Sandwich nozzle hot test on Vulcain 2 engine. Vulcain 2 Vulcain 2 + Vulcain 1 The information contained in this document is Volvo Aero Corporation Proprietary Information and it shall not either in its original or in any modified form, in whole or in part be reproduced, disclosed to a third party, or used for any purpose other than that for which it is supplied, without the written consent of Volvo Aero Corporation. Any infringement of these conditions will be liable to legal action.
Vulcain 2+ Nozzle Demonstrator 2 Reduces cost significantly Increases robustness and reliability TRL 6, Ready to start development Vulcain 2+ Nozzle Demonstrator objectives Vulcain 2+ Nozzle Demonstrator design Comparison of Vulcain 2+ Nozzle Demonstrator with Vulcain 2 Nozzle Results from testing Conclusion
What is the Sandwich technology? 3
Vulcain 2+ Nozzle Demonstrator 9 8 7 6 4 5 4 Laser welded sandwich identified as most promising to meet commercial requirements lead time, cost & flexibility. 3 2 96 97 98 99 00 01 02 03 04 05 06 07 1 2010-11-08, Slide 4
Milestones for Vulcain 2+ Nozzle Demonstrator 5 2004 With ESA s blessing a trilateral program was initiated to demonstrate a new nozzle technology in full scale on the Vulcain 2 engine. 2005 Sandwich technology was selected in competition with other technologies for full scale demonstration 2006 PDR 2007 MDR No blocking points identified in reviews with SNSB, CNES, ESA and Snecma, Astrium 2009 The Vulcain 2+ NE Demonstrator run in full scale hot testing at DLR
6 Main Overall Objectives for the Vulcain 2+ Nozzle Demonstrator Demonstrate potential for a recurring cost reduction > 30 % Increased reliability, by a simplified design and increased margins Increased robustness Applicability on Vulcain 2 engine and nozzles on future engines (EXP, SC) Engine performance Vulcain 2 engine Improve understanding of reliability margins by e.g. design tool validation, processes & material characterization, new NDT methods
Vulcain 2+ NE Demonstrator Definition 7 LMD jacket for axial stability Upper Sandwich Wall Box stiffeners for increased ovalization frequency Lower Sandwich Wall Stiffeners for radial stability
What is the Sandwich technology? 8 Major characteristics of the Sandwich Nozzle: Outer cone, laser welded Inner cone, with milled channels with constant mid wall thickness Laser weld Cover sheet Mid wall Flame side Channels milled from a thick sheet
Laser cutting of sheet metal Description of Volvo Aero Sandwich Wall Manufacturing sequence Cone Fabrication Channel Milling Channel Wall Assembly 9 Forming of segments Laser welding of segments Bell shape forming
Description of Volvo Aero Sandwich Wall Manufacturing sequence 10 Upper Sandwich Wall Lower Sandwich Wall Upper NE assembly Metal deposition Inlet manifold Stiffeners Lower NE assembly Stiffeners Outlet manifold Sandwich NE assy Cone joint Instrumentation Thermal Barrier Coatings
Laser Metal Deposition (LMD) 11 Robot laser weld cell Wire based LMD LMD is a robust process with: high quality of deposited material process applicable in the robot weld cell high deposition rate negligible impact on channel geometries low deformation levels
Applications of Laser Metal Deposition 12 Upper interface Reinforcement Jacket Stiffener attachment (Upper NE assembly) Cone joint reinforcement
Significant product cost reduction compared to Vulcain 2 NE 13 Vulcain 2+ Nozzle Demo How? Effort in concept choice phase Fewer parts Much less manual operations Shorter Manufacturing leadtime. Automated manufacturing and control operations. Vulcain 2 NE
Vulcain/Vulcain 2 NE/Vulcain 2 SW Characteristics 14 Cooling structures Parts 456 Tubes 288 Tubes 4 Sheet Metal Cones Weld Starts 100% (TIG) 33% (TIG) 0% (5% before starts and stops are cut-off)
Vulcain/Vulcain 2 NE/Vulcain 2 SW Characteristics 15 Reinforcement Jacket Parts N/A ~100 sheet metal parts Solid Laser Metal Deposition Jacket Weld Effort N/A 100% (TIG mostly manual) 30% (Laser - automated)
Vulcain/Vulcain 2 NE/Vulcain 2 SW Characteristics 16 TEG system Parts N/A Injector Forgings Inlets Manifold Parts Bulk Heads Cone Joint and cover band Weld Effort N/A Yes (Many welds) 3 welds (automated)
Number of components: 17 Vulcain 2 NE Upper cooled wall 288 tubes + 288 inserts Vulcain 2+ NE Demonstrator 2 Cones from 4 metal sheets each. Lower cooled wall 1 skirt from 6 metal sheets + TEG (25 parts) 2 Cones from 5 metal sheets each Reinforcements Welded jacket + 25 stiffeners + 5 hat bands LMD Jacket + 31 stiffeners Number of parts total NE 768 66
Comparison of Design Margins and Performance, Vulcain 2+ Nozzle Demonstrator vs Vulcain 2 Nozzle 18 Life about 2 to 2.5 times longer life for the Demonstrator design Robustness for 1.5-1.9 times higher flight loads the robustness margin is at the same level for the Demonstrator as for Vulcain 2 NE Global Stability higher margin for axial stability and the same margin for radial stability Overall Performance ISP increase > 1.4 s
Full scale hot test results of the Vulcain 2+ Nozzle Demonstrator on the ARTA 8 Engine. 19 Sandwich demo nozzle mounted on Vulcain 2 engine. ESAs ARTA 8 campaign at DLR facility in Germany. Two hot test of total 930 s.
General test objectives 20 1. To verify function of the mechanical structure of a sandwich wall with reinforcements for the actual temperature load. Waviness, Ovality, Temperatures with / without TBC 2. To show robustness with respect to operating point Dump flow distribution in upper cone / lower cone, 3. To verify the mechanical properties of the nozzle Eigenfrequency in hot condition, response to loads, Roll moment, 4. To verify the temperatures predicted by calculating tools Hot wall temp (IR photo), coolant temp. Heat load from incipient separation. 5. To evaluate separation margins and side loads.
General Objective 1: To verify the function of the mechanical structure of a sandwich wall with reinforcements. 21 Two tests performed, in total 930s run Post test inspection show: No anomalies found Intact sandwich structure Intact stiffening structure No noticeable ovality, nor increased waviness. TBC performed well, no spalling.
General objective 2: To show robustness with respect to operating point 22 The operation envelope has been well covered by the operation seen by the NE The NE functioned well in all operation points visited, both in the envelope and in the extreme domain, respectively
General objective 3: To verify the mechanical properties of the nozzle 23 Response to transient and operational loads, Structural response of the MD & Cone Joint All strains measured on the MD and cone joint are elastic, except for a high start up peak on cone joint in 90deg. Inlet Manifold Cone Joint MD Jacket
General objective 4: To verify the temperature level for correlation of calculation tools 24 The measured hot wall and coolant temperatures are very close to the predicted data both with and without TBC. The pressure drop fits very well with the prediction The actual coolant pressure levels are slightly lower than the values predicted. The predicted pressures used for mechanical analysis are conservative.
General objective 5: To evaluate the side load 25 The start up and shut down side-loads are within expectation band and significantly lower than the design load taken into account The down ramping to explore transition to free shock separation below the operating envelope gives no increase in side load for the V2 + Demo, which is better than the spiralling tube nozzle NE 2-127 tested on same ARTA 8 engine. The down ramping sequence indicates that free shock separation is not present. V2 + Demo NE2-127 Downramping of operating pressure with the same sequence for both NE s
Demonstrator Hot-Test Success Criteria 26
Vulcain 2+ Nozzle demonstration test on ARTA 8 27 The performance of the sandwich nozzle in the two tests is regarded as a great success! All test success criteria are met. The hardware status after two tests is excellent Non-destructive expertise is in progress at Volvo Aero The nozzle is approved for more test. Next opportunity is on ESAs ARTA 9 campaign.
Conclusion 28 The engine test enabled the sandwich technology to reach TRL 6. Ready to start a development. The successful outcome of the Vulcain 2 + Sandwich Nozzle project is a significant risk reduction for further developments. Customer benefits from increased robusteness, increased performance, and of significant cost reduction. All major risks are identified and analysed Further activities for a development are identified The performance of the Vulcain 2 + Nozzle demonstrator in the two test is by all participant regarded as a complete success!
Acknowledgements 29 This program has been performed in close collaboration between Volvo Aero and its industrial partners Snecma and EADS Astrium under the auspices of SNSB, CNES, DLR and ESA.