“Repeatability” User Grou… · “Repeatability” Chris Philp Additive Process Manager,...

“Repeatability”

Chris PhilpAdditive Process Manager, Additive Integrated Product Team (IPT)GE Aviation

October 17, 2019

REPEATABILITY

REPEATABILITY REPEATABILITY

1-Column Layout

4

Who?Where?Why?How?When?Why? (again)

To lead the aviation industry in the application of additive technologies from design through industrialization to impact engine cost, weight, & performance.

ONE Aviation TeamONE Additive Mission

GE Aviation Additive IPT(Integrated Product Team)

5

The Who?

6

GE Aviation Additive IPT Global Footprint

BEC – Bangalore

Avio Aero – Turin (TAL)• “ATC Europe” & EBM Tech MatGEIQ – Queretaro

ATC – Cincinnati• Headquarters• NPI & cost out across PLs• Full technology roadmap

GEAC – PragueEDC – Warsaw

TTC – Istanbul

Auburn • DMLM Production

Avio Aero – Cameri• GE9x EBM Production

Avio Aero – Brindisi• Future Catalyst DMLM

Production

Engineering/Development

Component Production

Pittsburgh • DMLM & Future

EBM Production

The Where?

7

3rd

generationCMC materials

2nd#1most efficient engine in its class

generation Additive parts

4th

Generation compositefan blades

5th

generationarchitecture

~

M A R G I N

CAEP 8 NOxregulations

10%L O W E R

Specific FuelBurnversus GE90-115B

30%

5%

SFCthan any 2020 twin-aisle engine in service

8 dbStg 5 noise regulations

M A R G I N

B E T T E R

SPECIFIC FUEL CONSUMPTION

The Why? GE9X … world’s largest engine entering service in 2020

8

28

Inducers8

STAGE 5 & 6LPT BLADES

228T25 SENSOR

1

HEAT EXCHANGER

1COMBUSTOR

MIXERS

28

FUEL NOZZLES

GE9X … highest number of additive parts to date

9

DURABLE5x More

PARTS20 1

PRECISE30% More

PARTS10 1

LIGHTER50%

T25 SENSOR

FUEL NOZZLE

STAGE 5&6LPT BLADE

INDUCER

DURABLE2x More

PARTS13 1

MIXER

DURABLE3x More

LIGHTER6%

PARTS163 1

LIGHTER40%

SERVO HX

Buy to Fly3 2Target

GE9X … power of Additive

10

https://www.youtube.com/watch?v=v6frvqHwQfI

GE9X … world record breaker:134,000 lbs. of thrust

11

12

The How?

Typical production challenges…

• Printing repeatability

• Part quality

• Manufacturing productivity

13

The How?

Key factors contributing to variation

• Not monitoring the “critical Xs”

• Poor understanding of the ranges of control

• Lack of machine configuration control

• Incomplete work instructions for operators and maintenance

• No experienced additive machine engineers

and lack of repeatability

14

The How?

Critical Xs

• Beam Spot Size & Focal Flatness

• Beam Quality/Shape (Beam Profiling/Caustic)

• Scanfield Alignment (Position/Overlap)

• Power (Laser Degradation)

• Z Axis Accuracy (Layer Thickness)

• Airflow Consistency (Filter Cleanliness)

• Oxygen (Material Properties)

• Recoater Blade (Alignment & Reuse)

• Cleanliness (Affects all the above)

• Standard Work

15

The When?

Timing & Reoccurrence

• Initially always refer to the OEM preventative maintenance and suggested calibration intervals

• Check and verify the critical X’s regularly as you learn get more experience on the machine

• Validate the consistency of your critical X’s over time

• Determine the calibration intervals required to maintain your part quality

• Remember the key events that should trigger a recalibration:•Machine Movement •Replacement of key components •Software updates •Material changes

16

Production Reality

Org

an

iza

tio

na

l e

nth

usi

asm

Time

InitialInvestment

ProductionChallenges

Scaling Challenges

Initial Production

The Why? (again)

REPEATABILITY

REPEATABILITY REPEATABILITY

17

The GE Catalyst engine

Combustor test schedule reduced from 12 months to 6 months

PARTS855 12 LOWER

20%

FUEL BURN

WEIGHT 5%

REDUCTION

The Why? (again)

REPEATABILITY

REPEATABILITY REPEATABILITY

18

The Why? (again)

REPEATABILITY

REPEATABILITY REPEATABILITY

Oct 30 2018 - 30,000LEAP Fuel tips shipped

Current build rate 4,000 tips/month