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Wednesday, July 19, 2017 10:05:40 PM
3D printed engines, possible! (Avio Aero)
In Avio Aero's "About" magazine - 3D printed engines, possible! - Jul 2017
The introduction:
General Electric’s new 1,300 SHP-rated ATP (Advanced Turboprop) is the first entry in GE’s new family of turboprop engines aimed at Business and General Aviation aircraft in the 1,000-1,600 SHP range. The Advanced Turboprop engine will power the new Cessna Denali aircraft built from Textron Aviation, and GE Aviation has chosen Europe as the home for this incredible engine. The ATP is in fact an all- European project: its Design and Product Development Team is based in Italy, Poland, Czech Republic and Germany. The development activities are coordinated from the operations room in Rivalta while the assembly and test of the engine will be carried out in Prague. It was also recently decided that the additive manufacturing components related to the engine will be carried out in Brindisi where dedicated machines will be installed on site from 2018 and the first production activities will start between the end of 2018 and the beginning of 2019. ATP features an industry-best: 16:1 overall pressure ratio (OPR), enabling the engine to achieve a 15% lower fuel burn and 10% higher cruise power compared to competitor offerings in the same size class with better time between overhaul (TBO) and class-leading performance retention.
Some of the ATP’s advantages come from the use of additive manufacturing which simplifies the engine's design, with fewer parts and solutions not feasible with conventional technologies, resulting in a lighter, more compact engine. GE Aviation is a real pioneer of additive technology and has been working on this new technology over the last 10 years developing various components for new generation engines such as LEAP and GE9X, adopting processes including Electron Beam Melting and Direct Metal Laser Melting. ATP has gone much further: it is the first turboprop to include 3D-printed parts, 13 components, ranging from the combustion chamber to various structural elements, which have reduced the total number of parts in the engine by about 30%. Overall the benefits coming from additive manufacturing are extraordinary: a huge number of processes and inspections are eliminated, the risk of losses and leakages from joints are no longer there and manufacturing cost is reduced. “This is not a matter of simply replacing one production method with another, but of reinventing the way aviation engines are conceived and designed” said Giorgio Abrate, Avio Aero Engineering Leader.
_________________________________________________________________
In addition, and conclusion, Avio Aero is autonomously leading, technically and commercially, all non-US military opportunities of the ATP. This allows to separate the commercial and the military environment, as well as to guarantee that the commercial version of ATP is not influenced by any military requirement. So far Avio Aero has received the interest and is involved in several military campaign for UAV (Unmanned Air Vehicles) as well as military trainers, in Italy, Europe, Turkey and India, and other opportunities are being explored.
A truly important development for Avio Aero: from modules and components to the entire engine.
Uploaded on Jul 19, 2017
Brad Mottier talks about Avio Aero and the efforts in the development of the new Advanced Turboprop.
In Avio Aero's "About" magazine - 3D printed engines, possible! - Jul 2017
The introduction:
General Electric’s new 1,300 SHP-rated ATP (Advanced Turboprop) is the first entry in GE’s new family of turboprop engines aimed at Business and General Aviation aircraft in the 1,000-1,600 SHP range. The Advanced Turboprop engine will power the new Cessna Denali aircraft built from Textron Aviation, and GE Aviation has chosen Europe as the home for this incredible engine. The ATP is in fact an all- European project: its Design and Product Development Team is based in Italy, Poland, Czech Republic and Germany. The development activities are coordinated from the operations room in Rivalta while the assembly and test of the engine will be carried out in Prague. It was also recently decided that the additive manufacturing components related to the engine will be carried out in Brindisi where dedicated machines will be installed on site from 2018 and the first production activities will start between the end of 2018 and the beginning of 2019. ATP features an industry-best: 16:1 overall pressure ratio (OPR), enabling the engine to achieve a 15% lower fuel burn and 10% higher cruise power compared to competitor offerings in the same size class with better time between overhaul (TBO) and class-leading performance retention.
Some of the ATP’s advantages come from the use of additive manufacturing which simplifies the engine's design, with fewer parts and solutions not feasible with conventional technologies, resulting in a lighter, more compact engine. GE Aviation is a real pioneer of additive technology and has been working on this new technology over the last 10 years developing various components for new generation engines such as LEAP and GE9X, adopting processes including Electron Beam Melting and Direct Metal Laser Melting. ATP has gone much further: it is the first turboprop to include 3D-printed parts, 13 components, ranging from the combustion chamber to various structural elements, which have reduced the total number of parts in the engine by about 30%. Overall the benefits coming from additive manufacturing are extraordinary: a huge number of processes and inspections are eliminated, the risk of losses and leakages from joints are no longer there and manufacturing cost is reduced. “This is not a matter of simply replacing one production method with another, but of reinventing the way aviation engines are conceived and designed” said Giorgio Abrate, Avio Aero Engineering Leader.
_________________________________________________________________
In addition, and conclusion, Avio Aero is autonomously leading, technically and commercially, all non-US military opportunities of the ATP. This allows to separate the commercial and the military environment, as well as to guarantee that the commercial version of ATP is not influenced by any military requirement. So far Avio Aero has received the interest and is involved in several military campaign for UAV (Unmanned Air Vehicles) as well as military trainers, in Italy, Europe, Turkey and India, and other opportunities are being explored.
A truly important development for Avio Aero: from modules and components to the entire engine.
Uploaded on Jul 19, 2017
Brad Mottier talks about Avio Aero and the efforts in the development of the new Advanced Turboprop.
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