Avio innovation network for Green Engine

CONFERENCE GREEN AIRCRAFT
OCTOBER, 29 2009 TORINO, ITALY
Avio innovation network
for Green Engine
Franco Tortarolo
Head of R&TD
1

1903 …
Wright Flyer
…last century…
Today …
A380
Tomorrow …
Green Aircraft
2

• No. 1 in the world:
– Accessory Gearbox
Avio
– Power Transmission for helicopter
and turboprop (independent)
• No. 1 in Europe for Solid Space
Propulsion
• Eccellence in Turbines and Combustors
3

Avio is involved in main civil programs
TRENT 900 GENx 2B
(A380)
PW4000
(in competition with CF6-80)
SaM146
(Sukoi Superjet 100)
GE90
(B777)
PW2000
(B757, C17 military transport)
PW308 (Raytheon Hawker Horizon,
Dassault Falcon 2000EX BizJets)
CF6-80
CFM-56
(B747, B767, A330, A300, MD11) (B737, A320 family)
V2500
(A320 family)
PW150
(Bombardier Q400)
GENx
Boeing 787 Dreamliner
PW100
(ATR 42)
4

…and main military programs
EJ200 T700/CT7 TP400 F136/F135
Eurofighter/Typhoon Apache, Black Hawk,
EH101, NH90, Cobra
RB199
F119
A400M F-35
F110
TORNADO F-22 Raptor F-16 and F-15
5

ACARE 2020 and
the “green” challenge
6

From ACARE Goals to Green Engine
NOx+CO+UHC+Particles
ATM Contribution
Aircraft Contribution
Engine Contribution
• Reduce specific fuel consumption by 20%
• Reduce NOx by 60% to 80%
• Reduce noise by 6 dB
• Reduce accident rate by x5
• Reduce operational cost
• Halve time to market
Engine Configuration Driven by:
Low Noise, Low Emissions, and
Low Cost of Ownership
7

Which is the way?
Conventional Turbofan Radical Architectures
To increase the
By-Pass-Ratio
• New engine architectures
• Technological Step Change
• Integration with airframers
~2.2 m
~ 3.5 m
CFM-56 Open Rotor
8

Radical Architectures
“duct”
GEARED
Turbofan
Low Speed Fan, driven by
LPT via reduction gearbox
Lower Noise
Conventional
Puller
“unduct”
OPEN ROTOR
Pusher
Contro-rotanting propellers driven by turbine:
• “high speed” via a reduction gearbox
or
• “low speed” contro-rotanting (Pusher only)
Lower SFC
9

Impact and opportunities
for Avio products
10

Ultra low NOx
Combustor
New Engine Architectures Needs
High Power Density
Transmission Systems
High Reliability
Light Weight - Low
Noise - High
Efficiency Turbines
11

Power Gearbox Research Drivers
INNOVATIVE GEAR DESIGN METHOD
Innovative Gear Design Method for full use
of material capabilities to increase power
density, efficiency and reliability
SYSTEM DYNAMICS
Fully integrated Transmission
System Dynamics Simulation
HIGH LOAD CAPACITY BEARINGS
Journal Bearings, Integral Bearing
Race, Ultra High Hardness Materials
HEALTH MONITORING AND PROGNOSTIC
Incipient gears and bearing failure using
oil debris and vibration monitoring
12

Low Pressure Turbine: Research Drivers
MULTIDISCIPLINARY OPTIMIZATION
LPT Performance through multidisciplinary
design optimization and 3D CFD Calculation
LOW NOISE DESIGN
Turbine Noise by design, through integrated
Aerodynamic & Acoustic approach
ACTIVE THERMAL CONTROLS
Active clearance control has a strong impact
on engine performance improvement and
reduction of engine to engine SFC variation
LIGHT MATERIALS
Low density alloy with good specific strength,
corrosion/oxidation resistance and low cost
manufactoring process
AERODYNAMIC DESIGN DAMPING AND VIBRATIONS
13

Combustion: Research Drivers
Ultra Low NOx (ULN) Injection System
Alternative fuels characterization
for ULN Combustion stability
Challenge: Reduce Emissions
Thermo-acoustic numerical /
experimental investigation
Powder Sintering
High Temperature Material
14

Avio approaching the “green”
challenge
15

Avio approach to R&TD
Since many years Avio research has been based on:
– National and European Programs (FP 5,6,7; CleanSky)
– National / International collaborations with Universities and
Research Centers
Un, KARLSRUHE GERMANIA
UNIVERSITA’ MONACO GERMANIA
Design Unit Un. NewCastle UK
QINETIQ INGHILTERRA
CRANFIELD INGHILTERRA
ONERA Biarritz FRANCIA
CEPR FRANCIA
CNSR FRANCIA
GEAR RESEARCH INST. - PEN. STATE
OHIO STATE UNIVERSITY - OHIO
VON KARMAN INST. OLANDA
DELFT UNIVERSITY
Un, GRAZ AUSTRIA
CIAM MOSCA VIAM MOSCA
Poland
16

Politecnico Torino
Turbomachinery,
Aeromechanics, Materials
Univ. Genova
Experimental
Fluidodynamics
Univ. Pisa
Mechanical
Transmission
Univ. Firenze
Computational
Fluidodynamics
Univ. Roma
Space Propuls.
Univ. Cassino
Creep
Politecnico Milano
Lifing
Univ. Napoli/CIRA
Combustor
Nanofab
Nanotech
Univ. Lecce
E-Engineering
Manufact. Process
17

The Green Challenge requires
• Radical thinking
• New technologies & skills
• Significant research effort (affordability)
• Many key ingredients locally available:
– Excellent Academia
– Historical aerospace presence on the territory
– Many active and high tech SME’s
– Support from local Authorities
18

From single Collaborations to Partnership
Pragmatic approach towards:
• Research Network based on partnership:
– Avio
– Research Institutes / Universities
–SME’s
• Selective collaboration:
– Proven competencies
– Stability
– Cost sharing and returns among Partners
• Common “green” objectives
• Science Technology Application
AVIO
NEEDS CONTINOUS GROWTH IN KNOWLEDGE
RESEARCH INSTITUTIONS
NEEDS TO TEST KNOWLEDGE ON “REAL” CASES
SME’s
NEED “BRIDGES” TOWARDS LARGER WORLDS
EXPECTATIONS & ROLES
• “ENGINE” OF THE SYSTEM
• BRIDGE TOWARDS BUSINESS
OPPORTUNITIES
• PATH TOWARDS EUROPE
• BASIC RESEARCH SEAT
• SOURCE FOR KNOWLEDGE AND
SKILLED PEOPLE
• IT NEEDS TO TEST THE KNOWLEDGE
ON “REAL” CASE
• “NICHE” KNOWLEDGE
• FAST RACTION TIME
• FELXIBILITY
19

Two “GREAT GREAT” ” Initiatives
GReen Engine for Air Transportation 2020
To develop key technologies for next generation aircraft engines, supporting the local Aero-Engine
Industry to design and produce high-performance, low noise and low emission aero-engine
subsystems
• Regional Research Program
• Start: early 2009; Duration: 3 years; Effort:15M€
• Partnership: Politecnico (7 Depts.), CNR; 24 SME’s; 3 Large Comp.’s
• Share: 1/3; 1/3; 1/3
• Joint Lab between Avio – Politecnico
• Partnership agreement: signed middle 2008; duration 10 years
• Avio driving technologies for Green Engine
• PhD’s & Researchers funding evenly shared between partners
To develop “teaming” relationships and strong interaction with Politecnico to concentrate
academic expertise on solving issues of critical technical importance to green engine, to promote
technology transition, to enhance engineering education and to provide channel for employing topquality
students
GREAT LAB
20

Two “GREAT GREAT” ” Initiatives
GReen Engine for Air Transportation 2020
To develop key technologies for next generation aircraft engines, supporting the local Aero-Engine
Industry to design and produce high-performance, low noise and low emission aero-engine
subsystems
To develop “teaming” relationships and strong interaction with University to concentrate academic
expertise on solving issues of critical technical importance to green engine needs, to promote
technology transition, to enhance engineering education and to provide channel for employing topquality
students
GREAT LAB
21

GREAT2020
• Aggregated around 6 laboratories
• One Avio coordinator for Lab (Lab Leader)
• Differente SME’s and Depts. configuration for Lab
• Different projects for Labs (18 in total)
Mechatronics
Combustion Low
Emissions Systems
Advanced Gears
Technology
ZEC ECOPROLAB
AGEADES
AVIO
MCLAB
POLITO POLITO
LIFT
SMEs
AERONFLUX
Light Innovative Structures & Materials
Eco-friendly
Manufacturing
Aerothermal
Technologies
22

GREATLAB
Joint Lab between Politecnico Torino & Avio for Green Engine
Cittadella Politecnica
• Knowledge community
• Research & complex development problems
• High tecnological sponsorship
• Link to University Labs
• Training / Recruitment
Great Lab: sponsorship
5 Dicembre 2008
GM CoE (diesel, Hybrid)
Microsoft
SME’s Incubator
GREATLAB
23

Example of achievements
24

Example 1: Rapid Manufacturing
LIFT Lab
Need
LIGHT MATERIALS
Avio
Low density alloy with good specific
strength, corrosion/oxidation resistance
and low cost manufactoring process
Scientific Support
Polito - DISMIC
• Powder characteristics
• Process improvements
• Thermal treatment
• Chemical/Metallurgic
Analysis
Technological Niche
Protocast SME
Electron Beam Melting
Testing Facilities
Bytest
Mechanical Test
SME
Win-Win
• Low weight
• Alternative Low Cost
manufacturing process to
casting for TiAl Blades
• Very competitive blades
• Potential large business
• Possible NewCo
• Leading edge research
25

Example 2: Eco-Manufactoring
ECOPRO Lab
Goal 1: Development of Eco-friendly machining processes capable of maintaining the
highest level of geometrical accuracy and surface integrity
Bio Coolant
Micro Lubrication
Surface
Integrity
APR, NOVATEA, PROTOCAST, SILMAX, URMAROLLS; POLITO, ISTEC
26

Example 2: Eco-Manufactoring (cont.)
ECOPRO Lab
Goal 2: Development of world-class grinding machine capable of profiling intricate
3D shapes of jet engine turbine components
Win-Win
Eco benefits:
• enabling production of lightweight, high efficiency turbine
components with minimum need and waste of expensive
‘exotic’ materials
• reduction in usage/disposal of machining coolant
- from 10000 ml/h of water+oil moisture
- down to

Example 3: Reverse Engineering
LIFT Lab
• Reverse engineering of casting components
• Non destructive geometric inspections
• Reverse engineering of foundery tools (cores,
molds)
Polito - DISPEA
Blu-Engineering; Bytest; Getti Speciali; Polito
28

• Big (& Great!) challenges:
– Engine is changing
– Culture is changing
Conclusion
• People, skills (scientific,
technology, application), teaming,
common objectives are essential
• Building up togheter a new model
of research collaboration
• Emerging promising results
• Model open to wider collaboration
29

Thank you for the
attention
30