ceramic matrix composites taking flight at ge aviation · 2016 2026 $3.0b ~9.5% growth rate1 $7.5b...
Post on 26-Jul-2020
6 Views
Preview:
TRANSCRIPT
©2018 General Electric Company – All rights reserved
Ceramic Matrix Composites taking flight at GE Aviation May 1, 2018
LEAP is a product of CFM International, a 50/50 joint company between GE and Snecma (Safran)
©2018 General Electric Company – All rights reserved
Presentation Outline
• CMC Materials Systems
• Product Introduction
• Technology Maturation
• Industrialization
• Raw Material Sites
• Market Potential
2
LEAP is a product of CFM International, a 50/50 joint company between GE and Safran Aircraft Engines
January 22, 2018
©2018 General Electric Company – All rights reserved
Technology Maturation & Introduction
January 22, 2018 3
©2018 General Electric Company – All rights reserved
GE Aviation: SiC/SiC CMC Engine Test Experience
1st LPT blade testin F414 engine
1st blade in military test engine
3,000 cyclestest engine
Shroud in advancedhelicopter
World recordcompressor exit and turbine inlet temp
Multiple parts ADVENT test engine
1st JSF engine test
LPT nozzle
LEAP FETT
GE9X core test
F414 blade 1000 endurance cycles
2000-2009 2010 →
A320neo 1st flight
1st delivery
1st Commercial engine test
(combustor liners)
January 22, 2018 4
©2018 General Electric Company – All rights reserved
SiC/SiC CMC Component Certification: Commercial Engines
5
LEAP* Shroud
• Factory Testing: 77 engines/builds; 12,191 endurance cycles; 8,358 hrs run time
• Joint EASA/FAA Part 33 Certification – May 4, 2016
• Fleet statistics from the field:➢ Over 500 engines delivered➢ Total engine run time >50,000 hours
GE9x Components
• Engine certification program in-progress
• Delivered 8 test engines to date
• Factory Testing: 350+ endurance cycles; >800 hrs run time
• Additional 22 engine sets planned thru 2019
• Targeting engine certification 1Q19
CMC Combustor Liners, HPT shroud, HPT nozzles
LEAP is a product of CFM International, a 50/50 joint company between GE and Safran Aircraft Engines
January 22, 2018
©2018 General Electric Company – All rights reserved
Technology maturationinvention, application & industrialization
technology readiness➔ turnkey solutions, research to production
manufacturing readiness ➔ industrialization for cost and producibility
Global Research Center FastWorks lab
full-scale production
(Huntsville, ALAsheville, NC)
Supply chain
low rateProduction
(Newark DE)
product & process development
(Cincinnati, OH)
Lean lab
need idea researchproof of concept
product design
(Niskayuna, NY/Cincinnati, OH)
6January 22, 2018
©2018 General Electric Company – All rights reserved
Establishing a CMC Supply Chain
January 22, 2018 7
©2018 General Electric Company – All rights reserved
1Minerals Metals and Materials Society Journal, IJAER, ASM International, Composites World Blog, Grand View Research
GE Aviation High Temperature Composite Supply Chain
8
Fibers
Weavering /Prepregging
Large OEM toGEA Specification
Multiple Suppliers
Multiple Suppliers
Oxide
SiC
Carbon
Other
Matrix Material1
Multiple Suppliers
Densification
Coating
Asheville
Huntsville
Newark
Newark
Oxide SiC Carbon
A 50/25/25 JV betweenNippon Carbon Company, GE and Safran
50/50 JV betweenGE Aviation and Turbocoating Corp
Multiple SuppliersLarge OEM
January 22, 2018
©2018 General Electric Company – All rights reserved
Implementing a new SiC/SiC Supply Chain
Growing JVs Industrializing Building high-volume production facilities
NGS Advanced Fibers Co., Ltd. is a 50/25/25 JV between Nippon Carbon Company, GE and SafranAdvanced Ceramic Coatings, is a 50/50 JV between GE Aviation and Turbocoating Corp
Asheville, NC
Huntsville, ALAdvanced
Silicon Carbide
Fibers, LLC
9January 22, 2018
Newark, DEGEAviation
©2018 General Electric Company – All rights reserved
CMC Site Locations
Composites COEEvendale, Ohio
Advanced Silicon Carbide FibersHuntsville, AL
Asheville, NC
Newark, DE
Huntsville, AL
NGS Advanced FibersToyama, Japan
Core Engine Manufacturing Sites
Joint Ventures
Advanced Ceramic CoatingsDuncan, SC
10January 22, 2018
©2018 General Electric Company – All rights reserved
33
22
11
44
Ap
ril 0
3, 2
019
USG - GE partnership on Raw Material Maturation
OSD Title III Program for Domestic SiC Fiber
Full system run in 2015
MANTECH : Prepregging –Demonstrated technology in 2010
MANTECH :TOW Transport Testbed
MANTECH : Definition of in-line processing conditions
1 System operational in DE 3 on order for Huntsville
Fiber coating
SiC fiber Wet drum winding
Slurry prepregging
SBIR w/ Surface Optics : In line FTIR coating measurements
29 months into 44 mo. programfor domestic SiC
fiber
11
Huntsville, AL
January 22, 2018
©2018 General Electric Company – All rights reserved
Raw Material Build out
12January 22, 2018
©2018 General Electric Company – All rights reserved
Component Manufacturing – Asheville, NC
Dedicated component facility opened in Oct 2014
Delivered first production LEAP set Oct 2015
Preparing flow lines for GE9X part transition in 2018
Lay-up Preforming Machining Inspection
Compaction &
Densification
SiSiSiSiSiSiSiSi
13
Created LEAP flow line Current State – 20 min TAKTFuture State – 5 min TAKT
January 22, 2018
©2018 General Electric Company – All rights reserved
Digital Vision… Data Driven
14
Lay-up Preforming Machining Inspection
Compaction &
Densification
SiSiSiSiSiSiSiSi
Fiber coating
SiC fiber Wet drum winding
Slurry prepregging
Quick validation of process changes Manage WIP
Equipment Health
Tape Conformance
Component Conformance
Microstructure Validation
✓
✓
Process Modeling
Microscopy
Input material conformance
Process Health
January 22, 2018
©2018 General Electric Company – All rights reserved
Cost Out – LEAP* Experience
• Created Integrated Product team
• Transitioned part to Asheville, NC
• Data analytics identifying opportunities
• LEAN
• Design producibility
• Optimized processing cycles Shro
ud
Sh
ipse
t C
ost
($
)
2013 2015 2017
15
*LEAP is a product of CFM International, a 50/50 joint company between GE and Snecma (Safran)
January 22, 2018
©2018 General Electric Company – All rights reserved
Establishing Capacity … Leads to Future Opportunity
16
An
nu
al D
eman
d
2015 2020 2025 2030
Productivity & Equipment Utilization
Full Campus BuildoutUS & Japan
Huntsville, AL
Toyama, Japan
January 22, 2018
©2018 General Electric Company – All rights reserved
2016 2026
~9.5% Growth Rate1$3.0B $7.5B1ReportBuyer (April 2017) 2
Minerals Metals and Materials Society Journal, IJAER, ASM International, Composites World Blog, Grand View Research
Hypersonics
Space LaunchSatellite / CargoCommercial Space
Missile Defense
Aero Engine
Brakes
NuclearOther
Oxide
SiC
Carbon
Other31.1%
35.3%
19.9%
13.7%
Matrix Material2 Industry
Missile Defense
Space / SatelliteLaunch
Brakes
High Temperature Composite Market Potential
17January 22, 2018
©2018 General Electric Company – All rights reserved
Imagination at work
top related