Last year, GE Additive and GE Airlines proposed a metal rapid prototyping manufacturing project in cooperation with the US Air Force to accelerate the application of 3D printing on parts. The collaboration just achieved the first technical milestone by 3D printing the oil sump cover of the F110 jet engine, which is used on both F-15 and F-16 aircraft. The project aims to improve the military's combat readiness and eliminate the risk of the spare parts supply chain-especially the spare parts supply chain of old military aircraft.
Colonel Benjamin Boehm, Director of the AFLCMC / LP Promotion Bureau explained. "The collaborative effort between the U.S. Air Force and General Electric has shown that the use of metal 3D printed components as an option to solve the current and future maintenance challenges of the U.S. Air Force has broad prospects. This capability is Component sourcing provides an alternative method, especially in the face of a declining supplier base or low demand or small batch orders that are not attractive to traditional manufacturers. "
Additive metal manufacturing for military aircraft
The Air Force ’s Rapid Sustainment Office is responsible for ensuring that it is prepared for missions through the application of new technologies and related technologies that are conducive to the operation and maintenance of troops. However, as more and more aircraft in the fleet enter the sixth decade of service, it is becoming more and more difficult to purchase and produce spare parts using traditional production methods. This is the advantage of General Electric, which provides a wealth of experience in testing and identifying AM components that meet extremely stringent regulations in the aviation industry.
Lisa Coroa-Bockley, General Manager of Advanced Materials Solutions at GE Airlines, added: "Speed is the currency of additives. By applying our additive experience with LEAP fuel nozzles and other GE9X components to GE9X's additive printing, we can provide end-to-end The solution, while also applying lessons from a strong certification process, we have been able to accelerate the pace for the US Air Force. "
Since the implementation of the plan, its planned trajectory has been a "spiral development", and the complexity and scale of each stage have increased. The starting point is simple part identification, which gradually develops into a family of parts, and finally solves the entire complex system, such as a common core heat exchanger.
GE9X's 3D printed LEAP fuel nozzle
3D printing for F110 engine
These teams made the first major progress in the plan, identifying spare parts for the F110 and TF34 engines. After experiencing a very long delivery time of two to three years, it is difficult to cooperate with casting professionals, GE Aviation's large military engine team has begun to study metal AM, and explore the use and use of metal AM. They are completing the preliminary work of the F110 oil pan cover, so this part becomes the focus of the first phase.
James Bonar, engineering manager at GE Additives, explained. "Compared with other components on the F110 engine, the function of the oil sump cover may be lower, but it is very important. It needs to be durable, form a seal, and it needs to function for the entire engine-of course, this is in F- 16 is of course crucial on a single-engine aircraft like this. "
Bonar`s team worked hard to ensure the robustness of the additive design when General Electric ’s Additive Technology Center (ATC) in Cincinnati fine-tuned the AM parameters. GE's Additive M2 3D printer runs a cobalt-chromium alloy and is used to produce the first batch of oil pan covers. According to the Air Force, the plan has been completed in advance, and Phase 1b is already in the plan. The teams will soon focus on the oil pan cover of the TF34 engine more than 40 years ago.
Oil pan cover of AM engine of F110
At this point, the Air Force already has AM exposure, and not just jet engines. Earlier this year, a team of Air Force researchers successfully 3D printed a surgical retractor on a desktop 3D printer. This medical instrument will be used in hostile environments where logistics is challenging, where it is difficult or impossible to replenish. Elsewhere, the Air Force has developed a method of 3D printing high-performance steel (AF-9628) for weapons. The technology will be used to manufacture high-strength, lightweight ammunition.