M.J. Benzakein

M.J. Benzakein

GE Aircraft EnginesCincinnati, OH, USA

The Future of the

Jet Engine

GE Aircraft Engines

AT – 030905/2 – 25-May-06

100 Years of Propulsion Innovation

SpecificationsThrust Class (lb) 115,300Length (in) 218Bypass Ratio 7.1Pressure Ratio 42.2

Engine SpecificationsBore: 4 inches

Stroke: 4 inches

Displacement: 201 cubic inches

Compression Ration: 4.7:1

Horsepower: 25 hp

Cooling: Liquid Circulated by thermosiphon and radiator

Lubrication: Splash system, circulation by pump and gravity

Dry Weight: 180 pounds

GE90-115B

GE Aircraft Engines

AT – 030905/3 – 25-May-06

Propulsion Driving Industry Advances

PW4098PW4084

JT8D-217

JT8D-9

JT3D-1

JT9D-7R4G2

JT9D-3A

JT9D-7A

PW4056PW2037

V2500 A1

PW4168

CJ805

CF6-6DCFM56-2

CFM56-5A

GE90-85B

CF6-80ACFM56-5C4

CF6-80C2-B6F

CF6-80E1-A2

RB-211-535E4

TRENT 895

RB-211-524D

TAY 620

BR 715

1950 1960 1970 1980 1990 2000 2010 2020

Certification Date

SFC

35K

/0.8

Mn

Uni

nsta

lled

0.90

0.80

0.70

0.60

0.50

0.40

JT3C

Low Bypass Turbofan

2nd Gen High Bypass Turbofan

High Bypass Turbofan

Turbojet

GE90-115B

GE Aircraft Engines

AT – 030905/4 – 25-May-06

Noise Reduction Advancements120

110

100

901950 1960 1970 1980 1990 2000

707-100

DC-9-10

737-200

727-200

747-200

DC-10-30

A310

737-300

737-200 A321

747-400 A330

NoiseLevel,

EPNdB(1500-ft.sidelines)

Turbojet

First GenerationTurbofan

Second GenerationTurbofan

• Normalized to 100,000-lb. thrust• Noise levels are for airplane/engine

configurations at time of initial service

Year of Initial Service

GE Aircraft Engines

AT – 030905/5 – 25-May-06

1981 standardICAO NOx Standards

120

100

80

60

40

20

015 20 25 30 35 40 45

Engine pressure ratio

NOX

CAEP/4 - 2004

CAEP/2 - 1996

TrendCurrent GE Engines

Emissions

Emissions Stringency Increasing

GE Aircraft Engines

AT – 030905/6 – 25-May-06

21st Century Vehicle Systems

Regional 100-150 pax 250+ pax Global Reach Transport

Supersonic BisJet

Supersonic Transport

Long Range Strike Aircraft

Overland Capable, Environmentally Friendly, Supersonic Commercial Transport / Military Strike

Safe, Environmentally Friendly, Longer Range Commercial and Military Transportation

GE Aircraft Engines

AT – 030905/7 – 25-May-06

V-22 Osprey High Lift Vehicle

Predator Sensorcraft

Uninhabited Air Vehicles

Apache

Heavy-Lift Runway-Independent Aircraft21st Century Vehicle Systems

GE Aircraft Engines

AT – 030905/8 – 25-May-06

21st Century Vehicle Systems

Safe, Low-Cost Access-to-Space Vehicles / Spaceplane

GE Aircraft Engines

AT – 030905/9 – 25-May-06

Customer Satisfaction

Low Cost of Ownership

Low Emissions

Performance

Reliability

Low Noise

Simplicity

GE Aircraft Engines

AT – 030905/10 – 25-May-06

GENY – The Next StepGoals

CO2

Ultra Clean: NOX and CO2• 20% reduction in engine CO2(fuel burn) relative to current (GE90) technology

• 85% reduction relative to 1996 ICAO Ultra Intelligent

• 50% reduction in engine in-flight failures

• 50% reduction in delays and cancellations

• On-condition maintenance

Ultra Quiet• 55% Reduction in noise relative to today’s aircraft

• 33 EPNdB below Stage 3

21st Century Aeropropulsion Preeminence

GE Aircraft Engines

AT – 030905/11 – 25-May-06

GENY Technologies

Fluidics forNoise Reduction

and HighStage Loading Ceramic

Matrix Composite Liners, Blades,

& Vanes

CounterrotatingVaneless

LPT

HighPressure Ratio

Compressor

Active Combustor

Controls for Ultra-Low Emissions

Hybrid/CeramicBearings

NanoMaterial

Blade/StructureTechnology

Advanced Composite Fan

IntelligentEngine Controls and Adv. Sensors

Hi Temp.Rotor Materials

Technology to Revolutionize the State of the Art

GE Aircraft Engines

AT – 030905/12 – 25-May-06

Nano-Phase Aluminum Blades and Vanes

0

40

80

120

0 100 200 300 400Temperature (F)

Yiel

d St

reng

th (k

si)

Conventional 7xxx Alloys

Nano-AlGoals

Improved Strength and Fatigue Capability Using Advanced Al Alloys

200nm

20 nm

GE Aircraft Engines

AT – 030905/13 – 25-May-06

Ceramic Matrix Composites (CMC)

CMC’s Reduce Weight and Improve Performance

CMC Combustor Liner

2200°F Capability50% Cooling Air Reduction 50% Weight Reduction20% NOx Reduction

CMC Vane CMC Blade

2200°F Capability70% Weight ReductionReduced Cooling AirIncreased Efficiency

GE Aircraft Engines

AT – 030905/14 – 25-May-06

!Leading Cause of Bearing Failures Due to Hard Particle Contamination

!Nitriding Significantly Increases the Surface Hardness

Nitrided Surface

70 HRC

60 HRC

Microhardness

57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

2 4 6 8 10 12 14 16 18 20distance from edge (mils)

HR

C

Base Hardness

Nitrided Case

Nitrided Bearing Material Technology

GE Aircraft Engines

AT – 030905/15 – 25-May-06

Airfoil Materials Trendline

∆∆∆∆ Temp. Capability,

°F

1985 1990 1995 2000 2005

Introduction Date, NPI TG6

50

100

150

200

250

300

N4N5

N6

MX4N5/Baseline TBC

N5/TBC-1

N6/TBC-1.5

MX4/TBC-2

CMC Vane &Coating System

N6/TBC-1

MX4/TBC-1.5Advanced Allo

y

Advanced Thermal B

arrier C

oating

Gen I

Gen II

Gen III

Nb-Si &Coating System

Turbine Airfoil Material Advancements Pushing the Envelope

GE Aircraft Engines

AT – 030905/16 – 25-May-06

Chevron NozzleChevron NozzleChevron NozzleChevron NozzleChevron NozzleChevron NozzleChevron NozzleChevron Nozzle

Chevron Nozzle Technology Development

Flight Tested on Bombardier CRJ700Production Nozzle on CRJ900

GE Aircraft Engines

AT – 030905/17 – 25-May-06

Improved Emissions/Operability/Reliability

NOx Reduction

Lean Blowout Detection & AvoidanceLow NOx Production

Microelectromechanical Local Flow Control

Goal: Levels 85% Below CAEP 2

GE Aircraft Engines

AT – 030905/18 – 25-May-06

Revolutionary Improvement in Reliability

MissionOptimization

ServiceOptimization

Fault Detection &Accommodation

Adjust OperationDetect and Isolate Predict Service Need

Intelligent Engine

GE Aircraft Engines

AT – 030905/19 – 25-May-06

Improved Thrust-to-Weight and Reduced Engine Envelope

• Lowered Acquisition Cost• Reduced Fuel Burn• Smaller Spot Factor• Reduced Vulnerability

Engine Technology Improvements• Reduced Volume• Reduced Weight• Improved Fuel Consumption• Reduced Cost• Improved Thrust-to-Weight

AircraftBenefits

Relative Engine Size At Equal Thrust

Year 1960 1980 2000 2020Technology J79 F404 F414/F120 VAATEThrust-to-Weight 4.5 7 9 20

GE Aircraft Engines

AT – 030905/20 – 25-May-06

Payoffs• Highly Integrated Engine/Airframe

– Fixed/Simpler Inlets/Nozzles• Extended Range• Significantly Improved Survivability• Low Community Noise• Improved Durability – Turbines,

Exhaust System

Adaptive Cycle Engine

Features• Versatile Core with Core Drive Fan

– Lower Low Spool Temperatures– Fixed Nozzle Capability

• FLADE– Inlet flow control (simpler/lighter inlets)– Improved installed SFC– Smaller diameter / reduced drag– Nozzle cooling

• Multiple Nozzle Configuration Capability

GE Aircraft Engines

AT – 030905/21 – 25-May-06

Space

Hypersonic

SubsonicSupersonic

Technology Needs to Achieve A Long Range Propulsion Vision

Compression•High Stage Loading•Flow Controlled Airfoils•Core Drive Fans•Passive & Active Stability•Composite High Speed Airfoils•Blisks

GE Aircraft Engines

AT – 030905/22 – 25-May-06

Space

Hypersonic

SubsonicSupersonic



Combustion•Low Emission Research•High Mach Combustion•High Heat Sink Fuels•Coke Barrier Coatings•Active Combustion Control

GE Aircraft Engines

AT – 030905/23 – 25-May-06

Space

Hypersonic

SubsonicSupersonic



Turbines•Integrated Turbine Blades/Disks•Advanced Cooling•Wake/Shock Management•Clearance Management•Highly Loaded Aerodynamics


GE Aircraft Engines

AT – 030905/24 – 25-May-06

Space

Hypersonic

SubsonicSupersonic





Mechanical Components•High DN Bearings•Magnetic Bearings•Air-Oil Brush Seals

GE Aircraft Engines

AT – 030905/25 – 25-May-06

Space

Hypersonic

SubsonicSupersonic






Materials•High Temp. Ni Alloys•CMC’s•PMC’s•Nano Structures•Smart Materials & Structures•Advanced NDE•Accelerated Implementation Methods

GE Aircraft Engines

AT – 030905/26 – 25-May-06

Space

Hypersonic

SubsonicSupersonic







Inlet / Nacelle/ Nozzle•Light Weight Structures•Integrated Airframe/Engine Structures•TiAl Structures•Fluidic Mixing•Fluidic Vectoring

GE Aircraft Engines

AT – 030905/27 – 25-May-06

Space

Hypersonic

SubsonicSupersonic








Controls•Intelligent Controls•Distributed Control System•Prognostic Sensors•MEMS•Wireless Communications

GE Aircraft Engines

AT – 030905/28 – 25-May-06

Space

Hypersonic

SubsonicSupersonic









Modeling•Physics-based Tools•Time Unsteady Aero•Aeromechanics•CFD Design Tools•Combustor Codes•Digital Engine Model•Noise Prediction Tools•Manufacturing Modeling

GE Aircraft Engines

AT – 030905/29 – 25-May-06

Space

Hypersonic

SubsonicSupersonic









Modeling•Physics-based Tools•Time Unsteady Aero•Aeromechanics•CFD Design Tools•Combustor Codes•Digital Engine Model•Noise Prediction Tools•Manufacturing Modeling

GE Aircraft Engines

AT – 030905/30 – 25-May-06

Propulsion Vision for the 21st Century

Key to Success is Strong Cooperation Between Academia, Industry, and Government Agencies

Academia

Government

Industry

L O C K H E E D M A R T I NL O C K H E E D M A R T I NL O C K H E E D M A R T I NL O C K H E E D M A R T I N

GE Aircraft Engines

AT – 030905/31 – 25-May-06

Summary• U.S. Aerospace industry provides export leadership .

• Propulsion key contributor to aerospace superiority.

• Propulsion is a technology – driven business

• Great advances have been made

• Lots of challenges and opportunities ahead

• Great payoffs in the commercial and military fields

• Propulsion requires aggressive short- and long-range technology development

• A strong Federal Labs /Industry/Academic World Partnership is key to maintaining U.S. leadership in Aeronautics .

Documents

M.J. Benzakein