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New Materials in the Design and Manufacturing of Hot Structures for Aircraft Engines Allvac 718Plus. Outline. Volvo Aero Engine Components ’Make it Light Strategy’ Present and Future Material Demands Alloy 718 Efforts with Existing Alloys René 220 and IN939

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Outline

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  1. New Materials in the Design and Manufacturing of Hot Structures for Aircraft Engines Allvac 718Plus Flygteknik 2010

  2. Outline • Volvo Aero Engine Components • ’Make it Light Strategy’ • Present and Future Material Demands • Alloy 718 • Efforts with Existing Alloys • René 220 and IN939 • Evolution of Alloy 718 type materials • Allvac 718Plus • Summary Flygteknik 2010

  3. Volvo Aircraft Engine Components ’HOT Parts’ Flygteknik 2010

  4. State of the Art for Hot Structures IN718 Fabrication for low weight Pressure for higher temperatures Lower weight Lower cost Flygteknik 2010

  5. The Hot Structure Designers Dream of New Materials 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 2010

  6. … and of course! 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 2010

  7. Good ’Old’ Alloy 718(Since 1959) Compressor Rear Frame - CF6 80C Temperature 650℃ Cast central body Front, rear wrought rings joined by EB-welding Alloy 718 – ”excellent” weldability Flygteknik 2010

  8. 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 – 718 + René 220 - joined! Flygteknik 2010

  9. IN 939 Temptation Compare alloy 718 High temperature 200 ºC over alloy 718 Flygteknik 2010

  10. CLEAN IN 939 Development Effort Flygteknik 2010

  11. IN 939 Parts Can Only be Cast… There are no perfect castings! Flygteknik 2010

  12. ’Soft’ filler material, C263 IN 939 Weld Repair Draw Back The art of avoiding new cracks! Grind out Grinding Overaged material Flygteknik 2010

  13. and Again! No casting without weld repair! Flygteknik 2010

  14. New promises! Alloy 718 Max 650℃ Allvac 718Plus 700℃ Waspaloy Max 750℃ Flygteknik 2010

  15. 718Plus • 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 2010

  16. 718Plus European Work Since 2002 All OEM’s do individual work Joint Assessment Program for materials data base Vital program – Volvo Aero + ITP Flygteknik 2010

  17. Remember!For Volvo low weight assembly parts we need Wrought parts Sheet metal Cast material and WELDABILITY Flygteknik 2010

  18. 718Plus Wrought Material’All in Place’ Flygteknik 2010

  19. 718Plus Wrought Material’All in Place’ • AMS specification • Material data bases • Approved for flying application • GE 90 LPT • Still – the alloy is sensitive to heat treatment variations Flygteknik 2010

  20. 718Plus Sheet Material Flygteknik 2010

  21. 718Plus Sheet Material • But! • No AMS spec. • Sensitive to processing • Still • Allvac tunes the processing • Spec. in one year Flygteknik 2010

  22. 718Plus Cast MaterialThe VITAL program Flygteknik 2010

  23. 718Plus Cast Material • Part of the MAI program • Some draw backs • VITAL • Confirms results from the MAI program • New MAI program • Spec. in two years? Flygteknik 2010

  24. The key issue Weldability! Flygteknik 2010

  25. Weldability? • No cracking! • Not when the weld solidifies • Not in the heat affected zone during cooling down • Not in the heat treatment afterwards Flygteknik 2010

  26. Weldability 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 2010

  27. Summary • A ”sucessful” alloy > 650℃ for structuresmust meet • Strength performance • Cost performance • All – wrought, sheet and cast – product forms • Excellent weldability – on par with Alloy 718 • 718Plus offers 700℃ • Wrought OK • Sheet in oneyear • Cast in twoyears • Weldability is the strongestpoint Flygteknik 2010

  28. Thank You for your attention! Flygteknik 2010

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