Materials for Competitive Aero Engines - MTU Aero Engines
Materials for Competitive Aero Engines - MTU Aero Engines
Materials for Competitive Aero Engines - MTU Aero Engines
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<strong>Materials</strong> <strong>for</strong> <strong>Competitive</strong> <strong>Aero</strong> <strong>Engines</strong><br />
Aircraft Engine World China Summit 2011<br />
Nov 2-4, 2011, Shanghai, China<br />
Dr. Jörg Eßlinger, <strong>MTU</strong> <strong>Aero</strong> <strong>Engines</strong> GmbH
Agenda<br />
• Advanced <strong>Aero</strong> <strong>Engines</strong><br />
• Challenges <strong>for</strong> <strong>Materials</strong> & Processes<br />
• Material & Processes Developments <strong>for</strong> Advanced <strong>Engines</strong><br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 2
Adva nced<br />
<strong>Aero</strong><br />
<strong>Engines</strong><br />
• Advanced <strong>Aero</strong> <strong>Engines</strong><br />
• Challenges <strong>for</strong> <strong>Materials</strong> & Processes<br />
• Material & Processes Developments <strong>for</strong> Advanced <strong>Engines</strong><br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 3
Improvements in Engine Development<br />
∆SFC,<br />
∆CO2 %<br />
100<br />
18 %<br />
Turbojet:<br />
JT3C (B707)<br />
20 %<br />
Turbofan:<br />
1st generation<br />
BPR=2<br />
JT8D (B727, B737)<br />
12 %<br />
2nd generation<br />
BPR=4-6<br />
PW2037 (B757)<br />
12-20 %<br />
3nd generation<br />
BPR=7-8<br />
PW4084,<br />
GE90 (B777)<br />
10-15 %<br />
new engine<br />
concepts:<br />
geared turbofan<br />
BPR>10<br />
10-15 %<br />
1950 1960 1970 1980 1990 2000 2010 2020<br />
counter-rotating<br />
geared turbofan<br />
recuperative<br />
engine concept<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 4<br />
2030<br />
year
ACARE 2020: Substantial Challenges <strong>for</strong> Engine Improvements<br />
Safety & security<br />
• Reduce accident rate by 80%<br />
• Zero successful hijacked aircraft<br />
Quality & af<strong>for</strong>dability<br />
• Half time to market<br />
• Reduction of travel charges<br />
Air transport system efficiency<br />
• 99% on time arrival/departure within 15 minutes<br />
• 3X increase in aircraft movements<br />
Environment<br />
• Reduce perceived noise level by half<br />
• Reduce NO x by 80%<br />
• Reduce CO 2 by 50%<br />
Engine contribution<br />
• Reduce fuel burn & CO 2 by 20%<br />
• Reduce NO x by 60% to 80%<br />
• Reduce noise by half<br />
• Reduce accident rate by 5X<br />
• Reduce operational costs<br />
• Half time to market<br />
Reference: year 2000 in service engine<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 5
Claire – <strong>MTU</strong>'s Clean AIR Engine Technology Program<br />
100<br />
∆CO 2<br />
%<br />
90<br />
80<br />
70<br />
Baseline CLAIRE 1 CLAIRE 2 CLAIRE 3<br />
up<br />
to<br />
15%<br />
V2500 GTF TM<br />
up to<br />
20%<br />
Advanced<br />
shrouded<br />
propulsor<br />
2005 2010 2015 2020 from<br />
2025<br />
from<br />
2030<br />
Advancedcycle<br />
engine<br />
• The geared turbofan is key to<br />
achieving the staged Claire<br />
targets<br />
• Up to 30% less CO 2 by 2035<br />
• Perceived aircraft noise is halved<br />
• All technologies required are<br />
either available, or their feasibility<br />
has already been demonstrated<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 6<br />
up to<br />
30%<br />
ACARE-aim<br />
from<br />
2035
The Geared Turbofan (GTF)<br />
Low-speed,<br />
high-BPR fan<br />
Reduction<br />
gear<br />
High-speed<br />
LPC & LPT<br />
Reduced noise TSFC decrease Reduced cost & weight<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 7
GTF: Noise Reduction<br />
Source: Wyle Laboratories<br />
FAA INM Version 6.2a<br />
Today’s aircraft<br />
Munich International Airport (MUC)<br />
GTF-powered next-generation aircraft<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 8
GTF Milestones and Applications<br />
2007<br />
2008<br />
2013<br />
Applications:<br />
Ground test<br />
1st flight<br />
EIS 1st application<br />
Airbus A320neo, Mitsubishi MRJ,<br />
Bombardier CSeries, Irkut MS-21<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 9
Challe nges<br />
<strong>for</strong> M aterials<br />
& Processes<br />
• Advanced <strong>Aero</strong> <strong>Engines</strong><br />
• Challenges <strong>for</strong> <strong>Materials</strong> & Processes<br />
• Material & Processes Developments <strong>for</strong> Advanced <strong>Engines</strong><br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 10
<strong>Materials</strong> Used in Aircraft <strong>Engines</strong><br />
Source: Frank Preli, Pratt & Whitney<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 11
Coatings in Aircraft <strong>Engines</strong><br />
Titanium-fire protection coatings<br />
Compressor casings<br />
Erosion protection coatings<br />
Compressor blades/vanes<br />
Abradable/abrasive linings<br />
and sealing coatings<br />
Casings, blade tips, seal rings<br />
Thermal barrier coatings<br />
Turbine blades/vanes, combustors<br />
Dimensional correction<br />
coatings<br />
All parts<br />
Corrosion / oxidation<br />
protection coatings<br />
Turbine blades/vanes<br />
Wear protection coatings<br />
Casings, blades/vanes, disks, shafts<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 12
New Engine Concepts Bring About New Challenges <strong>for</strong> <strong>Materials</strong><br />
That Have to be Tackled Within Reasonable Economic Limits<br />
Compressor Pressure Ratio<br />
45<br />
40<br />
35<br />
30<br />
25<br />
20<br />
15<br />
10<br />
sea level static,<br />
standard day<br />
JT8D TF30<br />
J57 J52<br />
JT3D<br />
CF6-50<br />
J79<br />
F100<br />
CF6-80 F100<br />
JT9D-7R4 4056<br />
2037<br />
V2500<br />
GE90<br />
4168<br />
4084<br />
4060<br />
F404<br />
5<br />
0<br />
Von Chain<br />
Whittle<br />
1930 1940 1950 1960 1970<br />
Year<br />
1980 1990 2000 2010<br />
Trent<br />
Gas Turbine Technology Evolution: A Designer’s Perspective<br />
Bernard L. Koff, TurboVision, Inc., Palm Beach Gardens, Florida 33418<br />
JOURNAL OF PROPULSION AND POWER<br />
Vol. 20, No. 4, July–August 2004<br />
High Speed LPT<br />
High mechanical loading<br />
Substantially reduced fuel consumption<br />
and emissions<br />
Light-weight material concepts<br />
Higher compressor temperatures<br />
Competition<br />
Stable engine price<br />
Faster materials development<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 13
Turbine Airfoils<br />
Density vs. T Parts Cost vs. T<br />
Ni-cast:<br />
Reduce high-density-expensive elementes of high-T-alloys<br />
Low-k TBC<br />
CMCs and Intermetallics:<br />
Optimize damage tolerant design<br />
Reduce production costs<br />
Establish supply chain<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 14
Rotating Parts<br />
Density / Yield Stress vs. T Parts Cost vs. T<br />
Ti- / Ni-Wrought Alloys<br />
Develop high-strength alloys<br />
Increase temperature limits<br />
High-T-alloys with reduced costs<br />
Improve fly-to-buy-ratio<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 15
Static Parts<br />
Density vs. T Parts Cost vs. T<br />
Al and PMC<br />
Increase temperature limits<br />
Steels<br />
Increase temperature limits<br />
Ni-Wrought<br />
High-T-alloy with reduced costs<br />
Additive Manufacturing<br />
Expand range of application<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 16<br />
CMC<br />
Reduce production costs<br />
Establish supply chain
Safety, Safety, Safety …<br />
Highest safety requirements<br />
• Damage-tolerant materials<br />
• Comprehesive statistical validation<br />
• Highest quality standards<br />
• Length approval process<br />
1960<br />
Uncontained engine failures<br />
per million departures<br />
today<br />
Source: FAA<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 17
Challenges <strong>for</strong> <strong>Aero</strong> Engine <strong>Materials</strong> Engineering<br />
Provide advanced materials<br />
allowing steps in per<strong>for</strong>mance<br />
Safe non-metallic design<br />
<strong>Competitive</strong> production<br />
processes<br />
Reduce production costs<br />
Near net shape processes<br />
Low-cost-substitutes<br />
Increase mat‘ls portfolio and<br />
reduce its development costs<br />
Partnerships<br />
Computational materials<br />
engineering<br />
Ensure raw materials supply<br />
Management of supply chain<br />
and IPRs<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 18<br />
§
Material &<br />
Processes<br />
Developmen<br />
ts f or<br />
Adva nced<br />
• Advanced <strong>Aero</strong> <strong>Engines</strong><br />
• Challenges <strong>for</strong> <strong>Materials</strong> & Processes<br />
• Material & Processes Developments <strong>for</strong> Advanced <strong>Engines</strong><br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 19
Last Decade‘s Developments<br />
High-T erosion coatings<br />
Low-cost / light-weight<br />
substitutes <strong>for</strong> Ni and Ti<br />
(Al, steel, PMC)<br />
Near-net-shape<br />
production routes<br />
<strong>for</strong> reduced costs<br />
High-strength Ti and<br />
Ni wrought materials<br />
Light-weight-high-T<br />
Ni-cast materials<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 20
Technical benefit<br />
Highly Innovative Developments <strong>for</strong> Future <strong>Engines</strong><br />
Ceramic Matrix Composites:<br />
Substantial weight reduction<br />
Extending Ni-temperature-limit<br />
! understand properties and design<br />
! Ensure raw material and supply chain<br />
! Reduction of parts cost<br />
Titanium Aluminide:<br />
Substantial weight reduction<br />
State-of-the-art <strong>for</strong> future LPTs<br />
! Establish supply chain<br />
! Reduction of parts cost<br />
Computational <strong>Materials</strong> Engineering:<br />
Substantial acceleration of<br />
materials & processes development<br />
Design of materials & processes<br />
! Tools ready to solve specific problems<br />
! Connect chains-links of simulation tools<br />
Additive Manufacturing:<br />
Substantial reduction of parts cost<br />
High flexibility of process<br />
! Process parameters vs. properties<br />
! Make use of potential <strong>for</strong> light-weight-design<br />
Cost reduction <strong>for</strong> development and parts<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 21
Computational <strong>Materials</strong> Engineering<br />
Examples <strong>for</strong><br />
applications<br />
Alloy Processing Microstructure & Defects Properties<br />
Design of materials Design of processes Effect of defects<br />
11. Oktober 2010 Werkstoffe für <strong>MTU</strong> Triebwerksmodule 22
Thank You <strong>for</strong> Your Attention!<br />
Aircraft Engine World China Summit 2011<br />
Nov 2-4, 2011, Shanghai, China<br />
Dr. Jörg Eßlinger, <strong>MTU</strong> <strong>Aero</strong> <strong>Engines</strong> GmbH
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