ceramic matrix composites taking flight at ge aviation · •cmc materials systems •product...

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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)


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


Technology Maturation & Introduction

January 22, 2018 3


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

http://upload.wikimedia.org/wikipedia/commons/3/3e/FA-18_Hornet_VFA-41.jpg


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


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


Establishing a CMC Supply Chain

January 22, 2018 7


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


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


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


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


Raw Material Build out

12January 22, 2018


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


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


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


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


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


Imagination at work

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