Recently, Honeywell Aerospace, headquartered in Phoenix, Arizona, USA, reported that the company has produced and installed the first certified flight-critical engine components using additive manufacturing. This part is called the #4/5 bearing seat and is the main structural part of the ATF3-6 turbofan engine used on the Dassault Falcon 20G maritime patrol aircraft. The French Navy uses it for patrol and search and rescue missions.
Currently only about 12 ATF3-6 engines are still flying. This poses procurement and supply chain challenges for operators of Dassault Falcon 20G aircraft. In addition, the manufacture of #4/5 bearing housing is very complicated, and the cost of replacement parts is very high due to the small number of orders placed. Traditional casting methods pour molten metal into a mold and harden it, and the tools required are expensive. Through additive manufacturing, these parts can be printed faster and in smaller quantities without the need for expensive tools.
"Although there are not many engines in service, Honeywell is responsible for supporting and maintaining these engines. We must find a way to solve these supply chain problems and allow these aircraft to continue flying." Honeywell Aerospace Manufacturing Engineering Vice President JonHobgood said. "Now, we can use our expertise in additive manufacturing to produce qualified parts faster, reducing delivery time from about two years to two weeks."
According to Honeywell, components such as #4/5 bearing housings are considered safety-critical or flight-critical components by regulatory agencies, which means they must always work normally. The failure or failure of these components will pose a major threat to the safety of passengers and crew, and may cause significant damage to the aircraft.
As safety-critical components face more stringent reviews, they must be approved by regulatory organizations such as the Federal Aviation Administration (FAA) before they can be used on aircraft, which also makes the process from development to qualification of the component very long. Honeywell explained that it has been working closely with the FAA to develop and certify a variety of additive-manufactured components. These efforts have made the bearing housing the first component approved under the FAA's normal authorization, further shortening the qualification time. Currently, the production of #4/5 bearing housings is in progress, and dozens of other bearing housings are expected to be produced by the end of 2020.
Hobgood added: "This is an important milestone for Honeywell. It proves our maturity in the additive manufacturing business and paves the way for the future. At the same time, this is also a major victory for the additive manufacturing industry. Although key flight components face strict review and high standards in certification and installation, our success proves that it can be done."