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Fundamentals of Additive Manufacturing Lesson 3: AM Case Study: GE LEAP Fuel Nozzle
Fundamentals of Additive Manufacturing
Lesson 3: AM Case Study: GE LEAP Fuel Nozzle
LEAP Engine Challenge
• LEAP (Leading Edge Aviation Propulsion) • Engine made by CFM
– CFM is GE & Snecma partnership• Exceeds required NOx emission reduction
by 50%• 15% better fuel economy
Source: CFM
Fundamentals - Case Study 2
LEAP Applications
• Airbus A320neo
• Boeing 737 MAX
Source: Airbus
Source: Boeing
Fundamentals - Case Study 3
Fuel Nozzle Function
• Adds fuel to air from compressor section• Air/fuel mixture ignited in burner can• Must withstand high temperature
Compressor
Nozzle
Burner
Source: GE Aviation
Fundamentals - Case Study 4
Fuel Nozzle Design Goals
• 15% better fuel economy• NOx reduction• 5x increase in service life• 25% weight reduction
Source: CFM
Fundamentals - Case Study 5
Traditional Manufacturing Case
• Extended supply chain for fasteners, gaskets, castings, machining of castings
• Factory space and work stations needed for in-coming certification, logistics, multiple work stations with work flow balance, and quality assurance testing
• Training and certification for subassembly workforcePart consolidation improves subassembly reliability and shrinks logistical foot print
Fundamentals - Case Study 6
Fuel Nozzle Design Brief
Source: GE Aviation
• Complex shape needed 20 piece assembly – Hidden channels, cavities, mounting
bracket– Impossible to machine as a single part– Uneconomical to cast as a single part
• AM necessary to meet goals
Fundamentals - Case Study 7
GE Commits to AM
• Cobalt-chromium PBF process• $50M invested to re-tool Auburn, AL plant• 10 AM machines to be installed; capacity
for 50 AM cells
Source: GE Aviation
Fundamentals - Case Study 8
GE Commits to AM
• Nozzle production starts 2015• 1,000/year to begin; 40,000/year by 2020• 19 nozzles per engine x 6,000 engines
ordered = 114,000 nozzles
Source: GE Aviation
Fundamentals - Case Study 9
Future Challenges
• Existing machines not efficient enough to economically produce high-production parts
• Next generation machines need to be 3-4x faster
• Speed & efficiency goals will be met by– Higher absorptivity wavelength lasers– Parallel laser processing– Integrate AM in conventional CNC machines– Hybrid DED manufacturing with tool path
distortion control– Enhance alloy design from existing alloys for
AM
Fundamentals - Case Study 10
Growth of AM
• Aerospace market expected to reach $1 billion/year in near future– Source: Credit Suisse, 2013
• GE investment shows value of AM to propel new design concepts and meet production of critical metal parts
Source: GE Aviation
Fundamentals - Case Study 11
ResourcesNorthern Illinois University (NIU)
Additive Manufacturing LabFederico Sciammarella, Director
Northwestern UniversityMechanical Engineering Department
McCormick School of EngineeringJian Cao
National Institute of Standards and Technology (NIST)Engineering Laboratory
Kevin Jurrens, Deputy Division [email protected]
This work was performed under the following financial assistance award 70NANB13H194 from the U.S. Department of Commerce, National Institute of Standards and Technology. The views expressed do not necessarily reflect the official policies of NIST; nor does mention by
trade names, commercial practices, or organizations imply endorsement of the U.S. Government.
