Lättviktsteknologi för                                   flygmotorer                                        sparar vikt oc...
Volvo Aero’s commercial component               specialization                 Fan/compressor structures                  ...
Larger fans and LP turbines in                    modern engines                    more focus on light weight components ...
Open rotor change the scene?                                                                                 Open rotor   ...
Lightweight technology          to reduce CO2               • The Volvo Aero target is to reduce the weight               ...
Volvo Aeros lightweight solutions                 • New manufacturing technologies                     fabrication, weld m...
Fabrication of engine structures                 • Use sheet metal and forged rings instead of large                   cas...
We are world leaders in               weld modeling                                                                     • ...
We are developing metal deposition                 • Laser or TIG welding                 • Powder or wire as material sou...
Important synergies with        space propulsion technology           • Laser welded T-joint with automated             we...
Geometrical features suitable for     metal deposition                                                            flange  ...
Carbon fiber composites                                                                                 Composite fan blad...
Volvo Aero develop               30% lighter composite               fan frame           • Lightweight fan frame developed...
leveransbild               January 2008, Slide 14               Volvo Aero Corporation Proprietary Information.           ...
Fan blade-out test successful               January 2008, Slide 15               Volvo Aero Corporation Proprietary Inform...
Compressor development                                                                                 Successful testing ...
Volvo Aero is already contributing with               lightweight designs               January 2008, Slide 17            ...
Partner with General Electric in the               GEnx engine for B787 & B747-8                                          ...
Our contribution to GEnx               is lightweight designs                 • Turbine Rear Frame                     opt...
GP7000 Turbine Exhaust Case               • Volvo Aero has been contracted by Pratt & Whitney to reduce the weight of     ...
PW1000G Geared Turbofan                                                                                        MRJ Mitsubi...
Trent XWB               January 2008, Slide 22               Volvo Aero Corporation Proprietary Information.              ...
• Volvo Aero is Associate Partner in Clean Sky                                               • Budget for Volvo Aero: 21 M...
Conclusion      • Light weight for reduced CO2      • Volvo Aero light weight technologies:          • Manufacturing      ...
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Session 2 Robert Lundberg.pdf

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Session 2 Robert Lundberg.pdf

  1. 1. Lättviktsteknologi för flygmotorer sparar vikt och bränsle Robert Lundberg EU R&D Director January 2008, Slide 1 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  2. 2. Volvo Aero’s commercial component specialization Fan/compressor structures Shaft Turbine structures Vanes Combustor structure Fan Case Compressor rotors LPT-Case January 2008, Slide 2 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  3. 3. Larger fans and LP turbines in modern engines more focus on light weight components JT8 engine (MD80) Bypass relation =1 Trent 1000 (B787) Bypass relation = 11 January 2008, Slide 3 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  4. 4. Open rotor change the scene? Open rotor January 2008, Slide 4 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  5. 5. Lightweight technology to reduce CO2 • The Volvo Aero target is to reduce the weight of cold and hot engine structures by 20% which will reduce the engine weight of future engines by almost 3 %. • If implemented in the current global commercial aircraft fleet this would reduce CO2 emissions by 1.3 million tons per year. For comparison, air traffic in Swedish airspace generated 1.5 million tons CO2 during 2005. January 2008, Slide 5 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  6. 6. Volvo Aeros lightweight solutions • New manufacturing technologies fabrication, weld modeling automation metal deposition • New materials composites • Intelligent aerodynamic design compressor design Make It Light January 2008, Slide 6 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  7. 7. Fabrication of engine structures • Use sheet metal and forged rings instead of large castings • Weld modeling, automation and metal deposition are key technologies to achieve optimized fabrications • Save 10-15% weight Make It Light January 2008, Slide 7 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  8. 8. We are world leaders in weld modeling • Our weld modeling minimizes deformation and weight • Optimized parameters, geometry and sequencing • Weld modeling is an enabling technology for lightweight fabrications Make It Light January 2008, Slide 8 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  9. 9. We are developing metal deposition • Laser or TIG welding • Powder or wire as material source • Building bosses and flanges on sheet metal or forged stock • Sheet and forged material (and MD material) is stronger than cast material => weight savings Make It Light January 2008, Slide 9 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  10. 10. Important synergies with space propulsion technology • Laser welded T-joint with automated weld guidance system (patent) • Laser Metal Deposition of stiffeners Developed for rocket nozzles Now used for aero engine components January 2008, Slide 10 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  11. 11. Geometrical features suitable for metal deposition flange bosses engine mount stiffener January 2008, Slide 11 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  12. 12. Carbon fiber composites Composite fan blades Composite fan case January 2008, Slide 12 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  13. 13. Volvo Aero develop 30% lighter composite fan frame • Lightweight fan frame developed in the EU funded VITAL project • Patented carbon-fiber design shows good performance • A resin transfer molding process enables high-volume production • Industrialization at ACAB Linköping January 2008, Slide 13 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  14. 14. leveransbild January 2008, Slide 14 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  15. 15. Fan blade-out test successful January 2008, Slide 15 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  16. 16. Compressor development Successful testing of VITAL LP compressor Synergies with development of military engine fan module • 3D aerodesign of blades and vanes • Fewer stages (9 -> 5) • Blisk design => 40% lower weight January 2008, Slide 16 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  17. 17. Volvo Aero is already contributing with lightweight designs January 2008, Slide 17 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  18. 18. Partner with General Electric in the GEnx engine for B787 & B747-8 Turbine Rear Frame Booster Spool Volvo Aero development, manufacture and product support throughout the life cycle Fan Hub Frame January 2008, Slide 18 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  19. 19. Our contribution to GEnx is lightweight designs • Turbine Rear Frame optimized fabricated component concept developed in ANTLE EU project (FP5) => 10 % lighter January 2008, Slide 19 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  20. 20. GP7000 Turbine Exhaust Case • Volvo Aero has been contracted by Pratt & Whitney to reduce the weight of the turbine exhaust case for GP7000 • Volvo Aero’s design reduces the weight of the part by more than 10% • Production to start 2010 January 2008, Slide 20 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  21. 21. PW1000G Geared Turbofan MRJ Mitsubishi Regional Jet Bombardier CSeries January 2008, Slide 21 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  22. 22. Trent XWB January 2008, Slide 22 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  23. 23. • Volvo Aero is Associate Partner in Clean Sky • Budget for Volvo Aero: 21 M€ (50% from EU) • Involved mainly in 3 engine demonstrators: • Open Rotor (geared) – Rolls-Royce • Open Rotor (direct drive) – Snecma • Geared Turbofan – MTU RR Open Rotor Snecma Open Rotor MTU Geared Turbofan January 2008, Slide 23 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4
  24. 24. Conclusion • Light weight for reduced CO2 • Volvo Aero light weight technologies: • Manufacturing • Composites • Aero design • Important to be able to continue our participation in demonstrator programs • Utilize synergies with space and military programs • Light weight technologies lead to business: GEnx, GP7000, PW1000G, Trent XWB January 2008, Slide 24 Volvo Aero Corporation Proprietary Information. Robert Lundberg Make It Light10110 Utg. 4

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