DEVELOPMENT OF AN AIRCRAFT ENGINE COMBUSTION … › wp-content › uploads › 2014 › 10 › 09-Castagne-Fribo… · INTRODUCTION PROJECT OBJECTIVES Replacingthe currentFuel Nozzlesolution

DEVELOPMENT OF AN AIRCRAFT ENGINE

COMBUSTION CHAMBER PART

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Ce document et les informations qu’il contient sont la propriété de Snecma. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Snecma.Ce document et les informations qu’il contient sont la propriété de Snecma. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Snecma.

COMBUSTION CHAMBER PART

MANUFACTURED BY METAL INJECTION

MOLDING (MIM)

[email protected]

[email protected]

7th International EWI/TWI Seminar on Joining Aerospace MaterialsSeptember 17th-18th 2014

SCOPE

�Introduction

� Part presentation : Jet Engine Fuel Nozzle

� Project Objectives

�Project development

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Ce document et les informations qu’il contient sont la propriété de Snecma. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Snecma.

� Definition

� Validation

�Conclusion

EWI-TWI 7th Seminar – Joining aerospace materials – SNECMA SAFRAN GROUP – G. Fribourg – JF. Castagne

Introduction

/01/


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Introduction


Secondary flow

Primary flow

INTRODUCTION

JET ENGINE – AIR FLOW

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1. Intake 2. Compression 3. Combustion 4. Expansion 5. Ejection

INTRODUCTION

FUEL NOZZLE – PRINCIPLE & REQUIREMENTS

� Tmax ~900°C

� Design requirements:

� Creep

� High T° oxydation

� Permeability

INTRODUCTION

FUEL NOZZLE – BASELINE

� Material : Hastelloy-X

� UTS (20°C) > 440MPa

� YS (20°C) > 240MPa

� Standard process :

� Bar extrusion

� Machining : turning, milling / 4 sub-parts

� Brazing treatment

� Heat treatment (SHT@1110°C + Air cooling)

Ni Cr Fe Mo Co W C Mn Si B

47 22 18 9 1.5 0,6 0,1 <1 <1 <0.008

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� Heat treatment (SHT@1110°C + Air cooling)Swirlers

Intern bushing

Fuel nozzle guide

Cup

INTRODUCTION

PROJECT OBJECTIVES

� Replacing the current Fuel Nozzle solution by a Metal Injection Moulded part

foundry

Current solution New solution

Material Hastelloy-X / Extruded Hastelloy X / Powder Metallurgy

Process Machined + brazed MIM

Cost Baseline Lower

Properties Baseline Similar to material

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Properties Baseline Similar to foundry material

Geometry

INTRODUCTION

OVERVIEW ON THE MIM PROCESS

3-Debinding 4-Sintering1- Mixing

Metal powder + binder

2-Injection

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Feedstock Green part Brown part Sintered part

Project development

/02/


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Project development


PROJECT DEVELOPMENT STAGES

�Definition

� Process design

� Part design

� Feedstock definition

� Moulds design

� Injection, debinding & sintering cycle definition

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� Injection, debinding & sintering cycle definition

� Post-sintering heat-treatment definition

�Validation

� Metallurgical validation

� Functional validation

� SPEC definition


PROJECT DEVELOPMENT – DEFINITION

PROCESS DESIGN

�Injection of 4 sub-parts

�Machining in the green state

� Sprue removal

� Holes drilling

�Sub-parts assembling Controls+

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�Sub-parts assembling

�Debinding

�Sintering

�Heat-treatment

�Final machining


+Controls


POWDER, BINDER, FEEDSTOCK

� Powder : Gas atomised ; D50 = 10µm ; D90 = 20µm

� Binder : Polyacetal base

� Feedstock : powder volume fraction ~55%

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MOULDS DESIGN

� Mould joint

� Sprue, ejectors…

� Machining strategy

� Oversize factor : ~1,17

� Mould temperature regulationPost-injection machining

Mould joint

Sprue Ejectors

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Post-sintering

machining


INJECTION & DEBINDING CYCLE DEFINITION

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� Catalytic debinding in HNO3 at 110°C

� Thermal debinding below 600°C


SINTERING CYCLE

Sintering

temperature

DTA measurements

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Dilatometer measurements (typical) Sintering cycle (typical), Argon


POST-SINTERING HEAT-TREATMENT

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Spec Wrought material

Moulded material

Spec Moulded material

PROJECT DEVELOPMENT – VALIDATION

INJECTION TRIAL

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METALLURGY – MICROSTRUCTURE & POROSITY

MoC, WC

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METALLURGY – BOUNDARIES

Swirlers

Intern

bushing

Fuel nozzle

guide

Cup

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Former joint

Radius


METALLURGY – NDT

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� FPI

� X-Ray control

� X-Ray

tomography


METALLURGY – CHEMISTRY

800

1000

1200

1400

1600

1800

� Spec : 500 – 2000ppm

� No carbon trapped

during sintering

� Slight decarburizing

Ni Cr Fe Mo Co W C Mn Si B

47 22 18 9 1.5 0,6 0,1 <1 <1 <0.008

Thermal debinding

+ sintering

Solvant

debinding

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0

200

400

600

800

Specimen

� Spec : 500 – 2000ppm


METALLURGY – PROPERTIES

HT + Machining

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HT + Machining

Creep tests

Tensile tests0,1

1,0

10,0

0,1 1,0 10,0 100,0 1 000,0

Time (h)

1 2 3 4


FUNCTIONAL VALIDATION – GEOMETRY

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� High dimensional stability

� Some non-conforming

measurements, requiring post-

sintering partial machining

� Process optimization allowed

reducing non conforming results


FUNCTIONAL VALIDATION – PERMEABILITY

� Process capability :

� Cp = 1,55

� Cpk = 1,24

� Definition :

� Permeability is a measure of the ability of a material/part to allow fluids to pass through

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90%

95%

100%

105%

Part serial number

MIM Batch 4


FUNCTIONAL VALIDATION – ENGINE TEST BENCH

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EWI-TWI 7th Seminar – Joining aerospace materials – SNECMA SAFRAN GROUP – G. Fribourg – JF. Castagne MIM

BrazedBrazed


SPEC DEFINITION

�Specifications :

� Powder

� Feedstock

� Part

�Requirements :

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�Requirements :

� Cut-ups

� Microstructure

� Porosity

� Mechanical properties

� Chemistry

� NDT


Conclusion

/03/


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Conclusion


CONCLUSION

� MIM is able to manufacture cost effective, complex

parts requiring a high standard of quality :

� High dimensional stability / permeability

� Very good metallurgical quality : low porosity rate, low

defect rate, no chemical segregation

� Good mechanical properties : ~intermediate between

foundry and forged products, very strong joints

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� The MIMed fuel nozzle has been successfully

validated as alternative technology for one of our

engine under development

� This took 3 years, including process setting and

validation, as well as design office discussions and

supply-chain upgrading.

THANK YOU FOR YOUR ATTENTION

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Ce document et les informations qu’il contient sont la propriété de Snecma. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Snecma.Ce document et les informations qu’il contient sont la propriété de Snecma. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Snecma.

THANK YOU FOR YOUR ATTENTION

Contacts :

[email protected]

[email protected]


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DEVELOPMENT OF AN AIRCRAFT ENGINE COMBUSTION … › wp-content › uploads › 2014 › 10 › 09-Castagne-Fribo… · INTRODUCTION PROJECT OBJECTIVES Replacingthe currentFuel Nozzlesolution