3D printing for the aeronautics industry of the future. Paolo Gennaro
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1 3D printing for the aeronautics industry of the future Paolo Gennaro
2 AvioAero organization 7 Fan Power Gearbox Compressor Accessory Gearbox Combustion Chamber High Pressure Turbine Low Pressure Turbine Unique design & make capabilities Up to 30 MW power range Over 9M flight hrs Up to 700 kw power range GBX integration with oil system Over 1500M flight hrs World s largest LPT experience (GE90) State of the art turbine efficiency (GEnx) 2 Over 900M flight hrs It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent GE Avio S.r.l.. 2
3 Additive Manufacturing Technology Additive machines (EBM & DMLS) are special process to be qualified Design based on topological optimization put material only where it is needed Additive Manufacturing Weight: 327 grams (84% reduction) Conventional Manufacturing Weigh: 2,033 grams Powder atomization to produce powders is a special process to be qualified Design Materials Machines It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent GE Avio S.r.l.. 3
4 Technology Transfer : machines Machine development covering hardware + software trough research programs Program Funding Public Partners Private Partners Goals Regional Process parameters for AM machines Process parameters for AM machines Standards definition Gas atomization process ProTiAl Regional Gas atomization process It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent GE Avio S.r.l.. 4
5 Technology Transfer : materials Material development covering powders specification + atomization process trough research programs Program Funding Public Partners Private Partners Regional ProTiAl Regional Goals Powder specification for AM process AM material characterization TiAl Powder specification for AM process AM TiAl material characterization E BREAK Politecnico di Milano AM material characterization Powder specification for AM process AM material characterization It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent GE Avio S.r.l.. 5
6 Technology Transfer : Design Design development trough research programs Program Funding Public Partners Private Partners Goals Regional Design optimization Università di Firenze Design optimization Design with topological optimization IP protection through patents on applications It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent GE Avio S.r.l.. 6
7 Technology Transfer : approach Research Training Cross fertilization Polito AVIOAERO Process Component NDA Since 2013 Prima Industrie Technology Development It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent GE Avio S.r.l.. 7
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