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
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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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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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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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)
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 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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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
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