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Additive ManufacturingAdditive ManufacturingAdditive ManufacturingAdditive ManufacturingMay 14th, 2015May 14th, 2015

Bill BrindleyBill BrindleyManager Manager –– Manufacturing and Manufacturing and

Aftermarket TechnologyAftermarket Technology

This document has been publicly released©2015 United Technologies Corporation

Pratt & WhitneyIt’s in our power – 90 Years of Innovation

CommercialEngines

Pratt & WhitneyCanada

MilitaryEngines

Pratt & Whitney AeroPower

3This document has been publicly released©2015 United Technologies Corporation

Military Engines Products

Operational Military Engines

Photo credit: U.S. Air Force Photo credit: U.S. Navy Photo credit: U.S. Air Force

Mobility &

EA-6B ProwlerJ52 Engine

B-52 StratofortressTF33 Engine

F-15 / F-16F100 Engine

y

Surveillance SystemsC-17 Globemaster IIIF117 Engine

E-8 JSTARSJT3D & JT8D Engine

KC-46A TankerPW4062 Engine

Photo credit: U.S. Air Force Graphic credit: U.S. Air Force / Sylvia SaabPhoto credit: U.S. Air Force / Staff Sgt. Aaron D. Allamon II

Fifth Generation Fighter Engines

F-22 Raptor F-35 Lightning IIPhoto credit: U.S. Air Force

Advanced Engine Programs

pF119 Engine F135 Engine

ProgramsAH-64 ApacheHPW3000 Engine

Predator C AvengerPW545 Engine

Future Applications

All engine photos credit: Pratt & Whitney

Photo credit: Pratt & Whitney Photo credit: General Atomics Image credit: Boeing Illustration

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. 88ABW-2013-4382, JSF13-1195 4This document has been publicly released©2015 United Technologies Corporation

Pratt & Whitney Fleet InnovationFrom P&W powered bi-planes to the jet age

Speed

NoiseFuel economy

ReliabilityWeight

High Thrust

SpeedR

RangeThrustWeight

High Thrust

Lightweight Powerful

RangeWeight

1925 Today Future

Reliable


Geared Turbofan™ (GTF)Technology development and incorporation

LLQuieterQuieter

Th P P ® PW1000GLeanerLeanerThe PurePower ® PW1000G engine family improves fuel

burn up to 16 percent versus today’s best engines from

regional jets to mainline single-i l i ft

The PurePower ® PW1000G reduces aircraft noise

footprints by 50 to 75 percent. Operating 15 to 20dB below

today’s most stringent standard (ICAO Stage 4).

aisle aircraft.

GreenerGreenerGreenerGreenerThe PurePower ® PW1000G

cuts carbon emissions by more than 3,500 tonnes per aircraft

per year.CleanerCleanerThe PurePower ® PW1000G engine family will surpass the

t t i t t d d

6

most stringent standards (CAEP/6) by 50 percent for

nitrous oxide (Nox).


Additive Manufacturing AlignmentCategories for development and growth

Process Process UnderstandingUnderstanding

CostCost SourceSourceCost Cost ReductionReduction

Source Source CapabilityCapability

Design for Design for AdditiveAdditive

PrototypingPrototypingAdditiveAdditive


Geared Turbofan™ (GTF)Enabling Technology includes Additive Manufacture

AM Efforts in support of GTFToolingToolingPrototypingRig components Engine Test componentsEngine Test componentsLow Rate Initial ProductionCost Effective Full Production


Pratt & Whitney Additive Evolution

Resin & Wax Powder Based Powder Based Powder Based

Rapid prototyping to production

Stereolithography Non-metallic Metallic Aerospace Metallic

1989: 1st P&W Machine

Supported Structures

Nesting

Unsupported Structures

Tooling Prototypes

Prototype

Medical Grade

Development

Tooling

ProductionTooling, Prototypes Production

1980’s 1990’s 2000’s Today


Candidate Part Evolution

Additive Manufacturing Additive Manufacturing

The big jump to metals – A part is a shape having the needed properties

ggTools Tools

• Cost Models• Build Simulators• Training Courses

• Cost Models• Build Simulators• Training Courses

Idea Generation

Desktop 3D Printing Aids In Idea Generation

g• Design Guides• Minimum Properties

Database• Standard Work

G i St d d

g• Design Guides• Minimum Properties

Database• Standard Work

G i St d d

Build Business Cases

Quick Design Iterations • Governing Standards• Governing StandardsDown Select Processes & Materials

Technology DevelopmentTechnology Development & Prototyping

Low Rate and Full Rate

Electron Beam MeltingPowder Bed Fusion

LaserPowder Bed Fusion

Production


Additive Manufactured PartsMetallic component examples

Laser Powder Bed Fusion Electron Beam Melting Powder Bed

Fuel By-pass ManifoldProximity Probe Bracket PT8 Instrumentation Egress: Oil Strut Torque Box

Bl d B ll C k B k t VFG C l M t

AP 24, 31, 32, 34 Fittings

Bleed Bell Crank Bracket VFG Cooler Mount

HPC Stators Gearbox Mount

2000+ parts built to support test rigs, engine development,


engine test, or are headed to production

GTF Additive ManufacturingProduction examples

acke

tsac

kets

Stat

ors

Stat

ors

Sync

h R

ing

Br

Sync

h R

ing

Br

Com

pres

sor S

Com

pres

sor S

Electron Beam Powder Electron Beam Powder Bed FusionBed Fusion

Laser Powder Bed Laser Powder Bed FusionFusion


Freeform Fabrication MethodsGreatest benefit by designing for the process

Potential BenefitsLead-time Savings

Cost and Weight Savings

Purchasing Leverage

Phase 1A Phase 1B Phase 2Purchasing Leverage

Make As Is Design For Producibility Design For Competitive Advantage

Direct SubstitutionMinor Modification for

Process Capability

Design with Optimized Weight,

Cost and PerformanceProcess Capability Cost and Performance


Positioning for Continued SuccessCollaboration and StandardsAcademiaAcademia University of Connecticut

North Carolina State University

University of Texas at El Paso

P St t ’ A li d R h L b tPenn State’s Applied Research Laboratory

IndustryIndustry Original Equipment Manufacturers

Engine Component Suppliers

North East US Development Additive North East US Development Additive Manufacturing Center of ExcellenceManufacturing Center of Excellence

Engine Customers

Engine Suppliers

G t/G t/Government/Government/NotNot--ForFor--ProfitProfit

America Makes

American Society for Testing and Materials (ASTM)

Society of Automotive Engineers (SAE)

Regulatory BodiesRegulatory Bodies

Other Agencies/Groups (DOD, NCMS, NCDMM, NNMI, NIST, NASA …)


ConclusionLeadership, Innovation, Production Differentiation

• 25 Year History of Additive Manufacturing

• Various Materials Including Metals

• 25 Year History of Additive Manufacturing

• Various Materials Including MetalsLeadership

PW Additive Video• Incorporation in the Design,

Prototyping, and Production Cycle• Expand the Design Envelope Based

on the Freeform Fabrication Process

• Incorporation in the Design, Prototyping, and Production Cycle

• Expand the Design Envelope Based on the Freeform Fabrication Process

Innovationon the Freeform Fabrication Processon the Freeform Fabrication Process

• Business Case Driven Incorporation to Create Real Value for Our Customers

• Business Case Driven Incorporation to Create Real Value for Our CustomersProduction Create Real Value for Our Customers

• Necessary Next Step to Compete Globally

Create Real Value for Our Customers• Necessary Next Step to Compete

Globally

Production Differentiation


15

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