GE Aviation: Perspectives on Clean, Efficient Engines Dr. Dale Carlson May 14, 2013 “I find out what the world needs, then I proceed to invent it.” – Thomas Edison 2 2 GE Aviation GE Aviation Technical innovation … Key to our past and future First U.S. jet engine U.S. turboprop engine Mach 2 engine High bypass engine Variable cycle turbofan engine Unducted fan engine Composite fan blade in airline service 120,000+ lb thrust engine 4D trajectory flight in revenue service Modular power tile FMS-controlled Unmanned Aircraft System 3 GE Aviation 50 years of engine improvements Flight Safety Thrust to Weight 25 8 20 6 15 4 10 5 90% improvement 0 1940 0.9 1960 350% increase 2 0 1980 2000 Fuel Efficiency 1940 130 0.8 120 0.7 110 0.6 100 0.5 0.4 1940 45% improvement 1960 90 1980 2000 80 1940 1960 1980 2000 Engine Noise 35 db decrease 1960 1980 2000 4 GE Aviation Commercial engines…by thrust rating New Technology In Each Power Class 130 100 Did you know? CFM56 Fleet of 22,000 Engines Accumulates 1 Million Hours Every 8.5 Days! GE90-115B GE90-90B GP7282 GE90-85B CF6-80C (FADEC) CF6-80C (PMC) GP7277 GP7270 GE90-76 70 GE9X GENX CF6-80E1A3 CF6-80E1A4 CF6-80E1A2 CF6-80C2 CF6-50 40 R88DT HPT CF6-80A CF6-6 CFM56-5C CFM56-5A CFM56-3 TF39 CFM56-2 10+ 1970 CF34-3A TF34 1980 CFE738 1990 CFM56-7B CFM56-5B CF34-8C CF34-3B LEAP CF34-10 2000 HF120 Passport 2010 World’s Broadest, Most Modern Product Line CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE EA (GP line) is a 50/50 JV between GE and Pratt & Whitney 5 GE Aviation The Future: Global forces/environment 6 GE Aviation Industry drivers Oil & crack spread Energy Information Agency (EIA) WTI 5.1% YoY … Avg August crack spread $36 WTI $/bbl WTI oil $/bbl Refining costs $/bbl (“crack”) EU assurances to support banks & rising tensions with Iran have both pushed oil prices to 3 month high 2009 2010 2012 2011 Global semi-conductor billings U.S Non-defense capital goods orders SIA, 3 month moving average (Per MM) U.S Bureau of Labor Statistics (Orders, seasonally adjusted, $B) Down 3.4% YoY Historical Peak Semi-conductors are high value, low volume commodity … significant for freight demand 2009 2010 2011 2012 Orders signify capital investments & indicator for purchasing … June showed decline continuing 2009 2010 2011 2012 7 GE Aviation Commercial aviation growing steadily Airframe Traffic growth (Trillion RPKs) Production rate (’12 ’14) A380 2.7 3.5 GP 777 7 8.3 GE90 787 3.5 10 GEnx 737 38 42 CFM A320 40 42 CFM EJet 8.7 9.2 CF34 CRJ 2.5 2.5 CF34 9.3% 5.4% CAGR CAGR ‘10 ’14F ’20F Highest production ramp rates in 3 decades … inconsistent with demand growth Boeing and Airbus are increasing rates to ~40 / month. That means: 40 x 2 (Airbus & Boeing) x 11.5 mth. / yr. = 920 / yr. or ~1,000 including the other new single aisles.1,000 x 5 years = 5,000 / 10 yrs. = 10,000 / 20 yrs. = 20,000 aircraft. CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE EA is a 50/50 JV between GE and Pratt & Whitney 8 GE Aviation Technology success takes commitment and opportunity Commitment … $1-2 billion continuous technology investment per year GE90 core tests GP7 core test 1995 2000 GEnx core tests 2005 LEAP eCore tests 2010 CF34-10E GE90 CFM56-5B CF34-8C CFM56-7B Opportunity … GE90-94B GEnx-1B GE90-115B GP7200 GEnx-2B 10 new engines proving and maturing technology CFM i CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE s a 50/50 JV between GE and Snecma EA is a 50/50 JV between GE and Pratt & Whitney 9 GE Aviation Our Industry-Specifically Propulsion • Timescales of innovation long…safety demands technologies to be proven…strategic vision/commitment a must (Gamma TiAl, CMC, etc.)…multi-decade VISION • Almost every flying technology started as a USG funded (NASA, DoD, etc.) early TRL level study, many driven to TRL 5 or 6. Changing dynamics/players…WTO agreement, sequestration, emerging funding sources • Doubling of revenue miles every 13-15 years despite “shocks” such as 911 • Question: How many “tube/wing” iterations are left? 15% campaign/campaign FB improvement a must ICAO 2050 CO2 commitment, other regs looming 10 GE Aviation Technology Readiness to Serve Today and Tomorrow 11 GE Aviation GE Aviation Engineering UK 665 engineers 463 engineers United States Turkey 5529 engineers 126 engineers Mexico 929 engineers Poland India China 142 engineers 644 engineers Over 8000 engineers around the globe 3000 technologists at 5 Global Research Sites 12 GE Aviation Practical innovation … GE’s model Global resources teamed to advance technology Idea creation • Internal + Technology maturation • Cross-disciplinary teams • Customers • Technology roadmaps • Government • TRL/MRL maturation plans • Universities • Long-term growth strategies (300+ relationships) • Tactical funding = Winning products • 30+ new technologies by 2020 13 GE Aviation 2020-2050? Today The Physics of “Readiness to Serve” • Highly Loaded Compressors • Low Loss Inlets • High OPR Low Emissions Combustors • Variable Low Loss Exhausts • Adaptive cycles • Constant Volume Combustion • Distributed Power • Hybrid Electric Transmission Propulsion • Very High BPR Turbofans • Novel Alloys / MMC’s • Non-metallics • Ultra High BPR Turbofans • Open Rotors • Advanced Engine Architectures • Distributed Propulsion • Wake Ingestion 14 GE Aviation Essential technologies … keeping the pipeline filled Technology Composites 2010 Advanced turbofan Lean combustion Advanced cooling Integrated engine and aircraft systems High-temp materials Flight Management Adaptive cycles Advanced architectures 2020 Architecture Integrated propulsion Integrated power generation Core efficiency New designs 15 GE Aviation Technology demonstrator programs AETD FATE HEETE 10s 00s OPEN ROTOR ADVENT 90s 80s AATE 70s TECH56 UDF E3 QCSEE Renewing our technology DNA for new products and upgrades of fielded products GE Proprietary Information Subject to restrictions on the cover or first page 16 GE Aviation Advanced materials 17 GE Aviation Carbon fiber fan blades have proven durability GE90 field experience … No Airworthiness Directives (AD’s) or special inspections No flight line lubrication Incredibly durable … … almost maintenance free 180+ bird ingestion events with only 1 blade not serviceable SOURCE: GE90 in service record 16 30 + YEARS in service + MILLION flight hours 18 GE Aviation Ceramic Matrix Composites … future of performance Enhancement • Stg1 Shroud CMC • CMC HPT stage 2 airfoils • Further CMC incorporation Engine fuel efficiency EIS configuration No cooling air losses 1/3 the weight 1st Higher commercial application 2016 thermal capability Future EIS performance 19 GE Aviation GE ceramic-matrix composites (CMCs) development 1 st G E N E R AT I O N 2 nd G E N E R AT I O N 3 rd G E N E R AT I O N 2000s 2016 2020 Power Generation turbine shroud Aviation LEAP HPT shroud Aviation and Power Gen hot section airfoils and combustor • 15,000+ service hours • 1st FAA certification • 10M+ service hours by ‘20 Game changing material technology … reduced Fuel Burn through lower cooling flow and weight CMC service introductions built on 20+ years of development 20 GE Aviation Gamma TiAl turbine blades World’s first certified intermetallic application 10s TiAl turbine blade Complete Material Database 05s Engine Testing of TiAl Components 00s Component Casting Trials 90s Alloy Development 80s TiAl LPTB weight reduction vs. Ni superalloys … 100 lb./stage 21 GE Aviation Manufacturing Development Turbine airfoils Rotating parts Manufacturing support Automation Dayton Cincinnati Cincinnati Canada PMC/Ox-Ox composites Structures Additive manufacturing CMC composites Cincinnati Cincinnati Cincinnati Newark Technology readiness research to production Manufacturing readiness industrialization 22 GE Aviation Aerodynamics 23 GE Aviation Evolution of fan technology 1992 - CF6-80E Titanium blades Today Compound swept aero Metal casing Composite blades 34 airfoils Composite casing Shrouded 18 airfoils Radial aero Unshrouded High eff / high flow Significant fuel burn reduction 24 GE Aviation eCore technology…delivers thermal efficiency and retention Performance efficiency Double wall, 360º aft case • Next generation 3D Aero • 22:1 PR in 10 stages … best in industry Performance retention • Short, stiff core retains performance • Rigid aft case maintains clearances • Blisks minimize dovetail leakage Operability • Stall-free performance Stage 1-5 blisks 25 GE Aviation Compressor aerodynamics for LEAP Efficiency, performance retention, maintenance costs 3rd generation 3-D aerodynamic design • Advanced sweep • End wall contouring… tip and root • Balanced stage loading Bowed stators Integral bladed disks CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE 26 GE Aviation Advanced turbine cooling & efficiency HPT S1B Hgas LE Film Effectiveness All Streamlines Htc Hrel PS SS xs Cooling Flows HPT S1B Ttb Purge, Leakage Flows 27 GE Aviation Combustion 28 GE Aviation Lean-burn combustion … over 25 million hours of experience Cruise NOx improvement versus typical rich-quench-lean combustor (NOx emission per lb of fuel*) Continued emissions reductions while meeting the increased turbofan cycle demands % RQL NOx emissions 100 75 Dual Annular (CFM) • 10M+ flight hours 50 25 0 Dry Low Emissions (Aeroderivative) • 15M+ industrial hours 1994 • 2-nozzle lean burn mode Twin Annular Premixing Swirler (TAPS) • Compact staging Next-gen TAPS • LEAP engine • Certified on GEnx 1998 *On ground, 1000F combustor inlet temperature Comparison with DLE made assuming equivalent operating pressures and liquid fuel 2011 2016 Potential TAPS evolution … maintenance cost reductions 2020+ CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE. 29 GE Aviation Lean combustion lowers NOx Traditional Combustor Temperature Rise Curve NOx production zone (Fuel / Air Ratio) Lean burning TAPS Combustor .042 .030 Stoichiometric Temperature .030 Temperature .12 .07 Excess Fuel Excess Air Rich Lean (Fuel / Air Ratio) 30 GE Aviation Lean-burn combustion … lowers HPT distress & improves thermal efficiency TAPS lean combustor Typical rich burn • Lean flame reduces local hot spots combustor • Improves turbine part life for better TOW and HPT maintenance cost • Reduced NOx, achieves CAEP/10 limits Local hot spots TAPS lean burn combustor *Twin Annular Pre-mixing Swirler 31 GE Aviation Bringing it all together 32 GE Aviation Technology readiness for EIS and growth Continuous investment produces multiple technologies & innovations Composites Core efficiency Combustor Lighter, durable blades & case 3rd generation 3D aero Low temp. profile and lean burning … maintenance free fan & debris rejection High Press. Ratio HPCs … durable combustor CMC’s / TiAl / Cooling / Coatings Better efficiency with same metal temp. … durable HPT & LPT 33 GE Aviation GEnx Integrating new technologies throughout the engine COMPOSITE CASE & FAN BLADES 1000 lbs./ aircraft CONTROLS LPT Model based TiAl spin casting Distributed High temp packaging HPT 15% reduction in cooling flow Next gen disk materials Entry Into Service in 2011 787 COMBUSTOR 50% NOx margin TAPS FAN BLADE AERO & ACOUSTICS Improved SFC Adv. noise prediction COMPRESSOR Performance retention Adv. aero and stability modeling 747-8 34 GE Aviation LEAP The next generation of technology Entry Into Service ~2016 STRUCTURES Rigid structures 3600 double wall HPC case HPT Proven materials 3D aero Adv. Cooling DIRECT-DRIVE High bypass ratio COMBUSTOR Lean-burn A320 NEO COMAC C919 COMPRESSOR Integral bladed disks Advanced 3D aero COMPOSITES Fan blades & fan case 737 MAX 35 GE Aviation The Future: Open rotor tests GE/FAA/NASA testing began in 2009 Test builds on 1985 demonstration • Acoustics validation • Aero model validation • New blade concepts • Installation effects • Pitch change effects • Pylon, sidewall interaction 36 GE Aviation No Tube & Wing? BLI / Wake Propulsion Reenergizing aircraft wake via distributed propulsion Turbulent B.L. Flat Plate Cummulative Mass Ave P/P0 for 35K/0.8/ISA Condition 120 100 Y (in) 80 60 40 20 0 0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 Cummulative Mass Ave P/P0 Aircraft Installation and integration Critical > 10% Fuel Burn Savings Potential 37 GE Aviation Hybrid Turbo/Electric Engine Concepts NASA N+3 Boeing-GE SUGAR Volt Hybrid Fuel/Battery Airplane N+3 SUGAR GE hFan Hybrid Turbo/Electric Engine Multiple potential configurations • Power transfer between shafts • Back-up power, eliminate APU, EPU • Aircraft systems synergy • Electric idle / taxi operation • Reduced energy costs Superconducting Machines 38 GE Aviation Superconducting Turbo-Electric Propulsion Fuel Burn Reduction* (%) 30 20 10 0 Conventional Turbo-Electric Turbo-Electric Turbo-Electric Turbo-FC-Electric Battery Turbofan Fan Distributed Distributed Distributed Turbo-Electric (FPR~1.6) (FPR~1.35) Fan Wake Fan Wake Fan Distributed (FPR~1.25) (FPR~1.25) (FPR~1.25) Wake Fan (FPR=1.25) * Relative to 2000 SOA TF 39 GE Aviation GE’s commitment … • Technology innovation for customer value • Learning from the world’s largest installed fleet • Focusing on people, processes, and tools • To be prepared for, and shape, the future of flight