Perspective on Aero Propulsion Needs for Micro-Nano-Technologies Robert Schafrik GE Aircraft Engines...

Perspective on

Aero Propulsion Needs for

Micro-Nano-Technologies

Robert SchafrikGE Aircraft Engines

[email protected]

Presented at:

CANEUS 20042 November 2004

Monterey, CA

2 Perspective on AeroPropulsion Needs for MCTCaneus 2004, Nov 2, 2004

Overview

Context & Drivers for Innovation

New Product Introduction (NPI) Process

Potential MNT Applications in Jet Engines

Summary & Take Aways

Context & Drivers for Innovation


Drivers for Innovation

Improve Customer Value

Performance

Reliability

Cost of ownership

Mitigation Strategies for Implementation Risk

Technical, Schedule, Cost


Performance Improvement

1956 1958 1961 1962 1968 1974 1981 1986 1992 1992 19960.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

Th

rust

-to

-Wei

gh

t

1956 1958 1961 1962 1968 1974 1981 1986 1992 1992 1996

Year

J57

J79

J85

J58

F10

0

TF

34

F40

4

F11

0-10

0

F11

0-12

9

F10

0-22

9

M88

Ref: Aviation Week


Conceptual Cycles and Temperatures

Cruise

ClimbSupersonic

(Future)Supersonic

(Future)

Time

T41 Land

Take-off

Existing Sub-sonicExisting Sub-sonic

Cruise

Climb


Engine Departure Rate

99.0

99.2

99.4

99.6

99.8

100.0J

an

-88

Ja

n-8

9

Ja

n-9

0

Ja

n-9

1

Ja

n-9

2

Ja

n-9

3

Ja

n-9

4

Ja

n-9

5

Ja

n-9

6

Ja

n-9

7

Ja

n-9

8

Ja

n-9

9

Rat

e

99.97%


Pro

cess

Co

ntr

ol &

ND

E

Improved Engine Materials

NewNewMaterialMaterial

Mat

eria

l Co

mp

osi

tio

n &

Str

uct

ure

Pro

ces

sin

g

Introducing a New Material RequiresMuch More Than Material Development


Interplay of Process and Material Development

Titanium

Stainless Steel

Cobalt

Nickel Superalloys

Polymer Matrix Composites

Thermal Barrier Coatings

Vacuum Induction Melting

Arc Melting

Investment Casting of Complex Shapes

Powder Metal Superalloys

Turbine Coatings

TIM

E

Directionally Solidified and Single Crystal Airfoils

Multiple Vacuum Melting Cycles

Intermetallics

Ceramic Matrix Composites

1950

s19

60s

1970

s19

80s

1990

s20

00s

EB-PVD

Large Structural Castings

Iso-Thermal Forging

SiC Melt Infiltration

Laser Deposition

MNT Materials


Typical Development Times for a New Material

I. Modification of an existing material for a non-critical component Approximately 2-3 years

II. Modification of an existing material for a critical structural component Up to 4 years

III. New material within a system that we already have experience Up to 10 years

• Includes time to define the chemistry and the processing details

IV. New material class Up to 20 years, and beyond

• Includes the time to • Develop design practices that fully exploit the performance of the

material

• Establish a viable industrial base

GRAND CHALLENGEDrastically Reduce Development Times for New Materials

…Without Reducing Application Risk!


Competing Implementation Pressures

New Materials Development

Business NeedRisk

Development Cost Technical Maturity

Business Need Is Driven by Customer Needs and by Competitive Market Forces

Higher efficiency, higher performance, lower cost are important within this context

The Business Process Is Iterative

Adapt to changing conditions and requirements

Constancy of funding to full maturity is seldom available


Dilemmas

A Designer Is Reluctant to Select a New Material Until it is Evaluated in Service

BUT a New Material Cannot be Evaluated in Service Until a Designer Selects it

New Materials Will Not Gain Market Acceptance Before their Costs Decrease

BUT Costs Will Not Decrease Until the Material Gains Market Acceptance

Ref: Arden Bement, Purdue Univ, at National Materials Advisory Board Forum, Feb 2000, Washington, DC


Past Materials Transition Approach

Customer for Materials Development: Materials & Processes (M&P) Organization

Push technology

Tendency to over-sell what a new material will do

Development Approach

Empirical and heuristic-based

Lots of characterization

In actuality, can’t test everything

Bottomline: Required Many, Many Trials Over Many Years


Development Sequence (PAST)

Development Iterations

Make It Test It

Improve It Test It

Cost Reduce It Test It

Materials Development

Idea and Initial Feasibility

Design Practice

Real Component Application

Production Scale-Up

Committed Component Application


Today’s Materials Transition

Customer: Systems Engineering

Set top level requirements

M&P determines specific materials requirements


Beginning to apply M&P modeling and simulation

Use fundamental knowledge to develop models that predict behavior beyond current experience base

Fewer and more focused iterations

Disciplined Design-of-Experiments


Development Sequence (CURRENT)

Development Iterations

Design It Analyze It

Make It Test It

Optimize & Cost Reduce It Test It


Design Practice

Production Scale-Up

Integrated Teams Guided by a Disciplined

Development Process

Manufacturing


Vision for the Future

Customer: Systems Engineering

Materials Development Team integral member of the Systems Engineering Team

Materials development cycle matches design cycle

Perform design study trade-offs with estimated properties

Evolve design practices in parallel with materials development


Fully exploit Materials Modeling and Simulation

Accurately estimate properties with Modeling and Focused Testing

Understand sources of variation


Development Sequence (FUTURE)

Single Development Iteration

Optimized Analysis Validate It


Design Practice

Production Scale-Up

Integrated Teams Guided by a Disciplined

Development Process

Manufacturing

Integrated, Seamless Computational Environment

Across all Disciplines & Objectives

New Product Introduction (NPI) Process


Feasibility Demonstration MaturationTTG3 TTG6 TTG9

Feasibility Demonstration MaturationTG3 TG6 TG9

Product Creation

Initial evaluation-lab scale

Estimates of key characteristics

Sub-scale demonstration

Components

produced to prelim specs

Production windows estim

Process capability fully established -Production specifications in place -Supply chain established

All necessary property data obtained

Computer simulations, sub-scale testing of concepts

Performance estimates made

Full scale testing

Product performnce validated

Technologies at maturation.

Production components designed

Product engines certified

Products enter service

Development StagesProducts launched when

technologies are mature

TOLLGATE

KEY REVIEW

STAGE 0:PREPLANNING

Identify TeamLeader andChampion 0-2

Define InitialScope of theProgram 0-3

EstablishBusiness Need

0-1

Review ScopingPlan with theCustomer 0-4

Select andAssembleCore Team 0-5

STAGE 1:MATERIAL/PROCESSFEASIBILITY

Review Planwith Customerand CommitFunding 1-4

ResearchPrior Work

1-5

Formulate theDetailed Plan

1-3

Conduct Basicor AppliedResearch 1-6

IdentifyCandidateMaterials/Processes 1-7

DefineProgramObjectives 1-1

Define andQuantifySuccess 1-2

EstablishMaterial/ProcessFeasibility 1-8

PLAN

DO

CHECK

Get Feedback,Measure Success andCompare to CustomerRequirements 1-9

Identify andCompileLessonsLearned 1-10

CommunicateLessonsLearned 1-11

DefineFollow-onWork 1-12

DocumentResults 1-13

ACT

STAGE 2:MATERIAL/PROCESSDEMONSTRATION


SelectCandidateSolutions 2-5


2-3

EvaluateCandidateSolution 2-6

Select theApproach

2-7



Establish FundamentalMaterial/ProcessUnderstanding andControl Strategy 2-8

PLAN

DO

DemonstrateMaterial/Process andControl 2-9

CHECK





DocumentResults 2-14

ACT

STAGE 3:PILOT ORPRODUCTIONSCALE-UP



3-3



PLAN

DefineProductionScale-up Issues 3-5

AddressProductionScale-up Issues 3-6

Define andDocument theProcess and ControlMethods 3-7

DOTransition andTrain

3-8

CHECK


Pilot orProductionDemonstrationRun 3-10

ApproveProductionProcess (SSE) 3-9

Release toProduction

3-12




DocumentResults

3-16

ACT

1

2

3

4 5

6

7

8 9 10

Material/Process Development Cycle

Potential MNT Applications

in Jet Engines


Important Material Characteristics

Thermal and Mechanical Stability Maintain desirable micro/nano features during processing

and in-service use

Meet all Mechanical Property Requirements Understand variation Specific requirements depend on the application

Price & Life Cycle Cost Customer Value

Ability to Scale-up for Actual Components Production capacity

Need High Reliability & Availability at Production Rates


Potential Applications in Jet Engines

Nano-structured Coatings

Achieve desired balance of properties that previously were not obtainable

Wear resistant, lubricious coatings

Damping with no substrate debit

Environmental protection coatings with no substrate debit

Polymer Matrix Composites

Enhanced mechanical properties with micro-nano-particles

Carbon nanotubes & clay nano-particles

• Challenges with dispersion, texturing/orientation, bonding to the

matrix, reproducibility of properties, cost, availability

In-situ chem formation (self-assembly) of micro-nano-sized structures

Adhesives important as well


Potential Applications in Jet Engines

Intelligent Materials and Structures

Micro-sensors and actuators

Shape changing polymer matrix composite structure

Structural health and monitoring systems

Challenges with system architecture, feasibility, durability in

severe environmental conditions, etc.

Functional Materials

Novel nano-engineered soft magnetic materials

Permanent magnets for light weight electric motors,

actuators, magnetic bearings


Potential Applications in Jet Engines Monolithic Ceramics

Fine grained silicon nitride for hybrid bearings

Use in applications in which bearings are highly loaded under

severe operating conditions

Challenges with synthesis and consolidation

Metals

Nanophase aluminum alloys with increased strength and toughness

Challenges include synthesis and consolidation, balance of

properties, environmental resistance

Modeling and Simulation of M-N-Materials

Predict properties for different scale lengths

Estimate long time performance in service environment

Optimize materials to achieve desired properties

Summary & Take Aways


Summary

Transition of new materials technology can take considerable time Difficult to “push” materials technology into applications Must understand and mitigate risks

Little experience base for nano materials

Structural applications have the longest development time Consequence of failure is high Nano coatings and functional materials more attractive for early

introduction

Must continue to develop and implement materials modeling and simulation tools

Perhaps only realistic way to reduce number of iterations and long, drawn out time sequence

Goal: Gain “experience” through high fidelity simulations


Sprague’s Law

The first information you hear about a new material is

usually the best thing you’ll ever hear about it

Basis

Initial claims based on scant property data

Early data generated from laboratory quantities

Little consideration given to effects of processing

variations

Lack of understanding that defects ultimately control

usable properties


Take Aways New material should have a significant performance advantage to

displace existing material

Enthusiasm for CNT high…developing most appropriate applications will take further significant effort

CNT has the potential to impact nearly every component in the engine

Focus on highest impact applications to gain acceptance and experience

Transition of CMT is following conventional long drawn-out process for many applications

R&D needs include the following areas:

Modeling of materials behavior at nano length scales for high fidelity simulations of service performance

Manufacturing methods, including synthesis and consolidation

Perspective on Aero Propulsion Needs for Micro-Nano-Technologies Robert Schafrik GE Aircraft Engines...

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