GE Aviation

Titanium Utilization & Vision For The Next Decade:Vision For The Next Decade: An Aircraft Engine OEM Perspective

David LingerS t b 16 2009September 16, 2009

Aviation Ti-TeamJon Blank Mike PerettiDavid Linger Andy WoodfieldEric Ott

Agenda…

• Business UpdateBusiness Update

• Material Trends & Case Study

• Novel Ti Manufacturing

• Additive Manufacturingg

• A Perfect Storm…

• Supply Chain

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A global provider of engines, systems and servicesand services

Segments• CommercialCommercial• Military• Business & General

Aviation3

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Aviation

GE Aviation portfolio … $19.2B($ in billions)

Commercial engines

Commercial engineservices

Military engines & services

n n

Unison Engine Components

Systems Business & General Aviation

$5.2 $6.8 $4.2’08 Revenue–a)

ComponentsGeneral Aviation

$2.2 $0.4’08 Revenue $0.4

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A leading aviation technology business (a-Includes GE’s 50% of CFMI & EA

CFMI is a 50/50 JV between GE and Snecm aEA is a 50/50 JV GE and Pratt & W hitney

Commercial outlook … strongCommercial engines Commercial installed base

• Most popular on regional … 1,230

22,400 CFM

g ,engine backlog

• Most popular on single-aisle … 5,850 22,400

13 300

CFMsingle aisle … 5,850engine backlog

• Most popular on Boeing 787 730

14,0008 300

5,200

13,300

GE

Boeing 787 … 730engine backlog

• Most popular on wide-bodies 8,300

4,500EA

‘97 ‘07 ‘17F

wide-bodies … 2,300 engine backlog

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Fleet in active com m ercial serviceSource:CASE, GE internal studies

GP7000 developed by GE/P&W Engine AllianceCFMI is a 50/50 joint com pany between GE and Snecm a

Material Trends…

-Composites-Titanium

Composites

AcousticAcoustic Panels

Fan BladePlatform Bonded VanesPlatform Bonded Vanes

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DuctsFan Containment Case

Gamma TiAl Turbine Blades – World’s FirstCertified Intermetallic Material ApplicationCertified Intermetallic Material Application

TiAlTiAl

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Material Options…Gamma TiAl ~ 50/50 Ti and Al

250Ti – good to ~ 550CAl – good to ~ 250C

Gamma TiAl good to 800C

gth

))

200Gamma TiAl – good to ~ 800C

It’s a miracle!!!

TitaniumAlloys

TiAlfic S

tren

ga/

(Mg/

m3 )

150

Alloys

Mg Al

Single CrystalSuperalloysSp

eci

(MP

50

100

CMCSuperalloys

RefractoryMetals and Intermetallics

g50

Temperature

REF. Advanced Metallic Materials, Dallis Hardwick, AFRL

(ºC) 200 700 1200 1700

LPT Blade Manufacturing Sequence

Casting Ingot Production

Melt and cast partsp

HIP

Pre HIP Solution

Xray/FPI (repair as necessary)

Post HIP Heat Treat

Xray/FPI (repair as necessary)

Machining and coating

LPT A blLPT Assembly

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Pre Introduction Test Components

All three cast gammat f llcomponents successfully

machined and engine tested.

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Novel Manufacturing…

BlueArc™ ECDM Rapid Roughing…A new high speed electro-erosion process:•Simultaneous Discharge/arcing

•High Current

Sparks & Globules

Electrode wheel (Steel, copper,

brass, etc)

Sparks & Globules

Electrode wheel (Steel, copper,

brass, etc)

•High Current

•Abundant Flushing

•Added relative interelectrode surface motion for process stability improvement

Electrolytic coolant fills gapFast Feed

Electrolytic coolant fills gapFast Feedprocess stability improvement

Grinding Application

g p

Grinding Application

g p

Surface finish on Ti64Surface finish on Ti64

Achieved 4X cycle time/75% tooling cost reductionas compared with the mechanical milling

Surface finish on Ti64Surface finish on Ti64

Rapid material removal rates, 5-15 in3/min, with low HAZ, 0-5

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mil.

Projection Welding of Bosses

Pneumatic CylinderPneumatic Cylinder

Solid state fabrication process for hollow bosses/ports…

MoveableMachine Platen

Spring

MoveableMachine Platen

Spring

Fixed Machine Platen

Independent Fixture Block

Hard Stop

Upper Part Clamp

Lower Part Clamp

Fixed Machine Platen

Independent Fixture Block

Hard Stop

Upper Part Clamp

Lower Part Clamp

PlatenPlaten

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Additive Manufacturing…

Bulk Deposition Technologies…

• Spray Casting- • Cold Spray-

• Metal Injection Molding-M t l P d L• Metal Powder Laser

Sintering-

• Electron Beam Melting-•

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Feature Deposition Technologies…

• Plasma Transferred Arc Solid Free Form Fabrication-

• Electron Beam Free Form• Electron Beam Free Form Fabrication-

• Laser Net Shaped ManufacturingManufacturing-

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History Tells Us…

Em ergence of Alum inum in the MarketPre-

>10,000 $/lb

Pre-1852 Hall-Heroult & Bayer Processes

Revolutionized Alum inumTransitioning it from a Precious

(200

6$/lb

)

350 $/lb1852-1885

n n ng mMetal to a Com m on Material

erag

e Pr

ice

1886 Hall-Heroult Process -Alum inum Sm elting1888 Bayer Process -Alum ina extraction from ore

Ave

19149 $/lb

1900

1919 1stall-Al plane

1 $/lb

4 $/lb 200519671939

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Demand (Metric Tonnes)

ThePerfect Storm …

Additive Manufacturing Converges with Meltless Ti Powder

Meltless Ti Alloy Powder is…Alt ti t Ti l t hi h lit d til• Alternative to Ti sponge - lower cost, higher quality, and more versatile

• New breakthrough chemical and electrochemical powder synthesis

Vit l f ffi i t d t i• Vital for more efficient downstream processing

• Enables new novel Ti alloys

A l t & b d f di t t l d lid ti• Accelerates & broadens use of direct metal powder consolidation

The Vision for Meltless Ti …

OR

PowderPowder

Consolidation Mill Product Near Net Shape

OR

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Meltless Ti Alloy Eco Benefits

GE Aviation• 2/3 Less Energy Consumption

• 50% Less CO2 emissions

GE AviationAnnual Energy SavingsMaterial Synthesis2

• Processing infrastructure

y>341 billion BTU/yr.* benefit vs. Kroll thru billet

Component Processing>55 billion BTU/yr.*A i l 20% i ld

• Transportation energy*Assuming only 20% yield

Product Use0.2-0.5% Specific Fuel Consumption

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Novel Alloys

Novel Meltless AlloysMeltless TiMeltless Ti

pabi

lity

/ Tem

p. Kroll Ti + Melting

Allo

y C

apSt

reng

th /

A S

M ltl Ti h bl l ti ll d biliti24

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Meltless Ti approach enables revolutionary new alloys and capabilities

Novel Titanium Alloys – New Capabilities

Strength Modulus

New

FatigueCorrosion Current

New

T t WearTemperature

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New Capabilities = Market Growth

ApplicationsOuter duct(Military)Booster spool

and blades Outer turbine

static parts(Military)

Ti HPC case / vanes

HPC spool disks/blades Engine mount

Tip cap

MLE Tail cone(not visible)

Tip cap Trailing edge

Afterburner case(Military)

Nozzle caseHeat shield

Fan disks(not visible)

(Military)

HPC disks/blades further back

Tubing/Ducts(Military) CP Ti

Alloy

Fan case(Military) Bearing housing

(not visible)Fan frame(not visible)

in compressorTi-64

N l

Ti-64/Ti-3-2.5

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Novel

Novel Ti Alloy Enables Expanded Use

• Weight Ti Cases- Replace steel cases pLower stator weightImproved clearances

Temperature Ti Disks/Shafts• Temperature Ti Disks/Shafts- Replace Ni/steel componentsLower rotating weightLighter stator weight

Engine level benefit

Up to75lbsLighter stator weightImproved designs

• Temperature Ti Airfoils

Up to 75 lbs

3-5m il clearance

%- Replace Ni/steel blades/vanesLower rotating weightLighter stator weight

0.2-0.5% SFC

0.3-0.7% Fuel burn

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Supply Chain

Develop Supply Chain…

P dPowderSupplier Consolidator Processing

MillMillProduct

Ti Alloy Powder Producer Consolidation Ti Alloy

GFM Billetizing

Ch i l I d PM I d M t l I d t

Ti AlloyBar Roll

M t l I d t

NovelManufacturingChemical Industry PM Industry Metals Industry Metals Industry Manufacturing

PackagingPM

AdditiveManufacturing

Part

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Manufacturing

Meltless Ti Alloy TechnologyA New Titanium Supply Chain

Meltless TiMaterial Synthesis

• Efficient chemical processing• Direct alloying

Ti Alloy Powder

Powder Metallurgy

Component Processing • 40% improvement in material yield

• Direct alloying

Novel

Powder

Near Net

Metallurgy

Substitute mill products

p y• 50% reduction in process steps

Novel Alloys

Near Net Shape

Substitute mill products• 50% less mfg cost

N t h iTechnology Net shape processing• 75% less mfg cost

Novel alloys30

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Novel alloys • enhanced properties

Thank you!n y !