Emerging Trends in Aviation Propulsion - Turbo & Jet Engine ...

Emerging Trends inAviation PropulsionJohn QuinnGE AviationOctober 25 th , 2012

Top Industry Challenges, 2012• Declining defensebudgets• Increased cost ofweapons systemsprocurement• Increased sustainmentcosts• Cost of energy“In the year 2054, the entire defense budget willpurchase just one tactical aircraft. This aircraftwill have to be shared by the Air Force and Navy3½ days each per week except for leap year,when it will be made available to the Marines forthe extra day.” *2*Augustine’s Laws. Source Wikipedia. Creative Commons citation.

Aviation strategy for a volatile world…Provides a firm foundation for affordable military and commercial productsProcesses Technologies ArchitectureMaintenanceconceptsCost modelingEssential technologiesNew ProductsDemonstratorsProbabilisticlifingNon Brayton cyclecost containment, reduced development times becomingimportant differentiators3

Processes

GE Military Services Processes2Customer – Point of Use1Material Management/PlanningGE Supply ChainCustomerSuppliersBases /SquadronsForward deployed3WarehouseManagementNew PartsGE REP4Depot/Shops – Point of RepairRepair Facilities& OEMsDepotGE REPDATASYSTEMWarehouse6GE/Customer Engineering & MgmtSharedmetricsCustomer5Customer Systems5GE Aviation

Development cost modeling…6GE Aviation

Probabilistic Fracture Mechanics (PFM)New PFM surfaceanomaly distributions• Identifies individual featurecontribution to componentProbability of Fracture(POF)• Potential to eliminatedepot EC inspections forfeatures that contributelittle to overall POF7GE – Aviation

PFM Implementation ProgramPotential to implement PFM for reduced depot inspectionrequirements.With Depot ECWith FPIAppropriate use of EC and FPI provides opportunity forcustomer cost savings8GE – Aviation

Technology

Technology starts with R&D…TRLTechnology Readiness LevelGE Global Research – 5 locations, New York, Bangalore,Shanghai, Munich, Rio. Approx 3,000 employeesMRLMatRLIRLManufacturing Readiness LevelInspection / NDE, Welding / Brazing, LaserMachiningMaterials Readiness LevelNew materials, Mechanical Testing, TribologyComposite Processing, Special CoatingsIntegration Readiness LevelThermal management, Inlet particle separators,exhaust systems, IR, special coatings10

Essential technologiesKeeping the pipeline filledAdaptable fans Advanced HXRs CMCs Adv. CoolingHigh-TempMaterialsAugmentorTechnologyAdvancedIntegratedengine andaircraftsystemsAdaptivecycles2010 products2020Advancedarchitectures

Rapid Prototyping ActivitiesDirect Metal Laser Melting:Laser melts metal powder layerby layer to create complex, 3Dcomponents.Laser Manufacturing:Metal powder is introduced directly intolaser creating large components layerby layerDieless Sheet Forming:Sheet metal is locallyand incrementallydrawn using stylusabove and below workpieceIncreased speedEarly detection of design issuesDevelopment tooling costs reducedCatalyst for innovationElectroforming:Nickel alloy is plated directly ontotemporary tooling – creatingcomplex 3D shapes12

Inlet Particle Separator Technology…• State-of-the-art component testcapability• Extensive IPS geometry experimentaldevelopment• Rapid Prototyping Techniques• Latest in aerodynamic CFD andparticle physics modeling• Collaboration with GE GRC13February 2012

Architecture

Technology Demonstrator ProgramsStrong history … military/commercial benefits today & beyond2000’s2010’sAETDHEETE90’sADVENTAATE, FATE80’sLEAPCF6 F414Tech5670’sPassportUDFE 3GEnxQCSEEGE90F101CFM International is 50/50 joint venture with Snecma (SAFRAN Group)LEAP is a registered trademark of CFM International

Architecture: Technology demonstratorsMilitary/commercial technology synergiesAATE(Advanced AffordableTurbine Engine)FATE(Future AffordableTurbine Engine)ADVENT(Adaptive VersatileEngine Technology)HEETE(Highly Efficient,Embedded TurbineEngine)CustomerUS ArmyUS ArmyUS Navy/US Air ForceUS Air ForceProgramgoals25% better SFC65% hp/wt35% better SFC80% hp/wt20-200+% betterSFC35% better SFCTechnologies3D aero,materials3D aero,efficiencyVariable cycle,3D aero, FLADE TM3D aero,efficiencySegmentsAttack/utilityHelicoptersHeavy liftHelicoptersCombat aircraftTanker/TransportBlackhawk NextGen heavy lift 6 th Generation KC-135

Adaptive Engine Technology Development• AETD…new class of engines withup to 25% better fuel efficiency• Variable cycle technology• Technology demonstration thatbuilds on ADVENT• Foundation for future generationof combat propulsion17

F110 Product Family…Common CoreService Life Extension Program Benefits• SLEP exceeding programgoals….record setting time onwing. 2X base or better• NRIFSD rate at zero• Provides reduced cost ofownership and improvedreadiness• Incorporation of SLEP criticalto long term affordablesupportability of all F110family engines• Enables affordable upgradeto the 6000 TAC configuration18February 2011

GE38 Development…Heavy LiftPower for the Sikorsky CH53K• GE38 Versus T64 :18% Improved SFC57% More power63% Fewer Parts• Successfully completed1,000 hr missionizeddurability test.Performance retentionexcellent.• All ground test vehicle enginesinstalled. A/C rolled out.• Submitted 90% of requiredtest reports for first flight.19

Non-Brayton Cycle Propulsion(Electric, etc.)Brayton Cycle Propulsion(Turbo Gas Generators)Hybrid Turbo-ElectricPropulsionKey Technologies to Bridge The GapsHigh OPR CoresAdvanced Propulsors (FLADE, Open Rotor, etc.)Electrical Systems (Fuel Cells, Batteries,Superconductivity, Electric Motors, etc.)Distributed Propulsion Concepts1950 - 2010 2010 - 2030 2030 - 2050Timeframe

LNG as a transportation fuel…Marine – Emissions regulationsdriving change to littoral vesselsRail – LNG is “the next big thing”Trucking – OEM conversion kits,new make.GE Oil & Gas– RAPID mini LNGequipment growthHuge price disparity and LNG build-out creating opportunity todramatically reduce cost of energy for aviation2110/19/2012

Summary…Process – Maintenance conceptselection can have multi billion dollarimpact to the bottom line.Technology - is the lifeblood of thebusiness - From materials to advancedcooling. Near term to 2050+architectures.Architecture – Leverage commercial &military. Over-the-horizon…nonBrayton cycles. Must rethink energy.22GE Aviation

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