1. New Materials in the Design and Manufacturing of Hot Structures for Aircraft Engines Allvac 718Plus
Oktober 2010
Flygteknik 2010

2. Outline Volvo Aero Engine Components ’Make it Light Strategy’
Present and Future Material Demands
Alloy 718
Efforts with Existing Alloys
René 220 and IN939
Evolution of Alloy 718 type materials
Allvac 718Plus
Summary
Oktober 2010
Flygteknik 2010

3. Volvo Aircraft Engine Components
’HOT Parts’
Oktober 2010
Flygteknik 2010

4. State of the Art for Hot Structures
IN718
Fabrication for low weight
Pressure for higher temperatures
Lower weight
Lower cost
Oktober 2010
Flygteknik 2010

5. The Hot Structure Designers Dream of New Materials
Temperature – HOTTER
Mechanical properties - BETTER
Cost – LOWER
Available in all material forms – wrought, sheet, cast – OF COURSE
Joining, forming, machining, repair – NO PROBLEM
Risk – NONE
Oktober 2010
Flygteknik 2010

6. … and of course! Stable alloy and processing specs!
Durability (fatigue, crack prop, thermodynamic stability)
Defect control methods available
Environmental resistance
Environmentally friendly
Available from several suppliers
Available for decades to come
Oktober 2010
Flygteknik 2010

7. Good ’Old’ Alloy 718 (Since 1959)
Compressor Rear Frame - CF6 80C
Temperature 650℃
Cast central body
Front, rear wrought rings joined by EB-welding
Alloy 718 – ”excellent” weldability
Oktober 2010
Flygteknik 2010

8. Effort with a New (1990) Alloy René 220
Compressor Rear Frame - CF6 80E
80E to run close to 700 ℃
Cast central body cast René 220 (max 700 ℃)
Wrought Alloy 718 front and skirt parts joined to casting by EB-welding
Two different materials – René joined!
Oktober 2010
Flygteknik 2010

9. IN 939 Temptation 200 ºC over alloy 718 Compare alloy 718
High temperature
200 ºC over alloy 718
Oktober 2010
Flygteknik 2010

10. CLEAN IN 939 Development Effort
Oktober 2010
Flygteknik 2010

11. IN 939 Parts Can Only be Cast…
There are no perfect castings!
Oktober 2010
Flygteknik 2010

12. IN 939 Weld Repair Draw Back
The art of avoiding new cracks!
Grind out
Grinding
’Soft’ filler material, C263
Overaged material
Oktober 2010
Flygteknik 2010

13. No casting without weld repair!
and Again!
No casting without weld repair!
Oktober 2010
Flygteknik 2010

14. New promises! Alloy 718 Max 650℃ Allvac 718Plus 700℃ Waspaloy Max 750℃
Oktober 2010
Flygteknik 2010

15. 718Plus Early work 1990’th Allvac
MAI (Materials Affordability Initiative) program
US Air Force funding
Joint effort
GE, Honeywell and P & W
Firth-Rixson and Ladish Co (forgers)
Primary metal producers Allvac and Carpenter Technology
Air Force Research Laboratory
Oktober 2010
Flygteknik 2010

16. 718Plus European Work Since 2002 All OEM’s do individual work
Joint Assessment Program for materials data base
Vital program – Volvo Aero + ITP
Oktober 2010
Flygteknik 2010

17. Remember! For Volvo low weight assembly parts we need
Wrought parts
Sheet metal
Cast material
and
WELDABILITY
Oktober 2010
Flygteknik 2010

18. 718Plus Wrought Material ’All in Place’
Oktober 2010
Flygteknik 2010

19. 718Plus Wrought Material ’All in Place’
AMS specification
Material data bases
Approved for flying application
GE 90 LPT
Still – the alloy is sensitive to heat treatment variations
Oktober 2010
Flygteknik 2010

20. 718Plus Sheet Material
Oktober 2010
Flygteknik 2010

21. 718Plus Sheet Material But! No AMS spec. Sensitive to processing Still
Allvac tunes the processing
Spec. in one year
Oktober 2010
Flygteknik 2010

22. 718Plus Cast Material The VITAL program
Oktober 2010
Flygteknik 2010

23. 718Plus Cast Material Part of the MAI program Some draw backs VITAL
Confirms results from the MAI program
New MAI program
Spec. in two years?
Oktober 2010
Flygteknik 2010

24. The key issue
Weldability!
Oktober 2010
Flygteknik 2010

25. Weldability? No cracking! Not when the weld solidifies
Not in the heat affected zone during cooling down
Not in the heat treatment afterwards
Oktober 2010
Flygteknik 2010

26. Weldability No cracking during EB welding.
At par with Alloy 718 at weldabiltiy testing (Varestraint, TransVarestraint and Gleeble testing).
Improved understanding of homogenization and weld repair of cast material!
Oktober 2010
Flygteknik 2010

27. Summary A ”sucessful” alloy > 650℃ for structures must meet
Strength performance
Cost performance
All – wrought, sheet and cast – product forms
Excellent weldability – on par with Alloy 718
718Plus offers 700℃
Wrought OK
Sheet in one year
Cast in two years
Weldability is the strongest point
Oktober 2010
Flygteknik 2010

28. Thank You for your attention!
Oktober 2010
Flygteknik 2010