New Materials in the Design and Manufacturing of Hot Structures for Aircraft Engines Allvac 718Plus 18 - 19 Oktober 2010 Flygteknik 2010

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 18 - 19 Oktober 2010 Flygteknik 2010

Volvo Aircraft Engine Components ’HOT Parts’ 18 - 19 Oktober 2010 Flygteknik 2010

State of the Art for Hot Structures IN718 Fabrication for low weight Pressure for higher temperatures Lower weight Lower cost 18 - 19 Oktober 2010 Flygteknik 2010

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 18 - 19 Oktober 2010 Flygteknik 2010

… 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 18 - 19 Oktober 2010 Flygteknik 2010

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 18 - 19 Oktober 2010 Flygteknik 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! 18 - 19 Oktober 2010 Flygteknik 2010

IN 939 Temptation 200 ºC over alloy 718 Compare alloy 718 High temperature 200 ºC over alloy 718 18 - 19 Oktober 2010 Flygteknik 2010

CLEAN IN 939 Development Effort 18 - 19 Oktober 2010 Flygteknik 2010

IN 939 Parts Can Only be Cast… There are no perfect castings! 18 - 19 Oktober 2010 Flygteknik 2010

IN 939 Weld Repair Draw Back The art of avoiding new cracks! Grind out Grinding ’Soft’ filler material, C263 Overaged material 18 - 19 Oktober 2010 Flygteknik 2010

No casting without weld repair! and Again! No casting without weld repair! 18 - 19 Oktober 2010 Flygteknik 2010

New promises! Alloy 718 Max 650℃ Allvac 718Plus 700℃ Waspaloy Max 750℃ 18 - 19 Oktober 2010 Flygteknik 2010

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 18 - 19 Oktober 2010 Flygteknik 2010

718Plus European Work Since 2002 All OEM’s do individual work Joint Assessment Program for materials data base Vital program – Volvo Aero + ITP 18 - 19 Oktober 2010 Flygteknik 2010

Remember! For Volvo low weight assembly parts we need Wrought parts Sheet metal Cast material and WELDABILITY 18 - 19 Oktober 2010 Flygteknik 2010

718Plus Wrought Material ’All in Place’ 18 - 19 Oktober 2010 Flygteknik 2010

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 18 - 19 Oktober 2010 Flygteknik 2010

718Plus Sheet Material 18 - 19 Oktober 2010 Flygteknik 2010

718Plus Sheet Material But! No AMS spec. Sensitive to processing Still Allvac tunes the processing Spec. in one year 18 - 19 Oktober 2010 Flygteknik 2010

718Plus Cast Material The VITAL program 18 - 19 Oktober 2010 Flygteknik 2010

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? 18 - 19 Oktober 2010 Flygteknik 2010

The key issue Weldability! 18 - 19 Oktober 2010 Flygteknik 2010

Weldability? No cracking! Not when the weld solidifies Not in the heat affected zone during cooling down Not in the heat treatment afterwards 18 - 19 Oktober 2010 Flygteknik 2010

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! 18 - 19 Oktober 2010 Flygteknik 2010

Summary 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 18 - 19 Oktober 2010 Flygteknik 2010

Thank You for your attention! 18 - 19 Oktober 2010 Flygteknik 2010