficiency
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INNOVATIVETECHNOLOGIES
Additive manufacturing
• 3-D Printing
Additive manufacturing is transforming the way engines are built. This technology "grows" engine parts directly from a CAD* file using layers of fine metal powder and a laser. This results in complex, fully dense and lighter parts, manufactured in a fraction of the time it would take using traditional subtractive methods. Each LEAP engine will contain up to 19 metal 3-D-printed fuel nozzles, which is up to 25% lighter than its counterparts. CFM will produce approximately 100,000 of these parts each year…
• 3-D Woven carbon fiber composites: less weight, more durable
Advanced materialsThe 3-D woven RTM (Resin Transfer Molding) carbon fiber composites used for the fan blades and casing on the LEAP engine are revolutionizing the single-aisle market. This new technology reduces the weight (500 lbs per engine) of the fan module. It also enables blade geometries that are challenging to produce with titanium. The 3-D RTM technology is highly impact resistant and thus reduces maintenance requirements.* Computer Assisted Design.
CFM ‘s LEAP engine is an impressive package of innovative technologies. It is set to establish a new standard in engines for single-aisle commercial jets, based on its 15% reduction in fuel consumption and CO2 emissions versus current engines.
CFM has a tradition of consistently investing in technologies that enhance product performance and customer satisfaction.
The best-selling CFM56 family successively introduced a full array of product upgrades, including the FADEC (Full Authority Digital Engine Control), several generations of 3-D aerodynamic design and, most recently, the suite of improvements dubbed Tech Insertion in 2007 and the CFM56-7BE and CFM56-5B PIP (Performance Improvement Package) introduced in 2011.
All of these enhancements were not only incorporated in new engines, but also available as upgrades on engines already in service. Over the years, CFM has improved specific fuel consumption*, all while reducing emissions and significantly lowering maintenance costs.
This long-standing philosophy of continuous improvement is already an integral part of the LEAP family, and will be pursued throughout its service life. CFM has also introduced lighter and stronger materials. The company’s experience with composites reaches back more than 30 years, unrivaled among aero-engine manufacturers.
Research is ongoing and the product line will eventually add an increasing number of thermo-structural composite parts to reap the benefits of both the lighter weight and higher temperature capabilities these materials provide.
* by more than 5% and increased thrust by 16%.
TECHNOLOGY MATURATION
LEAP-1B first flight on a modified 747 flying testbed.
CFM has always met its commitments by delivering reliability for all customers.
To date, the company has developed different engines models for 21 aircraft entry into service, all of which were delivered on time, as well as eight upgrades, certified on time and on spec.Today, this textbook case of French-American industrial partnership can be summarized in three figures: nearly 28,000 engines delivered on time, more than 750 million flight-hours, and a fleet-wide 99.98% dispatch reliability rate.
CFM has leveraged all of this unrivaled experience for the LEAP engine program, and the basic principle hasn’t changed: give customers the best possible engine, today and for years to come.
CFM has a long history of constantly investing in its product lines to deliver greater value.
This is the approach the company is using to develop the LEAP engine and will continue to develop new technologies that will be incorporated into the engine throughout its service life, as well as in a new generation of engines.
GE AND SNECMA TOGETHER SINCE 1974, PARTNERS THROUGH 2040
28,000
750550
299.98%
21
Nearly
More than
More than
Every
engines delivered to date
million flight-hours
operators around the world
seconds, a CFM powered aircraft takes off somewhere in the world
dispatch reliability
entries in service
LOWEST EXECUTION RISK
Industrial facilities smooth running, constantly improving.
CFM has designed, tested, certified, produced and supported the largest fleet of commercial jet engines in the single-aisle market over the last 30+ years. This achievement is anchored in the development and continuous improvement of world-class facilities on both sides of the Atlantic, with each partner responsible for half the workload.
GE is in charge of the core, comprising the high-pressure compressor and turbine and the combustor. Snecma designs and builds the low-pressure section, including the fan, the low-pressure compressor and turbine, and the accessory gearbox. Final assembly of CFM engines is performed by GE in Evendale, Ohio, near Cincinnati and by Snecma at its facilities in Villaroche, France near Paris.
CFM maintains the highest production rate in the industry and the company is modernizing and expanding its facilities to ensure the ramp-up in production for the new LEAP engine. Both GE and Snecma have added new manufacturing capability at sites throughout the U.S. and France, making a combined capital investment of nearly $800 million U.S.
The company is ramping up CFM56 production to more than 1,600 engines in 2016 before it begins to transition to LEAP engine production.
The full transition is expected to be completed by about 2020 with an anticipated production rate of more than 1,800 engines per year. CFM will continue to build CFM56 spare engines for several years.
CFM’S EXPERIENCE ASSURESSUCCESSFUL EXECUTION
Fan and booster Core Low pressure turbine
Snecma GE
1,800+1,600
2013 2014 2015 2016 2017 2018 2019 2020
0
500
1,500
1,000
2,000
engi
nes
years
CFM56 LEAP
+17% rate increase in 8 years
LEAP
CFM PRODUCTION AT GE AND SAFRAN FACILITIES
60+ 160 Customer Support Managers act as focal point for CFM support
technical and fieldrepresentatives serve customers on site
PROVEN, GLObAL SUPPORT NETWORK ALREADY IN PLACE
EIS READYNESS
3 Customer support and diagnostics centers
6 On-site support centers 5 Training centers
on 3 continents
CFM has launched many initiatives to support the launch of operations of the first LEAP operators and to make this new entry into service another success:
Customer Conference cycles
Road map towards the EIS customized for each client
Launch of a new CWC (Customer Web Center), dedicated to the CFM engines
Expert FSE (Field Service Engineers) dedicated to the new customers
Spare parts readiness by the end of 2015
Stress tests in the CFM network
Opening of a new CSC (Customer Support Center) for LEAP (24/7)
New areas dedicated to the LEAP engine in the CFM Training Centers
CFM PRODUCTION AT GE AND SAFRAN FACILITIES
Peebles, OH: testing capabilityDayton, OH: ducts and tubes
Evendale, OH: HQ, design,assembly & engine testing
Rutland, VT: airfoilsHooksett, NH:stator vanes & tubesLynn, MA: combustorlinersLafayette, IN: assembly
Techspace Aero, Liers (belgium):low-pressure compressor production
Famat, Saint-Nazaire (France): frames
Hispano-Suiza (Polska): dressing and equipment
CFM International head office, Cincinnati, OH
Snecma HAL (India): controland accessory production
Snecma Suzhou (China):engine module manufacturingand assembly
Snecma Xinyi Airfoil Castings Co. Ltd (China): low-pressure turbine blades and seals, nozzle guide vanes
Victorville, CAflight testing
Snecma, Querétaro (Mexico):engine modules manufacturing
and assembly
Asheville, NC: CMC turbine bladesDurham, NC:assembly and engine testingWilmington, NC:shafts & disksGreenville, SC:turbine bladesAuburn, AL:engine componentsEllisville, MS: compositeengine parts, thrust reversers
Safran Aerospace Composites, Rochester, NH:3-D Woven RTM fan bladeand casing
Snecma (France):Gennevilliers: forging, castingand machining of mechanical partsEvry-Corbeil: machining andassembly of engine partsVillaroche: design, assemblyand testing of enginesLe Creusot: machiningof low-pressure turbine disks
Safran Aéro Composites, Commercy: 3-D Woven RTM fan blade and casingHispano-Suiza, Colombes: accessory gearboxSagem, Massy: FADECAircelle, Le Havre: nacelles
JV 50/50
imagination at work GE
Safran companies
Snecma (Safran) / GE
Proven performance... Fuel consumption, maintenance cost, reliability, minimal environmental footprint
best technology... Simple architecture and $2b annual investment,
multiple proven and new technologies
Lowest execution risk... 21 CFM service entries: on time, on spec