Component quality and validation by design “Avio snapshots in CRESCENDO” Novembre 2007

Jan The information contained in this document is Avio S.p.A. proprietary information and is disclosed in confidence. It is the property of Avio S.p.A. and shall not be used, disclosed to others or reproduced, without the express written consent of Avio S.p.A.. 15 locations worldwide 4,800 employees R&D investments: 11.5% of revenues A Long Heritage in Aerospace Since 1908

3 AVIO BUSINESS ACTIVITIES EJ200 Ariane revenues €1,219m 14.5%8.5%29% 48% GE90-115B CIVIL MILITARY Engines and MRO SPACE CIVIL MRO

Strong Customer Relations … governmental institutions Avio components are installed on 60% of jet engines powering commercial fleets worldwide

5 SaM146 Russian Regional Jet Trent 900 Marine One Boeing 787 Dreamliner GEnx Avio is the Italian Partner in the Most Important Aerospace Programmes A380 CT7-8 Growth Vega launcher Ariane 5

6 Tight supply chains Business Strategic Drivers Green aero-engines Advanced materials Prognostics & Diagnostics Integrated M&RO solutions Collaborative and Robust process

7 Competitiveness Affordability Life Cycle Cost Performance Environment (Green Engine) Low Emissions CO 2 : -20% NO x : -80% Low Noise Perceived noise (-18 EPNdB) Ultra Green Ultra Green Ultra Secure Highly Cost Efficient Highly Cost Efficient Highly Time Efficient Highly Customer Oriented 22nd Century Vision NEW ENGINE ARCHITECTURES ACARE R&T Target – Vision 2020 SFIDE

8 Avio in R&T A.A.T. European Projects ANTLE/POA CLEAN VIVACE VITAL NEWAC FP7 Variable Geometry Intermediate Pressure Turbine Low Nox Combustor Low weight Low noise Low Pressure Turbine Innovative Combustor DREAM LP Turbine for Open Rotor CLEAN SKY JTI Distributed design Multidisciplinary/Multienterprise models TRL National programs

9 FP7 Technology Strategy – Level 2 GOLD VITAL CRESCENDO LEMCOTEC DREAM Emissions –NOx CO2 Noise Engine design Simulation Operational support Breakthrough technologies NACRE E Break-Comp 2008 Module Validator in engine NEWAC Call 2 OPENAIR Call 3Call 4 VIVACE EIMG Property

10 CRESCENDO Collaborative & Robust Engineering using Simulation Capability Enabling Next Design Optimisation Ambito : EU Research Framework VII Periodo: Partners: Main European Aerospace Manufacturers

11 Follow up from Collaborative Robust Process previous research projects - Knowledge Enabled Engineering: Design Practice Management Knowledge Access Point - Collaboration working process Collaboration Hub Environment Multidisciplinary CAD/CAE analysis - Manufacturing Design CAD 3D extensive modeling NC Simulation

12 More analysis at aircraft and component level to eliminate risk early in the design process – “Robust Prelim Design” Analysis based test strategy, planning & correlation to reduce the need for repeat testing – “Virtual Test” Fixed design, probabilistic analysis for service and aftermarket assessment of maintenance / cost – “Product Life-Cycle Analysis” More sophisticated, multi-physics analysis to accurately predict component and functional behaviour e.g. energy, performance, mechanical integrity, …. – “Virtual product” Use of analysis based optimisation and robust design to enable rapid definition at aircraft and component level – “Design by Analysis” Certification based on analysis, simulation & modelling – “Virtual Certification” CRESCENDO – Areas of interest EIMG Property

13 Avio Areas of interest Validation by design: Analysis models to further reduce physical tests Quality by design: Capability integration to reduce non quality costs Performance design: simulation of overall engine architecture to maintain leadership in component design Design for reliability: Optimization using service data Manufacturing design:Machining measurement and inspection optimization

14 Design for Reliability FMEA Failure mode Allowed event probability Allocation Severity Parts Classification Weak points: Need of heavy product experience people Uncertainties in allocation weight estimation by using not sophisticated algorithms Regulations Failure effect

15 Design for Reliability FMEA Failure mode Allowed event probability Allocation Severity Parts Classification Regulations Failure effect Structured for product types component types mission phase

16 Identify Key Characteristics / CTQs / Limits Flow Down to subsystems / components Understand variability of the Xs Build Transfer Functions RD / DFR - optimize to reduce p(d) Tolerance the Xs Validate the design Issue the design Quality by Design : DFSS Methodology

17 Integrated Models for critical parameters (X’s) evaluations and analysis of the Design space (Y’s) Quality by Design : Transfer Functions

18 Analysis Quality by Design : Uses of Transfer Functions Determine which factors are important in the system Sensitivities Prediction Build equations that can be used to quickly and inexpensively predict system behavior at new operating points and/or conditions Optimization Probabilistic Design Find the set of factor values that optimizes the mean while minimizing the sensitivity to variation Robust Design Design for Reliability

19 3D Stack up Analysis Numerical Control Machining, Inspections Manufacturing Design Availability of an “intelligent” CAD Model enabling the specification and the piloting of a virtual manufacturing environments.

20 Manufacturing Design: Extended Master Model (MM) + MM Detail Drawing “Product and Manufacturing Information” Extended Master Model

21 CMM Export Extended Master Model Manufacturing Design: Measuring & Inspection Coordinate Measuring Machines