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 AVIO AERO PROPRIETARY – approved for release Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission 5 AvioAero People 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 AVIO AERO PROPRIETARY – approved for release 22 Copyright – Avio Aero 2019 – do not replicate without Avio Aero’s written permission .

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