Page 26 - AAA NOVEMBER - DECEMBER 2013 Online Magazine

FEATURE ENGINE DESIGN

Testing a new engine
starts with components,
goes on to static
assemblies (pictured)
then a single test
engine on an otherwise
standard aircraft
systems and bleed air off-takes, creating on technical efforts to further improve they result in a high-cost failure; engines
a more efficient power plant. This move reliability.” are certainly becoming smarter, but self-
to remove such as starters, actuators and The work never stops, and incremental maintaining is probably far in the future,”
pressurisation and cabin conditioning to updates are part of the game for all the she smiles.
electronic control means more power major manufacturers; indeed with more Nearer to now is the possibility of
for thrust – and better economy. Contra- than 51million hours and nearly 10million printed engine parts. According to CFM,
rotating fans help contribute to a cleaner cycles of service experience, EA’s other its LEAP engine will be the first in aviation
burn and keep NOx emissions down. Rolls- models have contributed directly to the to introduce sophisticated engine parts
Royce is developing new technologies such new engine with lessons learned from created using additive manufacturing, or
as ceramic or active magnetic bearings, to the two existing programs, says Shannon 3D printing. Although it has been used
the point where they can be incorporated in Korson, EVP, Programs at Engine Alliance. extensively for rapid prototyping, CFM has
new engine programmes or retro-fitted to Some of the advances being made are adapted it for production in the form of the
existing engines. All these new components not within the engines themselves, but in LEAP fuel nozzle.
have to be capable of surviving the the control and support mechanisms. The “This high-technology nozzle
increasingly arduous conditions that exists outside of next generation engines will be dramatically reduces NOx emission by
at the heart of turbofans – temperatures bare of the current spaghetti of electrical pre-mixing fuel and air, so that the fuel is
equivalent to half that of the surface of harnesses and instead have connections burned much more efficiently,” explains
the sun and pressures equivalent to those embedded in composite rafts, saving more Jewell. “Using traditional manufacturing,
found half a kilometre beneath the surface weight, improving reliability and reducing the design of the part would be dictated
of the ocean. cost, says Rolls-Royce. by machine tools, but by using additive
There is little point reducing weight and manufacturing, engineers are only limited
burn rates if the engine is unreliable. So Not as we know it, Jim by their imaginations.” So instead of
researchers like the Engine Alliance place Looking even further ahead into the machined, straight edges and more than 25
a premium on reliability. “Engine reliability future, there is the glimmer of self individual parts brazed or welded together,
has always been one of our fundamental maintaining engines, agrees CFM’s Jewell the LEAP fuel nozzle has curved channels
principles,” says Kimberley Sullivan, EVP, – but it’s a very long way away. “Today’s and less than five parts.
Programs at the Engine Alliance. “As well engines are complicated machines, made Those massive pods slung under the
as extensive component, module and up of roughly 10,000 individual parts,” wings of your next intercontinental airliner
full engine testing that were conducted she says. “Advancements in remote built from parts printed by an inkjet?!
well before the first GP7200 engine flew, diagnostics are certainly making engine Believe us, it’s coming soon . . .
EA [managers] and technical resources maintenance more predictable. It is also
hold regular weekly meetings focused allowing airlines to identify issues before
26 ASIAN AIRLINES & AIRPORTS NOVEMBER / DECEMBER 2013 WWW.ASIANAIRLINES-AIRPORTS.COM