Additive Manufacturing - Pratt & Whitney Manufacturing Tools ... Oil Strut Torque Box 11 ... GTF...

Jesse Boyer

Fellow - Additive Manufacturing

Additive Manufacturing April 7th, 2015

This document has been publicly released

©2015 United Technologies Corporation

Commercial

Engines

Pratt & Whitney

Canada

Military

Engines

Pratt & Whitney

AeroPower

Pratt & Whitney

2

It’s in our power



History

3

It all began in 1925…

...Dependable Engines Frederick Rentschler



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

4 This document has been publicly released


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

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. 88ABW-2013-4382, JSF13-1195 5 This document has been publicly released


http://www.nellis.af.mil/shared/media/photodb/photos/080605-F-6911G-026.JPG

1925 Today Future

Lightweight

Powerful

Reliable

Speed

Range

Weight

Speed

Range

Thrust

Weight

Noise

Fuel economy

Reliability

Weight

High Thrust

Pratt & Whitney Fleet Innovation

6

From P&W powered bi-planes to the jet age



Geared Turbofan™ (GTF)

7

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).



Process

Understanding

Cost

Reduction

Design for

Additive

Source

Capability

Prototyping

Additive Manufacturing Alignment

Categories for development and growth



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

9

1980’s 1990’s 2000’s Today



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



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



GTF Additive Manufacturing

Production examples

12

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



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



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 …)



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



15

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