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Improvement of aeropropulsion fuel efficiency through engine design
Published in Emily S. Nelson, Dhanireddy R. Reddy, Green Aviation: Reduction of Environmental Impact Through Aircraft Technology and Alternative Fuels, 2018
Kenneth L. Suder, James D. Heidmann
The E3 Project from 1975 to 1984 developed many engine core technologies that were introduced into engine products into the 1990s and beyond. Specifically, GE’s large GE90 engine (Fig. 3.9), which powers the Boeing 777 aircraft, benefited greatly from the E3 Project efforts. To summarize, the E3 Project goals were to (1) reduce SFC by 12%, (2) reduce SFC performance deterioration by 50%, (3) reduce direct operating costs by 5%, (4) meet Federal Aviation Administration noise regulations, and (5) meet EPA then-proposed emissions standards (Ciepluch et al., 1987). The E3 Project achieved higher propulsive efficiency by using a low-pressure-ratio fan and higher thermal efficiency by using higher overall pressure ratio, higher turbine inlet temperatures, and improved component efficiencies. These are common themes in the effort to reduce SFC, and continue to be the main drivers for such efforts even today under NASA projects such as Environmentally Responsible Aviation (ERA) and the Subsonic Fixed Wing (SFW) Project.
A review on qualification and certification for metal additive manufacturing
Published in Virtual and Physical Prototyping, 2022
Ze Chen, Changjun Han, Ming Gao, Sastry Yagnanna Kandukuri, Kun Zhou
Some organisations have applied their developed qualification and certification frameworks to produce metal AM products in the fields of aerospace, marine and offshore, etc. A metal fuel nozzle printed by General Electric (GE) for a leading-edge aviation propulsion engine received dual certifications from the FAA and EASA, which significantly improved aircraft hardware component production and engine shipment (Russell et al. 2019). Within the certification framework, a printed T25 sensor housing for compressor inlet temperature monitoring was approved to be applied in the GE90 jet engine (Russell et al. 2019). NASA has been actively preparing AM components, such as injectors and combustion chambers printed and tested by the Marshall Space Flight Centre with internal qualification and certification procedures in rocket engines (Gradl et al. 2018). In the marine and offshore industry, leading certification organisations (e.g. DNV, BV, and LR) have qualified and certified industrial functional parts based on the standards, rules, and regulations listed in Table 4. Thyssenkrupp Tech Center Additive Manufacturing received the certificate for the approval of metal AM production from DNV in 2019 (Tess 2019). Later, Sembcorp Marine received certifications from DNV, which qualified its AM procedures and specifications for products in the field of construction and repair (Sembcorp Marine 2019). AML Technology and 3D Metalforge received the certification of metal AM facility from LR (LR 2018; Metal AM 2018). A metal AM propeller for shipbuilding (WAAMpeller) was developed by RAMLAB, Promarin, Autodesk, and Damen and is the world's first metal AM class approved by BV (Damen 2017).