Emerging Trends in

Aviation Propulsion

John Quinn
GE Aviation
October 25th, 2012
Top Industry Challenges, 2012
 Declining defense
budgets

 Increased cost of
weapons systems
procurement

 Increased sustainment “In the year 2054, the entire defense budget will
costs purchase just one tactical aircraft. This aircraft
will have to be shared by the Air Force and Navy
3½ days each per week except for leap year,
when it will be made available to the Marines for
 Cost of energy the extra day.” *

*Augustine’s Laws. Source Wikipedia. Creative Commons citation.

Aviation strategy for a volatile world…
Provides a firm foundation for affordable military and commercial products

Processes Technologies Architecture

Maintenance Essential technologies New Products
concepts
Demonstrators

Cost modeling

Probabilistic
lifing
Non Brayton cycle

cost containment, reduced development times becoming

important differentiators 3
Processes
GE Military Services Processes
2 Customer – Point of Use 1 Material Management/Planning
GE Supply Chain
Customer
Suppliers

New Parts
Bases /Squadrons 3 Warehouse
Forward deployed
Management
GE REP

4 Depot/Shops – Point of Repair

Warehouse
Repair Facilities Depot DATA
& OEMs SYSTEM
GE REP

6 GE/Customer Engineering & Mgmt Customer Systems

5
Shared Customer

metrics

5
GE Aviation
Development cost modeling…

6
GE Aviation
Probabilistic Fracture Mechanics (PFM)
New PFM surface
anomaly distributions

• Identifies individual feature

contribution to component
Probability of Fracture
(POF)

• Potential to eliminate
depot EC inspections for
features that contribute
little to overall POF

7
GE – Aviation
PFM Implementation Program
Potential to implement PFM for reduced depot inspection
requirements.

With Depot EC With FPI

Appropriate use of EC and FPI provides opportunity for

customer cost savings
8
GE – Aviation
Technology
Technology starts with R&D…
TRL Technology Readiness Level
GE Global Research – 5 locations, New York, Bangalore,
Shanghai, Munich, Rio. Approx 3,000 employees

MRL Manufacturing Readiness Level

Inspection / NDE, Welding / Brazing, Laser
Machining

MatRL Materials Readiness Level

New materials, Mechanical Testing, Tribology
Composite Processing, Special Coatings

IRL Integration Readiness Level

Thermal management, Inlet particle separators,
exhaust systems, IR, special coatings

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Essential technologies
Keeping the pipeline filled

Augmentor
High-Temp
Adaptable fans Advanced HXRs CMCs Adv. Cooling Technology
Materials

Integrated Adaptive
Advanced engine and cycles
2010 products aircraft Advanced
2020
systems architectures
Rapid Prototyping Activities
Direct Metal Laser Melting: Laser Manufacturing:
Laser melts metal powder layer Metal powder is introduced directly into
by layer to create complex, 3D laser creating large components layer
components. by layer

Dieless Sheet Forming: Increased speed

Sheet metal is locally
and incrementally Early detection of design issues
drawn using stylus
above and below work Development tooling costs reduced
piece
Catalyst for innovation

Electroforming:
Nickel alloy is plated directly onto
temporary tooling – creating
complex 3D shapes
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Inlet Particle Separator Technology…
• State-of-the-art component test
capability

• Extensive IPS geometry experimental

development

• Rapid Prototyping Techniques

• Latest in aerodynamic CFD and

particle physics modeling

• Collaboration with GE GRC

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February 2012
Architecture
Technology Demonstrator Programs
Strong history … military/commercial benefits today & beyond
2010’s
2000’s HEETE
AETD

90’s ADVENT

AATE, FATE
80’s LEAP

Tech56

70’s UDF
Passport

E3 GEnx
GE38
QCSEE
GE90

CF6 F414
CFM56
T700

CFM International is 50/50 joint venture with Snecma (SAFRAN Group)

LEAP is a registered trademark of CFM International

F101
Architecture: Technology demonstrators
Military/commercial technology synergies

AATE FATE ADVENT HEETE

(Advanced Affordable (Future Affordable (Adaptive Versatile (Highly Efficient,
Turbine Engine) Turbine Engine) Engine Technology) Embedded Turbine
Engine)

US Navy/
Customer US Army US Army US Air Force
US Air Force
Program 25% better SFC 35% better SFC 20-200+% better
35% better SFC
goals 65% hp/wt 80% hp/wt SFC
3D aero, 3D aero, Variable cycle, 3D aero,
Technologies
materials efficiency 3D aero, FLADETM efficiency
Attack/utility Heavy lift
Segments Combat aircraft Tanker/Transport
Helicopters Helicopters

Blackhawk NextGen heavy lift 6th Generation KC-135

Adaptive Engine Technology Development
• AETD…new class of engines with
up to 25% better fuel efficiency

• Variable cycle technology

• Technology demonstration that

builds on ADVENT

• Foundation for future generation

of combat propulsion

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F110 Product Family…Common Core
Service Life Extension Program Benefits
• SLEP exceeding program
goals….record setting time on
wing. 2X base or better

• NRIFSD rate at zero

• Provides reduced cost of

ownership and improved
readiness

• Incorporation of SLEP critical

to long term affordable
supportability of all F110
family engines

• Enables affordable upgrade

to the 6000 TAC configuration

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February 2011
GE38 Development…Heavy Lift
Power for the Sikorsky CH53K
• GE38 Versus T64 : • Successfully completed
1,000 hr missionized
18% Improved SFC
durability test.
57% More power
Performance retention
63% Fewer Parts
excellent.

• All ground test vehicle engines • Submitted 90% of required

installed. A/C rolled out. test reports for first flight.

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 Non-Brayton Cycle Propulsion
(Electric, etc.)

Hybrid Turbo-Electric
Propulsion
Brayton Cycle Propulsion
(Turbo Gas Generators) Key Technologies to Bridge The Gaps
High OPR Cores
Advanced Propulsors (FLADE™, Open Rotor, etc.)
Electrical Systems (Fuel Cells, Batteries,
Superconductivity, Electric Motors, etc.)
Distributed Propulsion Concepts

1950 - 2010 2010 - 2030 2030 - 2050

Timeframe
LNG as a transportation fuel…
Marine – Emissions regulations
driving change to littoral vessels

Rail – LNG is “the next big thing”

Trucking – OEM conversion kits,

new make.

GE Oil & Gas– RAPID mini LNG

equipment growth

Huge price disparity and LNG build-out creating opportunity to

dramatically reduce cost of energy for aviation
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10/19/2012
Summary…
Process – Maintenance concept
selection can have multi billion dollar
impact to the bottom line.

Technology - is the lifeblood of the

business - From materials to advanced
cooling. Near term to 2050+
architectures.

Architecture – Leverage commercial &

military. Over-the-horizon…non
Brayton cycles. Must rethink energy.
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GE Aviation
We invent the future of flight, lift people up,
and bring them home safely