Perspective on Aero Propulsion Needs for MicroNanoTechnologies

1
Perspective on Aero Propulsion Needs for
Micro-Nano-Technologies

• Robert Schafrik
• GE Aircraft Engines
• robert.schafrik_at_ae.ge.com
• Presented at
• CANEUS 2004
• 2 November 2004
• Monterey, CA

2
Overview

• Context Drivers for Innovation
• New Product Introduction (NPI) Process
• Potential MNT Applications in Jet Engines
• Summary Take Aways

3
Context Drivers for Innovation
4
Drivers for Innovation

• Improve Customer Value
• Performance
• Reliability
• Cost of ownership
• Mitigation Strategies for Implementation Risk
• Technical, Schedule, Cost

5
Performance Improvement
Thrust-to-Weight
F110-129
F100-229
F110-100
F404
TF34
F100
M88
J79
J85
J58
J57
1956
1958
1961
1962
1968
1974
1981
1986
1992
1992
1996
1956
1958
1961
1962
1968
1974
1981
1986
1992
1992
1996
Ref Aviation Week
Year
6
Conceptual Cycles and Temperatures
Take-off
Cruise
Climb
Supersonic (Future)
Climb
T41
Land
Cruise
Existing Sub-sonic
Time
7
Engine Departure Rate
99.97
100.0
99.8
99.6
Rate
99.4
99.2
99.0
Jan-88
Jan-89
Jan-90
Jan-91
Jan-92
Jan-93
Jan-94
Jan-95
Jan-96
Jan-97
Jan-98
Jan-99
8
Improved Engine Materials
New Material
Material Composition Structure
Process Control NDE
Introducing a New Material Requires Much More
Than Material Development
9
Interplay of Process and Material Development
MNT Materials
Intermetallics
Ceramic Matrix Composites
SiC Melt Infiltration
Laser Deposition
Thermal Barrier Coatings
Directionally Solidified and Single Crystal
Airfoils
Powder Metal Superalloys
EB-PVD
Large Structural Castings
Polymer Matrix Composites
TIME
Iso-Thermal Forging
Multiple Vacuum Melting Cycles
Turbine Coatings
Investment Casting of Complex Shapes
Titanium
Arc Melting
Nickel Superalloys
Cobalt
Vacuum Induction Melting
Stainless Steel
10
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!
11
Competing Implementation Pressures

• 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

12
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
13
Past Materials Transition Approach

• Customer for Materials Development Materials
  Processes (MP) Organization
• Push technology
• Tendency to over-sell what a new material will do
• Development Approach
• Empirical and heuristic-based
• Lots of characterization
• In actuality, cant test everything
• Bottomline Required Many, Many Trials Over Many
  Years

14
Development Sequence (PAST)

• Development Iterations
• Make It ?Test It
• Improve It ? Test It
• Cost Reduce It ? Test It

15
Todays Materials Transition

• Customer Systems Engineering
• Set top level requirements
• MP determines specific materials requirements
• Development Approach
• Beginning to apply MP 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

16
Development Sequence (CURRENT)
Design Practice
Integrated Teams Guided by a Disciplined
Development Process
Production Scale-Up
Materials Development
Manufacturing

• Development Iterations
• Design It ?Analyze It
• Make It ? Test It
• Optimize Cost Reduce It ? Test It

17
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
• Development Approach
• Fully exploit Materials Modeling and Simulation
• Accurately estimate properties with Modeling and
  Focused Testing
• Understand sources of variation

18
Development Sequence (FUTURE)
Integrated Teams Guided by a Disciplined
Development Process
Production Scale-Up
Integrated, Seamless Computational Environment

• Single Development Iteration
• Optimized Analysis ?Validate It

Across all Disciplines Objectives
19
New Product Introduction (NPI) Process
20
Development Stages
Products launched when technologies are mature
Initial evaluation- lab scale Estimates of key
characteristics
Process capability fully established
-Production specifications in place -Supply
chain established All necessary property data
obtained
Sub-scale demonstration Components produced to
prelim specs Production windows estim
Product Creation
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
21
Material/Process Development Cycle
TOLLGATE
STAGE 0 PREPLANNING
STAGE 1 MATERIAL/PROCESS FEASIBILITY
STAGE 2 MATERIAL/PROCESS DEMONSTRATION
ACT
DO
PLAN

Review Plan with Customer and Commit Funding
3-4
Define Production Scale-up Issues
3-5
Address Production Scale-up Issues
3-6
Define and Document the Process and
Control Methods 3-7
Transition and Train 3-8
Formulate the Detailed Plan
3-3
Define Program Objectives 3-1
Define and Quantify Success 3-2
STAGE 3 PILOT OR PRODUCTION SCALE-UP
22
Potential MNT Applications in Jet Engines
23
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
24
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

25
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

26
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

27
Summary Take Aways
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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

29
Spragues Law

• The first information you hear about a new
  material is usually the best thing youll 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

30
Take Aways

• New material should have a significant
  performance advantage to displace existing
  material
• Enthusiasm for CNT highdeveloping 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
• RD 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