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“Repeatability”
Chris PhilpAdditive Process Manager, Additive Integrated Product Team (IPT)GE Aviation
October 17, 2019
REPEATABILITY
REPEATABILITY REPEATABILITY
1-Column Layout
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Who?Where?Why?How?When?Why? (again)
To lead the aviation industry in the application of additive technologies from design through industrialization to impact engine cost, weight, & performance.
ONE Aviation TeamONE Additive Mission
GE Aviation Additive IPT(Integrated Product Team)
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The Who?
6
GE Aviation Additive IPT Global Footprint
BEC – Bangalore
Avio Aero – Turin (TAL)• “ATC Europe” & EBM Tech MatGEIQ – Queretaro
ATC – Cincinnati• Headquarters• NPI & cost out across PLs• Full technology roadmap
GEAC – PragueEDC – Warsaw
TTC – Istanbul
Auburn • DMLM Production
Avio Aero – Cameri• GE9x EBM Production
Avio Aero – Brindisi• Future Catalyst DMLM
Production
Engineering/Development
Component Production
Pittsburgh • DMLM & Future
EBM Production
The Where?
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3rd
generationCMC materials
2nd#1most efficient engine in its class
generation Additive parts
4th
Generation compositefan blades
5th
generationarchitecture
~
M A R G I N
CAEP 8 NOxregulations
10%L O W E R
Specific FuelBurnversus GE90-115B
30%
5%
SFCthan any 2020 twin-aisle engine in service
8 dbStg 5 noise regulations
M A R G I N
B E T T E R
SPECIFIC FUEL CONSUMPTION
The Why? GE9X … world’s largest engine entering service in 2020
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28
Inducers8
STAGE 5 & 6LPT BLADES
228T25 SENSOR
1
HEAT EXCHANGER
1COMBUSTOR
MIXERS
28
FUEL NOZZLES
GE9X … highest number of additive parts to date
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DURABLE5x More
PARTS20 1
PRECISE30% More
PARTS10 1
LIGHTER50%
T25 SENSOR
FUEL NOZZLE
STAGE 5&6LPT BLADE
INDUCER
DURABLE2x More
PARTS13 1
MIXER
DURABLE3x More
LIGHTER6%
PARTS163 1
LIGHTER40%
SERVO HX
Buy to Fly3 2Target
GE9X … power of Additive
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https://www.youtube.com/watch?v=v6frvqHwQfI
GE9X … world record breaker:134,000 lbs. of thrust
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The How?
Typical production challenges…
• Printing repeatability
• Part quality
• Manufacturing productivity
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The How?
Key factors contributing to variation
• Not monitoring the “critical Xs”
• Poor understanding of the ranges of control
• Lack of machine configuration control
• Incomplete work instructions for operators and maintenance
• No experienced additive machine engineers
and lack of repeatability
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The How?
Critical Xs
• Beam Spot Size & Focal Flatness
• Beam Quality/Shape (Beam Profiling/Caustic)
• Scanfield Alignment (Position/Overlap)
• Power (Laser Degradation)
• Z Axis Accuracy (Layer Thickness)
• Airflow Consistency (Filter Cleanliness)
• Oxygen (Material Properties)
• Recoater Blade (Alignment & Reuse)
• Cleanliness (Affects all the above)
• Standard Work
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The When?
Timing & Reoccurrence
• Initially always refer to the OEM preventative maintenance and suggested calibration intervals
• Check and verify the critical X’s regularly as you learn get more experience on the machine
• Validate the consistency of your critical X’s over time
• Determine the calibration intervals required to maintain your part quality
• Remember the key events that should trigger a recalibration:•Machine Movement •Replacement of key components •Software updates •Material changes
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Production Reality
Org
an
iza
tio
na
l e
nth
usi
asm
Time
InitialInvestment
ProductionChallenges
Scaling Challenges
Initial Production
The Why? (again)
REPEATABILITY
REPEATABILITY REPEATABILITY
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The GE Catalyst engine
Combustor test schedule reduced from 12 months to 6 months
PARTS855 12 LOWER
20%
FUEL BURN
WEIGHT 5%
REDUCTION
The Why? (again)
REPEATABILITY
REPEATABILITY REPEATABILITY
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The Why? (again)
REPEATABILITY
REPEATABILITY REPEATABILITY
Oct 30 2018 - 30,000LEAP Fuel tips shipped
Current build rate 4,000 tips/month