Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 1

Flygteknik 2010

18 - 19 Oktober 2010

NEW MATERIALS IN THE DESIGN AND MANUFACTURING OF HOT STRUCTURES

FOR AIRCRAFT ENGINES ALLVAC 718PLUS

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 2

1. Volvo Aero Engine Components

– ’Make it Light Strategy’

2. Present and Future Material Demands

3. Alloy 718

4. Efforts with Existing Alloys

– René 220 and IN939

5. Evolution of Alloy 718 type materials

– Allvac 718Plus

6. Summary

Flygteknik 2010

18 - 19 Oktober 2010

Outline

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 3

Volvo Aircraft Engine Components

Flygteknik 2010

18 - 19 Oktober 2010

’HOT Parts’

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 4

IN718

Fabrication for low weight

Pressure for higher temperatures

Lower weight

Lower cost

Flygteknik 2010

18 - 19 Oktober 2010

State of the Art for Hot Structures

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 5

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

18 - 19 Oktober 2010

The Hot Structure Designers Dream of New Materials

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 6

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

18 - 19 Oktober 2010

… and of course!

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 7

Compressor Rear Frame - CF6 80C

Temperature 650℃

Cast central body

Front, rear wrought rings joined by EB-welding

Alloy 718 – ”excellent” weldability

Flygteknik 2010

18 - 19 Oktober 2010

Good ’Old’ Alloy 718(Since 1959)

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 8

Flygteknik 2010

18 - 19 Oktober 2010

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!

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 9

Flygteknik 2010

18 - 19 Oktober 2010

IN 939 Temptation

Compare alloy 718 High temperature

200 ºC over alloy 718

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 10

Flygteknik 2010

18 - 19 Oktober 2010

CLEAN IN 939 Development Effort

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 11

There are no perfect castings!

Flygteknik 2010

18 - 19 Oktober 2010

IN 939 Parts Can Only be Cast…

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 12

Flygteknik 2010

18 - 19 Oktober 2010

IN 939 Weld Repair Draw Back

’Soft’ filler material, C263

Grind outGrinding

Overaged material

The art of avoiding new cracks!

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 13

No casting without weld repair!

Flygteknik 2010

18 - 19 Oktober 2010

and

Again!

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 14

Alloy 718 Max 650℃

Allvac 718Plus 700℃

Waspaloy Max 750℃

Flygteknik 2010

18 - 19 Oktober 2010

New promises!

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 15

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

18 - 19 Oktober 2010

718Plus

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 16

Since 2002

All OEM’s do individual work

Joint Assessment Program for materials data base

Vital program – Volvo Aero + ITP

Flygteknik 2010

18 - 19 Oktober 2010

718Plus European Work

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 17

Wrought parts

Sheet metal

Cast material

and

WELDABILITY

Flygteknik 2010

18 - 19 Oktober 2010

Remember!For Volvo low weight assembly parts we need

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 18

Flygteknik 2010

18 - 19 Oktober 2010

718Plus Wrought Material’All in Place’

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 19

• AMS specification

• Material data bases

• Approved for flying application

• GE 90 LPT

• Still – the alloy is sensitive to heat treatment variations

Flygteknik 2010

18 - 19 Oktober 2010

718Plus Wrought Material’All in Place’

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 20

Flygteknik 2010

18 - 19 Oktober 2010

718Plus Sheet Material

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 21

But!

– No AMS spec.

– Sensitive to processing

Still

– Allvac tunes the processing

– Spec. in one year

Flygteknik 2010

18 - 19 Oktober 2010

718Plus Sheet Material

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 22

Flygteknik 2010

18 - 19 Oktober 2010

718Plus Cast MaterialThe VITAL program

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 23

Part of the MAI program

– Some draw backs

VITAL

– Confirms results from the MAI program

New MAI program

– Spec. in two years?

Flygteknik 2010

18 - 19 Oktober 2010

718Plus Cast Material

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 24

Weldability!

Flygteknik 2010

18 - 19 Oktober 2010

The key issue

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 25

No cracking!

– Not when the weld solidifies

– Not in the heat affected zone during cooling down

– Not in the heat treatment afterwards

Flygteknik 2010

18 - 19 Oktober 2010

Weldability?

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 26

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

18 - 19 Oktober 2010

Weldability

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 27

• A ”sucessful” alloy > 650 for structures ℃ must 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 one year

– Cast in two years

– Weldability is the strongest point

Flygteknik 2010

18 - 19 Oktober 2010

Summary

Volvo Aero Corporation Proprietary Information. This information is subject to restrictions on first page.

Joel Andersson

10110 Utg. 12

Slide 28

Flygteknik 2010

18 - 19 Oktober 2010

Thank You for your attention!