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Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson 10110 Utg. 12 Slide 1 Flygteknik.

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Presentation on theme: "Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson 10110 Utg. 12 Slide 1 Flygteknik."— Presentation transcript:

1 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 1 Flygteknik Oktober 2010 NEW MATERIALS IN THE DESIGN AND MANUFACTURING OF HOT STRUCTURES FOR AIRCRAFT ENGINES ALLVAC 718PLUS

2 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 2 1.Volvo Aero Engine Components –’Make it Light Strategy’ 2.Present and Future Material Demands 3.Alloy Efforts with Existing Alloys –René 220 and IN939 5.Evolution of Alloy 718 type materials –Allvac 718Plus 6.Summary Flygteknik Oktober 2010 Outline

3 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 3 Volvo Aircraft Engine Components Flygteknik Oktober 2010 ’HOT Parts’

4 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 4  IN718  Fabrication for low weight  Pressure for higher temperatures  Lower weight  Lower cost Flygteknik Oktober 2010 State of the Art for Hot Structures

5 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 5  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 Flygteknik Oktober 2010 The Hot Structure Designers Dream of New Materials

6 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 6  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 Flygteknik Oktober 2010 … and of course!

7 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 7  Compressor Rear Frame - CF6 80C  Temperature 650 ℃  Cast central body  Front, rear wrought rings joined by EB-welding  Alloy 718 – ”excellent” weldability Flygteknik Oktober 2010 Good ’Old’ Alloy 718 (Since 1959)

8 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 8 Flygteknik Oktober 2010 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!

9 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 9 Flygteknik Oktober 2010 IN 939 Temptation Compare alloy 718High temperature 200 ºC over alloy 718

10 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 10 Flygteknik Oktober 2010 CLEAN IN 939 Development Effort

11 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 11 There are no perfect castings! Flygteknik Oktober 2010 IN 939 Parts Can Only be Cast…

12 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 12 Flygteknik Oktober 2010 IN 939 Weld Repair Draw Back ’Soft’ filler material, C263 Grind out Grinding Overaged material The art of avoiding new cracks!

13 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 13 No casting without weld repair! Flygteknik Oktober 2010 and Again!

14 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 14  Alloy 718 Max 650 ℃  Allvac 718Plus 700 ℃  Waspaloy Max 750 ℃ Flygteknik Oktober 2010 New promises!

15 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 15  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 Flygteknik Oktober Plus

16 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 16  Since 2002  All OEM’s do individual work  Joint Assessment Program for materials data base  Vital program – Volvo Aero + ITP Flygteknik Oktober Plus European Work

17 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 17 Wrought parts Sheet metal Cast material and WELDABILITY Flygteknik Oktober 2010 Remember! For Volvo low weight assembly parts we need

18 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 18 Flygteknik Oktober Plus Wrought Material ’All in Place’

19 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 19 AMS specification Material data bases Approved for flying application GE 90 LPT Still – the alloy is sensitive to heat treatment variations Flygteknik Oktober Plus Wrought Material ’All in Place’

20 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 20 Flygteknik Oktober Plus Sheet Material

21 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 21  But! –No AMS spec. –Sensitive to processing  Still –Allvac tunes the processing –Spec. in one year Flygteknik Oktober Plus Sheet Material

22 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 22 Flygteknik Oktober Plus Cast Material The VITAL program

23 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 23  Part of the MAI program –Some draw backs  VITAL –Confirms results from the MAI program  New MAI program –Spec. in two years? Flygteknik Oktober Plus Cast Material

24 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 24 Weldability! Flygteknik Oktober 2010 The key issue

25 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 25  No cracking! –Not when the weld solidifies –Not in the heat affected zone during cooling down –Not in the heat treatment afterwards Flygteknik Oktober 2010 Weldability?

26 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 26  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! Flygteknik Oktober 2010 Weldability

27 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 27 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 Plus offers 700 ℃ –Wrought OK –Sheet in one year –Cast in two years –Weldability is the strongest point Flygteknik Oktober 2010 Summary

28 Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page. Joel Andersson Utg. 12 Slide 28 Flygteknik Oktober 2010 Thank You for your attention!


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