Session 2 Robert Lundberg.pdf

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Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It LightJanuary 2008, Slide 1

Robert LundbergEU R&D Director

Lättviktsteknologi för flygmotorer

sparar vikt och bränsle

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Shaft

Vanes

Fan/compressor structures

Turbine structures

Compressor rotors

Combustor structure

LPT-Case

Fan Case

Volvo Aero’s commercial componentspecialization

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JT8 engine (MD80)Bypass relation =1

Trent 1000 (B787)Bypass relation = 11

Larger fans and LP turbines in modern enginesmore focus on light weight components

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Open rotor change the scene?

Open rotor

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• The Volvo Aero target is to reduce the weight of cold and hot engine structures by 20% which will reduce the engine weight of future engines by almost 3 %.

• If implemented in the current global commercial aircraft fleet this would reduce CO2 emissions by 1.3 million tons per year. For comparison, air traffic in Swedish airspace generated 1.5 million tons CO2 during 2005.

to reduce CO2

Lightweight technology

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Volvo Aeros lightweight solutions

• New manufacturing technologiesfabrication, weld modelingautomationmetal deposition

• New materialscomposites

• Intelligent aerodynamic designcompressor design

Make It Light

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Fabrication of engine structures

• Use sheet metal and forged rings instead of large castings

• Weld modeling, automation and metal deposition are key technologies to achieve optimized fabrications

• Save 10-15% weight

Make It Light

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We are world leaders in weld modeling

• Our weld modeling minimizes deformation and weight

• Optimized parameters, geometry and sequencing

• Weld modeling is an enabling technology for lightweight fabrications

Make It Light

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We are developing metal deposition

• Laser or TIG welding• Powder or wire as material source• Building bosses and flanges on sheet

metal or forged stock• Sheet and forged material (and MD

material) is stronger than cast material => weight savings

Make It Light

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Important synergies with space propulsion technology

• Laser welded T-joint with automatedweld guidance system (patent)

• Laser Metal Deposition of stiffeners

Developed for rocket nozzlesNow used for aero engine components

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Geometrical features suitable for metal deposition

bosses

flange

stiffener

engine mount

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Carbon fiber composites

Composite fan case

Composite fan blades

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• Lightweight fan frame developed in the EU funded VITAL project

• Patented carbon-fiber designshows good performance

• A resin transfer molding processenables high-volume production

• Industrialization at ACAB Linköping

Volvo Aero develop30% lighter compositefan frame

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leveransbild

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Fan blade-out test successful

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Compressor development

• 3D aerodesign of blades and vanes• Fewer stages (9 -> 5)• Blisk design

=> 40% lower weight

Successful testing of VITAL LP compressor

Synergies with development of militaryengine fan module

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Volvo Aero is already contributing with lightweight designs

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Partner with General Electric in the GEnx engine for B787 & B747-8

Volvo Aero development, manufacture and product support throughout the life cycle

Turbine Rear Frame

Fan Hub Frame

Booster Spool

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Our contribution to GEnxis lightweight designs

• Turbine Rear Frameoptimized fabricated componentconcept developed in ANTLE EU project (FP5)

=> 10 % lighter

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GP7000 Turbine Exhaust Case

• Volvo Aero has been contracted by Pratt & Whitney to reduce the weight of the turbine exhaust case for GP7000

• Volvo Aero’s design reduces the weight of the part by more than 10%• Production to start 2010

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MRJ Mitsubishi Regional Jet

Bombardier CSeries

PW1000G Geared Turbofan

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Trent XWB

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• Volvo Aero is Associate Partner in Clean Sky• Budget for Volvo Aero: 21 M€ (50% from EU)• Involved mainly in 3 engine demonstrators:

• Open Rotor (geared) – Rolls-Royce• Open Rotor (direct drive) – Snecma• Geared Turbofan – MTU

RR Open Rotor Snecma Open Rotor MTU Geared Turbofan

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Conclusion

• Light weight for reduced CO2• Volvo Aero light weight technologies:

• Manufacturing• Composites• Aero design

• Important to be able to continue our participation in demonstrator programs

• Utilize synergies with space and military programs• Light weight technologies lead to business: GEnx,

GP7000, PW1000G, Trent XWB

Session 2 Robert Lundberg.pdf

Business

Transcript of Session 2 Robert Lundberg.pdf