Helicopter Engine Technology for the 21st Century

October 7, 2010
9th Symposium On Jet Engines and Gas Turbines Technion, Haifa

Mike Epstein
GE Military Propulsion Engineering

GE Businesses and Portfolio

$37B Energy Infrastructure $51B Capital $43B Technology Infrastructure $15B NBC Universal $10B Consumer & Industrial

Commercial $4.1B

Commercial Services $7.1B

Military engines & Services $4.2B

Systems $2.9B

Business & General Aviation $0.4B

F136

GE38

F414

F110

T700

T64

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GE Helicopter Engine Experience

U.S. Military International Military Commercial/Civil
CT58/T58 T64 GE38
CH-53K

S-92

CT7/T700

50 Years/80+ Million Hours Of Experience

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Military rotorcraft environment: hot, high and harsh.

Search and rescue

Cargo lift

Attack

Special Ops

Supply
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CH-53E Landing in Desert

Helicopters and engines operating in desert are subjected to extreme sand environments

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T64 Compressor Following Service In Desert:

Airfoil Erosion. Degraded power and stall margin. Engine removals after only 100 hours.
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Voice of the Customer

Technology Needs

Sand tolerant compressors and turbines for desert operations Higher power and higher power to weight ratios to conduct missions in high / hot environment Reduced fuel burn
Extend mission payload/ range. Minimize fuel logistics footprint. Reduce fuel costs.
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Sand tolerant coatings and engine architecture Blisk with TiN Coating
Compressors with robust geometry, materials and erosion coatings Sand tolerant hot sections
Environmentally tolerant coatings Clean cooling air circuits designed with CFD

Improved inlet particle separators

CFD Modeling of inlet particle separator
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Erosion Coating Technology proven on T64 Engine

Extended Time on Wing 2-3X
T64 Rainbow Compressor Sand Ingestion Test at Kirtland AFB

non-coated coated

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Engine Lapse Rate and Limiters

Typical engine power lapse rate
Fuel flow limit Corrected speed limit Temperature limit Sea Level 6000 feet SHP 12,000 feet Physical Ng limit

Materials and design technology advances allow these limits to be raised.

OAT

Engine SHP limiters Corrected speed Fuel flow Turbine Temperature Compressor Physical speed

limited by materials/ design efficiency/ system design materials / design materials / design
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Technologies for increased power and improved fuel burn

Higher efficiency thermodynamic cycles
Improved compressor and turbine efficiencies from CFD Reduced cooling flows Higher Pressure ratios Higher Turbine Temperatures

Improved Materials / Processes/ Designs

Ceramic Matrix Composite turbine components Advanced blade cooling designs

Technology Reducing Operating Costs

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Innovations for tomorrow . . .

Leaving no stone unturned

Highly loaded components

Fuel burn technologies . . .

Aero, loading, component efficiency, weight 2015+

Novel titanium alloys

Advances in materials . . .
Metallurgy, composites, ceramics
Nano layers

Nanotechnology . . .
Unique strength, weight, fatigue properties
Ceramic-matrix composites

Alternative Fuels . . .
Ensuring broad operational capability
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Ceramic Matrix Composites (CMCs)

Less weight and better performance with reduced cooling Introducing composites beyond fan modules. Benefits for higher temperature components: Turbine airfoils Combustors. 1/3 density of metal for reduced weight better fuel burn
GE Ceramic Composite Products Site. State of Delaware, U.S. 13
GE Aviation

CMC prototype turbine nozzle

SFC and Power/Weight Improvement

Technology continues to improve fuel efficiency and power to weight ratio of turboshaft engines.
SFC versus Power to Weight
AE1107C

T55-714A

SFC

PW150A

GE38-1B
State-of-the-art product technology

Developing technology

FATE Goal

Power to Weight Ratio

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Helicopter payload and range benefit

Impact of Advanced technology
Improved Power increases TOGW capability Improved SFC changes slope

Payload

Payload

Helicopter retrofit with Advanced Technology Engine

Helicopter with Legacy Engine Technology

Mission Radius

Mission Radius
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Continuous Technology Infusion has doubled the power of the T700/ CT7 family
FADEC

Hot Section Durability Improvements

Hot Section 3-Stg PT

ITEP

3D Aero Compressor

CT7-8 2,600 SHP

CT7-8C 3,000 SHP

700 CT7-2A ~1500 SHP

401 701

401C 701C 1,900 SHP

Hot Section

2X Power 701D 2,000 SHP

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GE38-1B Applying the Technology

7500 SHP Class - Builds on T700 architecture
Top mounted accessories Modern turbine aerodynamics, materials and cooling schemes

Sand tolerant and Corrosion Resistant Materials

GE38 Versus T64 : 18% Improved SFC

Engine mounted FADEC with Prognostics & Health Management (PHM) Rugged Compressor with erosion coating

57% More power 63% Fewer Parts

Simple, robust, long-life configuration

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GE38 Video

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Advanced technology programs.

AATE
Advanced Affordable Turbine Engine (US Army)

Program goal 25% specific fuel consumption; maintain T700 weight; 65% power; and 35% acquisition and operational & support. Detailed design review completed May 09 programs runs through Jan 12. Engine Upgrade for Black Hawk and Apaches & Future Aircraft

Advanced cooling. Advanced Aero. IPS.

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Advanced technology programs.

ADVENT
Adaptive Versatile Engine Technology (USAF)

Phase I: Detailed design of fan rig, core and engine technology demonstrators (9/09) Phase II: Procure, assemble and test fan rig and core engine. Full engine demonstrator in planning. Contract runs through 9/2013. Position for Next Gen Air Vehicles.
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Advanced cycle. CMCs. Advanced cooling. Advanced Aero.

Development programs
F136
Joint Strike Fighter

Up to 5,000 aircraft potential. Demonstrated successful engine operation and obtained critical validation data. Test focus in 2010 6 engines, approximately 1,000 hours. Current testing aligned to support CTOL first flight in 2011.

CMCs Advanced cooling. Advanced Aero. Controls

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Alternative FuelsEconomic, Strategic, Environmental

GOM oil spillmore regulation, slower growth, more costly oil. Oil spot market pricescalm for now. - Last 18 months, flat and expensive. - Tied to economic outlook. Biofuelsmilitary and commercial approval moving towards completion. Biofuelsviable YESscalable?
Source: The Oil Drum. Sam Foucher blog.

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Summary
GE driving technology to meet customer needs GE is developing and leveraging technologies to greatly improve rotorcraft mission capability
High Hot operation Harsh Environments

GE Technology reduces cost of ownership

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