Jesse Boyer
Fellow - Additive Manufacturing
Additive Manufacturing April 7th, 2015
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Commercial
Engines
Pratt & Whitney
Canada
Military
Engines
Pratt & Whitney
AeroPower
Pratt & Whitney
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It’s in our power
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History
3
It all began in 1925…
...Dependable Engines Frederick Rentschler
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Innovation
What does this mean?
1: the introduction of something new
2: a new idea, method, or device
3: the process of making changes
Webster Definition
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Military Engines Products
Operational
Military Engines
Mobility &
Surveillance Systems
Fifth Generation
Fighter Engines
Advanced Engine
Programs
C-17 Globemaster III
F117 Engine
E-8 JSTARS
JT3D & JT8D Engine
KC-46A Tanker
PW4062 Engine
F-22 Raptor
F119 Engine
F-35 Lightning II
F135 Engine
AH-64 Apache
HPW3000 Engine Predator C Avenger
PW545 Engine Future Applications
Photo credit: U.S. Air Force
EA-6B Prowler
J52 Engine
B-52 Stratofortress
TF33 Engine
F-15 / F-16
F100 Engine
Photo credit: U.S. Air Force Photo credit: U.S. Navy Photo credit: U.S. Air Force
All engine photos credit: Pratt & Whitney
Graphic credit: U.S. Air Force / Sylvia Saab Photo credit: U.S. Air Force /
Staff Sgt. Aaron D. Allamon II
Photo credit: Pratt & Whitney
Photo credit: U.S. Air Force
Photo credit: General Atomics Image credit: Boeing Illustration
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1925 Today Future
Lightweight
Powerful
Reliable
Speed
Range
Weight
Speed
Range
Thrust
Weight
Noise
Fuel economy
Reliability
Weight
High Thrust
Pratt & Whitney Fleet Innovation
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From P&W powered bi-planes to the jet age
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Geared Turbofan™ (GTF)
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Technology development and incorporation
Leaner The PurePower ® PW1000G
engine family improves fuel
burn up to 16 percent versus
today’s best engines from
regional jets to mainline single-
aisle aircraft.
Quieter The PurePower ® PW1000G
reduces aircraft noise
footprints by 50 to 75 percent.
Operating 15 to 20dB below
today’s most stringent
standard (ICAO Stage 4).
Greener The PurePower ® PW1000G
cuts carbon emissions by more
than 3,500 tonnes per aircraft
per year. Cleaner The PurePower ® PW1000G
engine family will surpass the
most stringent standards
(CAEP/6) by 50 percent for
nitrous oxide (Nox).
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Process
Understanding
Cost
Reduction
Design for
Additive
Source
Capability
Prototyping
Additive Manufacturing Alignment
Categories for development and growth
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Resin & Wax
Stereolithography
Powder Based
Non-metallic
Powder Based
Metallic
Powder Based
Aerospace Metallic
Pratt & Whitney Additive Evolution
Rapid prototyping to production
1989: 1st P&W Machine
Supported Structures
Nesting
Unsupported Structures
Tooling, Prototypes
Prototype
Medical Grade
Development
Tooling
Production
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1980’s 1990’s 2000’s Today
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Candidate Part Evolution
Electron Beam Melting
Powder Bed Fusion
Desktop 3D Printing
Aids In Idea Generation
Quick Design Iterations
Laser
Powder Bed Fusion
Additive Manufacturing Tools
• Cost Models
• Build Simulators
• Training Courses
• Design Guides
• Minimum Properties Database
• Standard Work
• Governing Standards
Idea Generation
Build Business Cases
Down Select Processes & Materials
Technology Development & Prototyping
Low Rate and Full Rate Production
The big jump to metals
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Fuel By-pass Manifold
Additive Manufactured Parts
Metallic part examples
Laser Powder Bed Fusion Electron Beam Melting Powder Bed
Bleed Bell Crank Bracket VFG Cooler Mount
AP 24, 31, 32, 34 Fittings
HPC Stators Gearbox Mount
Proximity Probe Bracket PT8 Instrumentation Egress: Oil Strut Torque Box
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GTF Additive Manufacturing
Production examples
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Electron Beam Powder
Bed Fusion
Laser Powder Bed
Fusion
Syn
ch
Rin
g B
rac
ke
ts
Co
mp
res
so
r S
tato
rs
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Freeform Fabrication Methods
Greatest benefit by designing for the process
Phase 1A Phase 1B Phase 2
Direct Substitution Minor Modification for
Process Capability
Design with Optimized Weight,
Cost and Performance
Potential Benefits
Lead-time Savings
Cost and Weight Savings
Purchasing Leverage
Make As Is Design For Producibility Design For Competitive Advantage
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North East US Development Additive
Manufacturing Center of Excellence
Positioning for Continued Success
Collaboration and Standards
Academia University of Connecticut
North Carolina State University
University of Texas at El Paso
Penn State’s Applied Research Laboratory
Industry Original Equipment Manufacturers
Engine Component Suppliers
Engine Customers
Engine Suppliers
Government/Not-For-Profit
America Makes
American Society for Testing and Materials (ASTM)
Society of Automotive Engineers (SAE)
Regulatory Bodies
Other Agencies/Groups (DOD, NCMS, NCDMM, NNMI, NIST, NASA …)
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Conclusion
Leadership, Innovation, Production Differentiation
PW Additive Video
• 25 Year History of Additive Manufacturing
• Various Materials Including Metals Leadership
• Incorporation in the Design, Prototyping, and Production Cycle
• Expand the Design Envelope Based on the Freeform Fabrication Process
Innovation
• Business Case Driven Incorporation to Create Real Value for Our Customers
• Necessary Next Step to Compete Globally
Production Differentiation
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