GKN Aerospace Fan and Turbine Engine Structures
10110 Rev. 17
Enabling Today´s and Tomorrow’s Propulsion
Dr. Richard Avellán | 16th July 2014
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Contents
• The Company
• The Heritage
• Technology Drivers
• Existing Product Portfolio
• Key Engine Modules &
10110 Rev. 17
Novel Technologies
• Concluding Remarks
Source: Rolls-Royce
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
10110 Rev. 17
GKN Facts
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
3
GKN PLC: Delivering to our Markets
We have four operating divisions: GKN Driveline and GKN
Powder Metallurgy that focus on the automotive market; GKN
Aerospace, and GKN Land Systems. Every division is a market
leader, each outperforming its markets, giving unrivalled expertise
and experience in delivering cutting-edge technology and
engineering to our global customers:
GKN Aerospace
A leading first tier supplier to the
global aviation industry focussing on
aerostructures, engine systems and
products and specialty products.
GKN Driveline
A world leading supplier of
automotive driveline systems
and solutions, including
all-wheel drive.
2013 - Sales by division
£104m
Other
1%
£899m
Land
Systems
12%
£3,416m
Driveline
45%
10110 Rev. 17
£2,243m
Aerospace
30%
Powder
Metallurgy
12%
GKN Powder Metallurgy
The world’s largest manufacturer of
sintered components,
predominantly to the automotive
sector.
GKN Land Systems
A leading supplier of technologydifferentiated power management
solutions and services to the
agricultural, construction, industrial
and mining sectors.
£932m
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
GKN Aerospace
$3.5 billion Global Aerospace company, 35 sites in 9 countries, 11,700 people
Market leaders in airframe structures, engine components and transparencies
Increasing investment in technology and focus on deployment
10110 Rev. 17
Growing global footprint as part of drive for increasing competitiveness
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
GKN Aerospace – World Class Product Portfolio
Aerostructures Global #3
Engine structures
45% of Sales 2013
50% of Sales 2013
Wing
Fuselage
Nacelle and
Pylon
Global #2
Engine Systems and Services
Engine structures
Engine rotatives
Special
products
Global
#1/2
5% of Sales 2013
Transparencies
and Protection
Systems
J-UCAS Fuselage
A380 Fixed Trailing Edge
B747-8 Exhaust
B787 Anti-icing System
A350XWB Rear Spar
CH53K Aft Fuselage
A400M Engine Intake
V22 Fuel Tanks
A330 Flap Skins
10110 Rev. 17
B787 Floor Grid
B767 Winglet
HondaJet Fuselage
B787 Cabin Windows
B787 Inner Core Cowl
Full Engine MRO and support
Ariane 5 Exhaust nozzle
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
F35 Canopy
A Broad Customer Base
Military 27%
Civil 73%
10110 Rev. 17
2013 Sales
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Targeted Innovation – Technology
Engine
Statics
Engine
Rotatives
Future Wing
Technologies
Advanced
Fuselage
Nacelle,
Pylon &
Exhaust
Transparencies Protection
& Coatings
Systems
Composite Technology
Metallic Technology
10110 Rev. 17
Supporting Technology
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
GKN Aerospace Centres of Excellence and R&T Partners
14 13
9
• Intercase compressor
duct aero
19
20
SWEREA
10
4
2 1
Loughborough U.
20
16
19
5
17
15
7
6
18
8
11
• Composite design material,
manufacturing
•Casting technology
•Machining
•Material properties
19
19
3
12
1
Bath University
• Product and production
development
• Materials technology
• Solid mechanics
• Aerothermodynamics
7
University West
• Welding technology
• Machining technology
• Spraying technology
• Manufacturing simulation
• Automation
• NDT
13
UCON Hartford
10110 Rev. 17
• Composite manufacturing
• Additive manufacturing
2
NCC Bristol
• Composite manufacturing
methods
8
ERC Trollhättan
• Product technology
• Design solutions
• Manufacturing technology
• Advanced process
technology
• Automation
• Design methods
14
NACC
(Noth America composite center
• Composite manufacturing
• RTM
3
CRC Cowes
• Composite manufacturing
methods
9
Luleå University
• Solid mechanics
• Manufacturing simulation
• Materials technology
• Composite analysis
15
NAMC (North America
metallic center
• Linear friction welding
• Additive manufacturing
• Advanced machining
4
MTC Coventry
•Advanced assembly and
automation technology
10
KTH Royal Institute
• Aerothermodynamics
• Aero elasticity
• Composite material
16
Univ. of San Diego
• Metallic manufacturing
5
AMRC Sheffield
• Advanced metallic
manufacturing
11
COMPRASER
• Manufacturing of
composite material
17
Stuttgart University
• Turbine aero rig validation
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
6
Chalmers Univ.
• Product and production
development
• Materials technology
• Solid mechanics
• Aerothermodynamics
12
Lund University
• Aero rig validation
• High temperature/pressure
testing
18
Oxford Univ.
• Heat transfer and turbine
aero
A Knowledge Intensive Company
AdjunctAdj
Professors
(5) (5)
professorer
Professors (35)
PhD Students at Universities (50)
Swedish
Education
System
Research
Industrial PhD Students (10)
Ýoung Graduates (5)
MSc Thesis Workers (50)
University
COOP students (12)
Internal Courses (16/year)
Technology
and Product
Development
GKN Aerospace
Trollhättan
• 60 PhDs
• 20 Licentiates
• 300 MSc
• 150 BSc
Training (70+60)
High School
10110 Rev. 17
High School (24)
Elementary
School
Training (120)
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Our Heritage
10110 Rev. 17
Brief History of GKN Aerospace Engine Systems
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
11
Technology History as OEM (Military)
Supersonic:
RM12
RM8
RM6
RM5
RM6
RM1
DB-605
RM8
RM2
RM12
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Subsonic/transonic:
STWC3
DB-605
RM1
RM2
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
RM5
Technology History (Commercial and Space)
90% of the revenue from military business in the
early 1970s
• A strategic decision was made to broaden the company’s operations
• The basic idea was component specialization by world class
technologies
The company successfullyRM1
started commercial
operations in early 1980s
• Technical capability from the military engine programs was a success
factor
• The first commercial engine program was CF6-80
We entered the space market in the mid 70s
10110 Rev. 17
• Manufacturing of thrust chambers and nozzles for the Ariane 4 Viking
Engines
• Development of Nozzle extension, LOx and LH2 supersonic turbines
for the Ariane 5 Vulcain Engines
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
History of Design and Make Responsibility
BR715
PW1517G
GEnx-1B
T900
GEnx-2B
T-XWB
PW1423G
PW1133G
GP7000
1940
1950
1960
1970
1980
1990
2000
2010
2020
VULCAIN 2
RM8
RM5
VINCI
RM6
RM12
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RM2
2030
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Technology Drivers
10110 Rev. 17
Aircraft Engine Technology Trends
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
15
DT
Climate impact
1860
Billion RPMs
6000
Population
10
Increased
travelling
3000
5
10110 Rev. 17
2000
Population growth
01950
2000
2050
0
Adopted from: U.S. Census Bureau, International Data Base, July 2007
Based on ICAP Airline Traffic Monthly
Research and Development
Crude Oil Price Development
Pennsylvanian
Oil boom
140
USD per barrel
120
100
80
60
Iranian
revolution
Arab Spring
OPEC Oil
Embargo
Russian Oil Export
starts
Invasion of
Iraq
40
20
0
10110 Rev. 17
Year
Source: BP, June 2014, "Crude Oil Prices 1861-2012”. 2012 USD
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Efficiency Evolution
26
22
Aircraft
Jet
4.50
Low BPR
4.00
Energy Intensity [MJ/ASK]
Uninstalled Cruise SFC [mg/Ns]
Engine
High BPR
Trend - High BPR
18
Trend - Low BPR
14
ACARE 2020
10
ACARE 2050
New technology needed!
1960
1980
2000
2020
2040
2060
2080
Year of Certification
10110 Rev. 17
Jet
Piston Engine
3.50
Turboprop
3.00
2.50
DC-3
2.00
1.50
1.00
737-800
L-1049
0.50
0.00
6
1940
DH-106 Comet 3
ACARE Strategic
Research Agenda
1930
1945
1960
1975
1990
First Flight
Lockheed L-1049
Super Constellation
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
2005
Boeing 737-800
2020
Trends in Overall Engine Design Parameters
BPR
OPR
20
60
2000
40
1500
20
1000
0
2020 1940
500
2020
1930
15
10
5
0
1960
1980
2000
TET
EIS
• Increasing BPR:
1960
1980
EIS
2000
1950
1970
EIS
1990
• Increasing Pressure and Temperature:
+ Thermal efficiency
+ Jet noise reduction
+ Smaller core engines
- Weight
- Thermal management
- Installation drag
- Emissions of NOx
10110 Rev. 17
+ Propulsive efficiency
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
2010
Requirements and Profitability
Direct Cost Distribution for B737-300
Simulation, 2006
Landing & reg.
7.0%
Finance
1.0%
• Airlines
Fuel & oil
41.6%
Maintenance
27.2%
Depreciation
7.3%
•
Maximize profit ↔ maximize (payload*distance)/(time*cost)
•
Fuel costs typically > 40% of total direct operating costs (DOC), maintenance costs
i.e. time-on-wing also important !
•
Insurance
4.2%
Flight deck crew
11.7%
Aircraft OEMs
•
Maximize distance travelled/unit of fuel, i.e. specific range, S.R.
•
L
dRange
D
Maximize S.R. 

dm
W  SFC
L
D
Vflight
: max(M ) & min(W)
: min(SFC,W, D)
•
Engine OEMs
•
subject to…

Minimize SFC  mfuel 
10110 Rev. 17
FN
•
Vflight
ηth  ηp  LHV
and weight, W, and drag, D
•
Maximize propulsive efficiency, ηp, and thermal efficiency, ηth
•
For ηp increase
fan diameter↑ mass flow↑ jet velocity↓ FPR↓ BPR↑
•
For ηth increase
OPR↑ T41↑ component efficiency↑, thermal mgmt …
System/module/component manufacturers
•
Lightweight designs (W↓), nacelle aero (D↓), Component aero (ΔP/P) (SFC↓) …
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Propulsive, Thermal and Overall Efficiency
Open Rotors
BPR 30-40 and beyond
ηo
High BPR engines
BPR 5 - 10
10110 Rev. 17
Low BPR engines
BPR 0.3 - 1
0.65
0.85
0.95
ηth
0.6
0.4
6.5
7.3
8.5
10.0
GTF/Leap-X
High BPR
12.2
Low BPR
0.4
ACARE 2020
22.0
Lower FPR & BPR increase (fan size)
0.2
ACARE 2050
15.7
TJ
0.2
SFC
0.8
5.8
OPR & T41 increase
PW1000G/Leap-X
BPR 12 approx.
0.45
1.0
Technical risk
UHBR engines
BPR 15-20 and beyond
Mechanical, thermal difficulties, NOx, life
0.25
0.6
ηp
0.8
1.0
Gearbox necessary?
Technical risk
Installation, nacelle drag, LP system weight,
aerodynamic loading
Turbojets
(BPR 0)
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Some Future Aircraft Engine Technical challenges
Short duct nacelle/laminar flow
Acoustic liners
Fan containment & casing
Variable Area Fan
Nozzle
Power off-take
Short intermediate ducts
Adv. 3D fan blade design &
manufacturing
Variable Cycle
Thermal management
OPR 50+,
higher turbine
temperatures
Power gearbox
Combustor & turbine
cooling
Variable Pitch fan blades
Acoustic liners
Adv. 3D OGV design &
manufacturing
10110 Rev. 17
Weight of the LP system
Intelligent Engine
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Requirements
Non-technical factors
R&D +
Manufacturing
cost
Manufact.
Techn.
Low TRL
research
Interdisciplinary
design & system
optimization
10110 Rev. 17
Maint.
cost
Safety
Right design
systems &
methods
Fuel burn
Noise
Emissions
Aeroacoust./
noise suppr.
Lean burn
technology
Low weight
designs
Lifing &
SHM
methods
High core
temp techn.
High
aeroloading
techn.
Advanced
Nacelle/inst.
techn.
Material technology
metal alloys, PMC,
MMC,ceramics,
Organizational
Culture
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
FAA/EASA certification regulations
ICAO & local auth.
Airline
Present Product Portfolio
10110 Rev. 17
Enabling Today´s Propulsion
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
24
GKN Aerospace – World Class Product Portfolio
Aerostructures Global #3
Engine structures
45% of Sales 2013
50% of Sales 2013
Wing
Fuselage
Nacelle and
Pylon
Global #2
Engine Systems and Services
Engine structures
Engine rotatives
Special
products
Global
#1/2
5% of Sales 2013
Transparencies
and Protection
Systems
J-UCAS Fuselage
A380 Fixed Trailing Edge
B747-8 Exhaust
B787 Anti-icing System
A350XWB Rear Spar
CH53K Aft Fuselage
A400M Engine Intake
V22 Fuel Tanks
A330 Flap Skins
10110 Rev. 17
B787 Floor Grid
B767 Winglet
HondaJet Fuselage
B787 Cabin Windows
B787 Inner Core Cowl
Full Engine MRO and support
Ariane 5 Exhaust nozzle
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
F35 Canopy
10110 Rev. 17
Engine Product Portfolio
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
We have a Strong Presence in Today‘s Aircraft Fleets
More than 90 percent of all new large commercial aircraft engines use
our components
For these aircraft we provide:
Engine components
Engine technology
Engine technical support
Engine MRO services
Parts repair
10110 Rev. 17
−
−
−
−
−
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Some of our new Engine Programs
GP7000
GEnx
Trent XWB
GE-P&W
Engine Alliance
General Electric
Rolls-Royce
Trent 1000
Rolls-Royce
Pratt & Whitney
Boeing 787
Boeing 747-8
Airbus A350
XWB
Airbus A320neo
MRJ
Bombardier
CSeries
10110 Rev. 17
Airbus A380
PW1000
Family
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Boeing 787
10110 Rev. 17
GKN Aerospace Engine
Technologies
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
29
Four Module Strategy
Design, design support, manufacturing combined for customer need
Fan Rotatives
Extended Turbine exit
10110 Rev. 17
Booster/Low Pressure Compressor
Fan Statics
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
10110 Rev. 17
Fan Statics Module
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
31
GKN Aerospace Fan Frames Enabling Tomorrow’s
Propulsion
Advanced Manufacturing
Testing
Metals & Composites
Innovative Design Solutions
Advanced Computer Simulations
10110 Rev. 17
GKN Aerospace Design & Make
Experience
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
10110 Rev. 17
Turbine Exhaust Module
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
33
GKN Aerospace Turbine Frames Enabling Tomorrow’s
Propulsion
Manufacturing Simulations
Aerodynamic & Thermal Validation Rigs
Innovative Design Solutions
Destructive testing &
Static load conditions
10110 Rev. 17
GKN Aerospace Design & Make
Experience
Computational Aero
Acoustics & Experiments
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Novel Technologies
10110 Rev. 17
Enabling Tomorrow’s Propulsion
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
35
Technology – Targeted Innovation
Future Product Differentiation
Future Wing
Technologies
Advanced
Fuselage
Nacelle, Pylon
& Exhaust
Engine
Structures
Engine
Rotatives
Transparencies
& Coatings
10110 Rev. 17
Next Generation Composite Processes
Advanced Metallic Processes
Advanced Process Development
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
Ice Protection
Systems
Novel Technologies
Source: Chalmers University
Innovative Propulsion Concepts
Advanced Manufacturing
10110 Rev. 17
Light Weight Designs
Testing and Repair
Advanced Computer Simulations
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
10110 Rev. 17
Concluding Remarks
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
38
Concluding Remarks
GKN Aerospace Engine Systems possesses a strong technical capability
gained by the development and manufacturing of military aircraft engines
The successful expansion into the market for commercial aircraft engines
during the last decades has resulted in GKN Aerospace components in
over 90% of all new large engines
10110 Rev. 17
Our technology enables today´s propulsion and will continue to enable
tomorrow’s propulsion systems!
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion
10110 Rev. 17
Questions?
Source: Airbus
GKN Aerospace Fan and Turbine Engine Structures - Enabling Today´s and Tomorrow´s Propulsion