Aero Engine Materials - MTU Aero Engines
Aero Engine Materials - MTU Aero Engines
Aero Engine Materials - MTU Aero Engines
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<strong>Aero</strong> <strong>Engine</strong> <strong>Materials</strong><br />
Dr. Wilfried Smarsly<br />
Seminar<br />
Faculty of Mechanical <strong>Engine</strong>ering<br />
Cracow University of Technology<br />
Poland
Key drivers for materials development<br />
Performance<br />
Increase Life-time limits and<br />
increase materials temperature limits<br />
Costs<br />
Cost efficient materials and<br />
processes selection<br />
Reliability &<br />
Durability<br />
More efficient evaluation of materials<br />
and processes with the help of new<br />
simulation tools<br />
Fuel<br />
Consumption<br />
& Emissions<br />
<strong>Materials</strong> with lower specific weight for<br />
the compressor and turbine application<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 2
Requirements: Costs<br />
Complex shaped parts /<br />
50.000 €per Turbine Stage<br />
Efficient and<br />
production processes<br />
Safety requirements<br />
failure rate 1 from 10 9<br />
Modelling & simulation<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH TEW32004 of<br />
failure mechanism<br />
Damage tolerant<br />
materials & design
Requirements: Processability<br />
Availability<br />
of materials and<br />
processes<br />
Certified and efficient<br />
manufacturing<br />
processes<br />
Quality control<br />
concepts and<br />
technologies<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 4
Requirements: Temperatures<br />
Material Properties:<br />
- Creep Strength<br />
- Thermal Mechanical Fatigue Strength<br />
- Microstructural Stability<br />
max. 1200 °C<br />
Vanes<br />
max. 750 °C<br />
Discs<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 5
Requirements: Loads<br />
Material Properties:<br />
- Density<br />
- Yield and Rupture Strength<br />
- Fatigue Strength (LCF)<br />
Centrifugal Loads<br />
Kinetic Energy<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 6
Concepts: Material potential<br />
Strength<br />
Density<br />
MPa<br />
g/cm 3<br />
800<br />
400<br />
200<br />
100<br />
Carbon fiber<br />
reinforced polymers<br />
Ti-MMC<br />
Titanium<br />
alloy (35 Vol. %)<br />
Steel<br />
(20 Vol. %)<br />
Erosion, corrosion, abradable and fretting coatings<br />
TiAl<br />
forgings<br />
powder<br />
Nickel alloy<br />
(40 Vol. %)<br />
Oxidation Thermal barrier<br />
castings<br />
coatings<br />
500 1000 1500<br />
Temperature ° C<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 7
Concepts: Material selection<br />
Titanium Alloys/<br />
Polymer Matrix<br />
Composites<br />
Titanium Alloys<br />
Titanium &<br />
Nickel<br />
Alloys<br />
Nickel<br />
Alloys<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH TEW82004 TiAl<br />
AK 2002/ 1
Concepts: <strong>Materials</strong> volume distribution<br />
Volume %<br />
of material classes<br />
in the engine<br />
100<br />
80<br />
60<br />
40<br />
20<br />
0<br />
Light Metals (Mg-, Al-alloys)<br />
Ti-alloys<br />
Ni-alloys<br />
steel<br />
1950 1960 1970 1980 1990 2000 2010<br />
Polymer<br />
Matrix<br />
Composites<br />
(PMC)<br />
Metal Matrix<br />
Composites<br />
(MMC)<br />
Titanium-<br />
Aluminide (TiAl)<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 9
Melting metallurgy processing steps<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 10
<strong>Aero</strong> engine disc forging process steps<br />
Melting Forging Cutting<br />
Upsetting Forging Ring Rolling Precision forging<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 11
Applications of steel in areo engines<br />
ROLLER BEARING<br />
hardness<br />
friction and wear resistance<br />
GEAR<br />
hardness of edge layer<br />
toughness in the center of the parts<br />
CASING<br />
SHAFT<br />
young's modulus<br />
fracture<br />
toughness<br />
good deformations and welding properties<br />
high strength<br />
low price<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 12
Titanium alloy compressor parts<br />
Low Pressure<br />
Compressor Stages<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 13
Single crystal turbine blade processing steps<br />
Heating<br />
Zone<br />
Baffle<br />
Crystal<br />
Selector<br />
Cooling<br />
Plate<br />
.<br />
Qab .<br />
QZU v ab<br />
Molten<br />
Alloy<br />
Solidification<br />
Solid<br />
Alloy<br />
Front<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 14<br />
TEW 2004
Creep properties of nickel blade alloys<br />
Dehnung [%]<br />
Elongation %<br />
30<br />
20<br />
10<br />
0<br />
Creep Rupture Life /980°C, 230 MPa<br />
CC<br />
DS<br />
SC<br />
1. Generation<br />
SC SC<br />
2. Generation 3. Generation<br />
0 200 400 600 800 1000<br />
Zeit t [h]<br />
Time h<br />
3. Generation Alloy<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH TEW 152004
Advanced <strong>Materials</strong>: Polymer matrix composite parts<br />
3D <strong>Aero</strong> Design<br />
BENEFITS<br />
• Weight Reduction --50 50 %<br />
• Improved Clearance<br />
Control<br />
• Cost Reduction --70 70 %<br />
Mayor<br />
Advantages<br />
Over Light Metal<br />
Alloys<br />
Stator Cluster<br />
Erosion Resistant Airfoil<br />
CHALLENGES<br />
• FOD Resistant Design<br />
• Erosion Resistant<br />
Coatings<br />
• Quality Testing Methods<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 16
Advanced materials: Titanium matrix rotor parts<br />
Blisk Rotor Assembly MMC - Ring Bling - Rotor Assembly<br />
BENEFITS<br />
• Weight Reduction: --30 30 %<br />
• Improved Compressor Rotor<br />
Dynamics<br />
• Improved Clearance Control<br />
CHALLENGES<br />
• Low Cost Production<br />
• Structural Mechanics<br />
Methods<br />
• Quality Testing Methods<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 17
Advanced materials: Titanium aluminide components<br />
40 %<br />
Weight Reduction<br />
Potential<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH TEW 182004
Future materials technology driver<br />
• Improved Strength<br />
• Increased Temperature Capability<br />
• Improved Predictability and Reliability<br />
• Improved Design & Process Flexibility<br />
• Lower Density<br />
• Reduced Costs<br />
• Reduced Development Time<br />
• Reduced Environmental Impact<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 19
Use of advanced modelling and simulation tools<br />
Usable Modelling<br />
for<br />
R & D System<br />
Costs<br />
Design<br />
• Reduction of Time for Material and Process Development & Optimization<br />
• Reduction of Development Risks<br />
Phase Diagram<br />
Production &<br />
Manufacturing<br />
Process<br />
Microstructure<br />
<strong>Materials</strong> Properties<br />
copyright by <strong>MTU</strong> <strong>Aero</strong> <strong>Engine</strong>s GmbH 20