Avio Aero Introduction

WORKSHOP 26 novembre 2019 LA QUALITÀ NELL’AEROSPACE” Lo stato dell’arte e le sfide della Space Economy

In collaborazione con

Vincenzo Trovato

AVIOAERO

Additive manufacturing @AvioAero “______” Organizzato da Agenda

• Avio Aero introduction

• Additive in GE Aviation and Avioaero

• Additive component current qualification process

• EBM LPT blades case Avioaero introduction AvioAero History

FIAT AVIAZIONE FIAT AVIO AVIO AVIO AERO

In 2001 In 1904 first flight In 1956 In 2004 In 2013 the society has been EJ200 is the engine for new Wright brothers fighter-bomber G91 has Start the production of acquired by General Electric been selected as option for aircraft Genx engine, and start the design of new NATO fleet Eurofighter Typhoon Huge step forward in future’s engine: GE9X 80% of aeroengines in the aviation propulsion world are flighing with our tefchnology components

1904 1908 1956 1969 2001 2003 2004 2013 2014 2017 TODAY

AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission 4 AvioAero Products

ACCESSORY GEARBOXES POWER GEARBOXES TURBINES COMBUSTORS METTERE UNA FOTO PRODOTTO, NON SOLO CASTING

STRUCTURES MAINTENANCE SAND CASTING FOUNDRY ADDITIVE MANUFATURING

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4.200 57% 43% in Italy 31% Hourly Salaried employees Less than 36 years old +1000 people hired in the last 4 years. 83% 24% 17% of degrees have master 59% in Puglia in Campania in Engineering in Piedmont 22%

AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission 6 Additive in GE Aviation and AvioAero GE Aviation – Global IPT Additive Footprint

AVIO AERO PROPRIETARY – approved for release 8 Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission AvioAero Additive Technologies journey • Pioneering additive…

GE acquisition

EBM and Start of ARCAM DMLM First EBM Repair Center development Turin GE Catalyst partnership & processes Cameri Shop component opens: first GE9X TiAl on additive Additive Lab and DMLM EBM machine opens certified GBX cold Blades TiAl with qualified for open site opens development spray repair Protocast aeroengine (worldwide) parts

2007 2008 2012 2013 2014 2015 2016 2017 2018

• What’s next… Keep investing to fully exploit technologies opportunities: • next gen power bed machine (ATLAS & Mline) for large GBX structures and Catalyst • other modalities (DED) for LPT casings AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission Avio Aero – Cameri Production Site

First Additive Manufacturing plant for Aviation GE9X LPT Blades TiAl, 2 stages

FACILITY 2019 GE AirOilSeparator • 2,400+ Sqm Ti64, lattice • 50+ EBM production production machines

Confidential. NotAVIO to AERObe copied, PROPRIETARY distributed, – orapproved reproduced for release without prior 10 Copyrightapproval. – Avio Aero 2019 – do not replicate without Avio Aero’s written permission Avio Aero – Turin Additive Laboratory

TAL – Lean Lab Develop, Mature and Print! MRL Ownership Industrialize

New Product Pipeline Design 4 Additive

Technology Roadmaps Create!

22’000+ hrs, 100+ builds total printed in 2018 on Avio and Aviation projects 9,2M$ CFD gross in 2019 OP (Avio and BGA cost share not including P&E) 2 500m , 1EBM and 4DMLM machines 1 1 Additive components: Current qualification process Qualification: Specification Approach AM Process Additive • Machine maintenance • Specifications established to provide Process limits for quality critical Component • Tech Plan Spec manufacturing variables. Drawing • Machine qualification • Processes locked by Significant Part / material requirements Process Substantiation (SPS) Component • Material properties Spec • Microstructure • Hip / HT GE Aviation and AvioAero are actively supporting both EASA and FAA to write Powder Spec the future standard regulation for the use Powder • Chemistry of the additive technology in the aeronautical market spec • Powder size distribution Powder process Powder • Process and quality process spec controls

AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission Qualification steps … ”Every Machine a Micro-Foundry”

Powder…must meet specs for manufacturing and raw material reqs Additive Process…has to demonstrate to have all the procedures and in instructions in place to guarantee quality and traceability, including powder management and recycle Machine qualification… each single machine has to demonstrate material buy in and uniformity of results Part qualification (SPS)… each machine must demonstrate to be in control and capable to produce the component for all the relevant characteristics: dimensional, microstructure, chemistry…

Qualification…and then fixed process control

AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission EBM LPT BLADES

Confidential. Not to be copied, distributed, or reproduced without prior approval. This document contains non Export Controlled Technical Data GE9X Low-Pressure Turbine Blades

Unique Alloy

Electron-Beam process

17 EBM Processing Phases EBM Build Chamber Recoater

Pre Heating Pre Heating Melting Post Heating 1 2

Build chamber top view

Part Shape to be fabricated

Build platform Dosing of step down powder

18 EBM TiAl blade process

AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission Lesson learned : microstructure

Lamellar Grain size • TiAl material microstructure is sensitive to process variations. • All different microstructures have been characterized • Relationship between EBM parameter and effect on Microstructure have been built • Variation have been reduced through rigorous machine and process qualification

Lamellar phase %

Cameri 16/02/2018 AVIO AERO PROPRIETARY – approved for release 20 Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission Lesson learned: NDTs

Lack of cleanup Layers with microstructure changes Production of TiAl blades by EBM has typical indications that can be different from traditional technology and must be understood.

A catalog has been defined including: • Description • Root Cause Lack of stock material • Inspection methods to detect • Validated acceptance limits

Operators have been trained to recognize these indications with X-Ray, FPI; CT scan and visual inspections

Some of these can also be detected analyzing the machine logfiles Lack of melting on layer

AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission GE9X TiAl blade production taking off!

Cameri, Italy GE Aviation EBM production site

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