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2021-07-05

GE Gets USAF Nod for Metal 3D-printed Aviation Components

GE Aviation has received Engineering Change Proposal (ECP) approval from the U.S. Air Force (USAF), in just under a year, for an F110 additively manufactured sump cover.

The latest milestone in the USAF and GE’s pathfinder Pacer Edge programme, this F110 component is the first engine component designed for and produced by metal additive manufacturing to be qualified by any U.S. Department of Defence entity.

Matt Szolwinski, chief engineer and leader of GE’s Large Military Engineering team, explained: “Much like the GE90 T25 sensor that was an FAA certification pathfinder for metal additive manufacturing for GE Aviation in commercial aerospace, the F110 sump cover sets a solid foundation for many more additively manufactured component qualifications with GE’s military customers.”

According to Nathan Parker, deputy programme executive officer for the USAF Rapid Sustainment Office (RSO), “The Pacer Edge programme is an important initiative for reducing risk and showcasing the application of additive manufacturing in aerospace. The ability to additively manufacture an aircraft engine part and gain military airworthiness is a significant step forward in growing the adoption of additive manufacturing in the Air Force.”

John Sneden, director of the USAF’s Directorate of Propulsion, added: “The Chief of Staff of the Air Force, General Charles Q. Brown, Jr., has challenged us to ‘accelerate change or lose.’ The entire Pacer Edge process is built around the ‘accelerate change’ philosophy, and the speed of the F110 sump cover development and airworthiness approval is evidence of that. The capability that Pacer Edge is demonstrating will be a game changer to engine production and sustainment and will resolve many future Air Force readiness challenges.”

Spiral Development

The airworthiness qualification of the sump cover brings Pacer Edge Phase 1a of the pathfinder to its conclusion. Part of the key to the accelerated qualification was GE’s decade of metal additive engineering and manufacturing expertise.

The team’s in-depth knowledge of commercial aerospace engine airworthiness for flightworthy 3D printed metal parts is clearly proving instrumental in helping USAF establish its own robust process validation and certification processes for military airworthiness.

Close collaboration and knowledge sharing did the trick and enhanced USAF’s spiral development approach of continuously identifying, reverse engineering and developing technical data packages (TDPs) for increasingly complex and larger parts suitable for metal additive manufacturing.

Szolwinski elaborated: “We continue to share our learnings and have developed an efficient, structured way of working –especially for developing qualification processes and expediting design iterations. This lean, operational efficiency is already driving results and now sets us up for the next phases of the programme, including looking at complex and large format, load-carrying structures.”

Phase 1b is underway now and focuses on an out-of-production sump cover housing on the TF34 engine, which has been in service more than 40 years.

“We’re thrilled to be on this journey with USAF. Additive journeys are great, but even better when you have a good map and experienced guides. We started with a relatively easy part, but the spiral development model is coming into its own. It provides focus for the team and our experts help navigate and problem solve along the way,” pointed out Lisa Coroa-Bockley, general manager for GE’s Advanced Materials Solutions.

A digital thread also runs through the pathfinder. GE experts focused on digital twinning, maintenance-based predictive analytics and part lifecycle management expertise have been able to complement the USAF’s digital engineering strategy and in-house knowledge.

“Human interaction and collaboration both add immense value to our work, but digital is the enabler. Additive is a powerful digital technology that spans the entire process, from design and modelling, to in-situ monitoring through to inspection and final level assurances,” added Coroa-Bockley.

Supply Chain Hub

“Subsequent phases of the Pacer Edge programme involves the establishment of a metal additive manufacturing supply chain at Tinker Air Force Base in Oklahoma, capable of producing airworthy components in support of the DoD’s sustainment needs,” as per Lauren Tubesing, director - military accounts at GE Additive.

The Air Force’s Propulsion Directorate and RSO has already invested US$10M to fund additional phases of the Pacer Edge programme, leveraging the Defense Logistics Agency’s (DLA) Captains of Industry contract vehicle.

This funding will fast-track the development of the USAF’s organic AM capability and capacity to design and print flightworthy hardware for military engines, aircraft and support equipment.

The Pacer Edge team is utilising this capability to alleviate hard-to-source and obsolete spare parts constraints for legacy systems.

Melanie Jonason, chief engineer for the USAF’s Propulsion Sustainment Division, sums up: “The F110 sump cover was a terrific pathfinder, allowing us to exercise the USAF’s airworthiness process. There are numerous parts in queue that are ideal candidates for metal 3D printing. We are now focused on refining the airworthiness process, so it is as responsive as the technology.”

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