14 DAY TRIAL // It's one thing to 3D print a toy or decorative piece, and another to make something on which the lives of dozens of people will depend, but GE Aviation has successfully achieved that very thing.
In case you're not familiar with the GE Aviation LEAP engine, it is the best family of jet engines in GE's history, created jointly with France-based Snecma, though the original plans were developed by CFM International.
Avio is part of General Electric Aviation and it is they that developed the 3D metal printing process that was used in the making of new LEAP's. They and Arcam AB.
The first test flight of an airline jet powered by the 3D printed LEAP engines was carried recently, and CFM said that the engine “behaved well and completed multiple aeromechanical test points at various altitudes.”
That's a very big deal, because it opens the gates for everyone in the airline business to start using similar technology for their aircraft.
How the 3D printing technology works
It's a selective laser sintering process that employs the Electron Beam Melting (EBM) additive manufacturing method, whereby electrons are accelerated by exposing metal to a 3-kilowatt electron gun.
The method was used to create the light-weight titanium blades for the jet engine turbines, which are ultimately responsible for moving the airplane and amassing enough velocity to overcome the force of gravity.
The EBM 3D printing process is an electron acceleration method ten times more powerful than the laser beams used in normal laser-based metal printing techniques, leading to layers four times as thick as usual.
This now increases production efficiency significantly, allowing for eight turbine blades to be made in seven hours and to save $1.6 million / €1.26 million worth of fuel each year.
The material used brings with it some boons as well, most importantly the weight that is half as great as for the nickel-based allows usually utilized in low pressure turbine blades. The whole turbine's weight is, thus, cut by 20% in turn.
Other applications for the technology begin now
GE has already begun construction of a factory that will exclusively made 3D printed jet engine fuel nozzles in Alabama. The new material, called titanium aluminide (TiAl) will be featured heavily in the operations of that facility.
Meanwhile, the LEAP-1A engine will enter service in 2016 (Airbus 320neo), LEAP-B in 2015 (Boeing’s 737MAX) and LEAP-1C in 2018 (China’s COMAC C919).