Session A7 26 Disclaimer — This paper partially fulfills a writing requirement for first year (freshman) engineering students at the University of Pittsburgh Swanson School of Engineering. This paper is a student, not a professional, paper. This paper is based on publicly available information and may not provide complete analyses of all relevant data. If this paper is used for any purpose other than these authors’ partial fulfillment of a writing requirement for first year (freshman) engineering students at the University of Pittsburgh Swanson School of Engineering, the user does so at his or her own risk. ENVIRONMENTAL BENEFITS OF CERAMIC MATRIX COMPOSITES IN JET ENGINES Brandt Miao, [email protected], Mena 1pm, Brendan Marani, [email protected], Vidic 2pm Abstract—Most mainstream transportation methods involve the burning of fuel to power an engine which in turn releases harmful emissions into the atmosphere. With environmental consciousness being such a high priority issue, a devotion to developing more fuel-efficient engines has grown in recent years. One such result emerging from these efforts involves material usage within aircraft engines. The implementation of ceramic matrix composites (CMCs) into jet engines of aircraft provides a multitude of benefits, and drastically increases engine efficiency. The enormous turbines, compressors, and shrouds of most current jet engines are constructed from nickel based superalloys. CMCs, in this case silicon carbide fibers reinforced in a silicon carbide matrix, aim to replace these superalloys by offering substantially better thermal capabilities and much lighter weights. Manufacturing these CMC parts has proven to be the biggest challenge in their implementation; however, mass production methods involving numerous heat treatments are becoming more viable. As this process continues to improve, an increasing amount of jet engines will be able to use these lighter, more durable parts. A jet engine running with CMC components has shown to yield fuel savings of up to 15% when compared to an engine of traditional nickel based superalloys. This fuel reduction not only saves companies money, but it lessens the harsh carbon footprint of air travel, making CMCs both economic and environmentally sustainable. Aircraft are currently responsible for around 11% of the carbon dioxide emissions released in the United States, and it is estimated that these values will triple by mid-century. The immediate benefits of CMC usage in aircraft engines are apparent, but analyzing the less obvious results is just as necessary. The production of CMCs does produce waste as a byproduct, however this is an upfront downside that can be outweighed by the continuous fuel savings. Recycling is another concern that needs to be addressed. Currently, options for reusing CMCs are slim, but future research may be able to change this. The introduction of CMCs into the aircraft industry is a promising step towards a cleaner future. Key Words —Aircraft Emission, Ceramic Matrix Composites, Engine Efficiency, Jet Engine, Silicon Carbide University of Pittsburgh Swanson School of Engineering 1 3.31.2017 AN INTRODUCTION TO CMCS AND ENGINE EFFICIECY Environmental awareness is an ever-increasing topic in the world of transportation due to heavy use of combustion engines. These engines burn fuel and in return release high amounts of carbon and nitrogen oxide emissions. For aircraft, the lighter the plane, the less fuel that needs to be consumed during flight. One such way that engineers have been able to achieve this is through the usage of lighter materials. Recently, ceramic matrix composites have been a promising material to replace the nickel based superalloys used in the turbofan engines of commercial airliners due to their extreme light weight and thermal capabilities. CMCs are, however, nothing new to this world. Automotive applications of CMCs were first studied in the 1990s, and in the 2000s they were implemented in high performance sports cars [1]. The manufacturing process of these CMC brake discs and clutches however were extremely limited to only top-tier performance cars due to the impractically high production costs. Fortunately, this is no longer the case. Advancements in liquid silicon infiltration processes have reduced both the time and cost of mass producing CMCs [2]. This process involves surrounding ceramic fibers with carbon, and submerging them into liquid silicon to allow the carbon and silicon to react and form the ceramic matrix. The emergence of this material as a much more viable alternative allows the benefits associated with it to be more easily reaped at a commercial level. COMPREHENDING THE WORKINGS OF A JET ENGINE Almost all commercial aircraft utilize turbofan jet engines. The main components of this engine include an intake fan, a high-pressure compressor and turbine, a lowpressure compressor and turbine, and a combustion chamber, as seen in Figure 1. Brandt Miao Brendan Marani concrete. Crystalline ceramics, such as the silicon carbide (SiC) used in the CMCs of aircraft engines, are known for having exceptional hardness, but also being brittle. Therefore, by combining a SiC matrix with a reinforcing fiber, the resulting CMC will inherit the hardness of the ceramic matrix, while the fibers will stop brittle fractures. Different types of CMCs are referenced as “fiber/matrix”, so carbon (C) fibers in a silicon carbide matrix is given shorthand as “C/SiC”. Physical Properties The majority of current jet engines utilize nickel based superalloys specifically designed to withstand high temperatures. Large amounts of research and development have been put towards optimizing nickel based superalloys for aircraft engines, but the material in and of itself has limiting factors. CMCs have been a candidate material to replace these nickel based superalloys for some decades now, but are just now becoming commercially available. Previous production methods required up to ten cycles of treatment to create the appropriate matrix, whereas current processes only require one [2]. The additional cycles originally made for a time-inefficient process, as well as a costly one due to the need for additional materials. The resurgence of CMCs aims to finally replace the use of nickel based superalloys. Many different types of CMCs exist, each with their own unique properties. Silicon carbide ceramics have proven to be the most effective for use of both the fiber and matrix of CMCs in jet engines. These SiC/SiC CMCs yield two major benefits over the traditionally used nickel superalloys: significantly better operating temperatures, and a weight reduction of around 33%. The specific strength of a material is a measure of force per unit area at failure. Comparing specific strength values of materials at a given temperature is an effective way to assess the thermal capabilities of the materials. Figure 2 shows a graph of various types of CMCs and other materials, most notably nickel based superalloys, and their specific strength as a function of temperature. FIGURE 1 [3] Depiction of the components of a turbofan jet engine Surrounding the turbines are large stationary shrouds, which encase the turbines and help better direct air flow. These components of the engine which experience the greatest exposure to extreme temperatures are referred to as the core. As air flows into the high and low pressure compressors, it is compressed to the necessary temperature and pressure needed for combustion, which occurs in the combustion chamber. Combustion further raises the temperature and pressure of the air as it moves on to flow through the turbines, powering their respective compressors. The significant difference in temperature and pressure of the exhaust air provides thrust to power the aircraft. Air that does not flow through the compressors goes through the bypass ducts, represented by the pink colored channels above and below the core in Figure 1. The bypass ducts narrow as they near the rear of the engine, causing the air to achieve a high exhaust velocity. This process is similar to how a balloon produces a propulsion force when the neck is let open and air is allowed to flow out freely. In a jet engine, this process creates additional thrust force in conjunction with the thrust from the core. The primary components of interest at this point in CMC production include those of the engine’s core. CMCS: UNDERSTANDING TECHNICAL ASPECTS Composition Composites are constructed from multiple different materials with different properties. The composite will retain many of the characteristics of its parent materials, often resulting in a more favorable material. A common example of a composite material is reinforced concrete. Concrete on its own retains its shape well, but will break easily when stretched. To account for this weakness, steel bars are implemented into the concrete to increase its tensile strength. Here, the steel bars are acting as the fibers of the composite, while the concrete is the matrix which surrounds the fibers. Ceramic matrix composites are a group of composite materials with a similar overall structure to reinforced FIGURE 2 [4] Graphical representation of the specific strengths of various materials at different temperatures 2 Brandt Miao Brendan Marani This data comes from Professor Nitin P. Padture, the head of Brown University’s Advanced Ceramics and Nanomaterials Laboratory. The graph shows that C/SiC CMCs seem to offer better overall specific strength; however, they suffer one critical drawback. Professor Padture notes that while C/SiC CMCs have a higher specific strength, they are not as durable as SiC/SiC CMCs. SiC/SiC CMCs therefore, have a much more elongated lifespan, and are a better option for commercial jet engines since they will require less maintenance. In terms of jet engines, a SiC/SiC CMC built engine is capable of operating at up to 400°F (204°C) hotter than one of nickel based superalloys [5]. As a result of this, air that was previously needed to cool down the inferior nickel based superalloys and prevent component failure can be redirected to the bypass ducts. With more air flowing through the bypass ducts, more non-combustion related thrust can be produced. A current jet engine is not composed entirely of nickel based superalloys, so it is important to note how much they contribute to the overall weight of the engine. The Mineral, Metals, and Materials Society (TMS) estimates that nickel superalloys are responsible for about 50% of the weight of a jet engine [6]. While the actual numeric weight of a jet engine varies tremendously with different models, in total one third of the weight of the engine can be shed off, equating to hundreds of pounds, even the lightest models. Significant weight reduction requires less lift force to keep the aircraft suspended in air during flight. This lift force is directly related to the thrust force, meaning that less thrust from the engine would be required for aircraft operation. However, the development and optimization of spinning CMC components yield benefits even farther than just this. Citing the definition of rotational inertia and the rotational application of Newton’s second law of motion allow this to be proved through physics. Rotational inertia can be defined generally by I = Cmr2, where I is the object’s rotational inertia, C is a shape-dependent constant, m is the objects mass, and r is the radius of the object. Rotationally, Newton’s second law states that T = Iα, where T is the net torque on the object, I is once again the object’s rotational inertia, and α is the object’s angular acceleration. Combining these effectively provides an equation which shows that torque varies directly with mass. In other words, CMC parts of less mass will require less torque provided by the airflow to achieve the same angular acceleration as their nickel based superalloy counterparts. The excess air can therefore be redirected to the bypass ducts for further compression and thrust in a similar manner as the excess cooling air from improved thermal performance can. This effectively increases the percentage of engine thrust produced through non-combustion related sources. and impregnating them with a carbon-rich resin. This creates a tape of fibers, which is shaped to the necessary dimensions with a mold. A heat treatment is applied to the molded tape to set the geometry of the part. A burnout process called pyrolysis is then carried out to bake out unwanted compounds as a waste byproduct, resulting in a porous carbon matrix surrounding the fibers. The pores in the matrix are filled with molten silicon, which reacts with the carbon in the matrix to create the SiC matrix [2]. The fabrication of CMCs with this method is referred to as liquid silicon infiltration (LSI). The LSI production method produces a material that is incredibly dense in the sense that it has an extremely low porosity and level of impurity, allowing the resulting CMC to be incredibly resistant to corrosion. FIGURE 3 [2] Visual outline of the LSI process In most cases combining two brittle ceramic materials also yields a brittle material. This is where the initial proprietary coating of the fibers comes into play. The United States Department of Energy’s Oak Ridge National Laboratory has revealed that the bond-altering coating applied to the SiC fibers at the beginning of production changes the way in which the fibers and the matrix interact [5]. This chemical alteration allows the SiC fibers to act less brittle, and are able to carry the load on the material. As a result, the SiC/SiC CMC obtains a new dimension of strength, and becomes a valuable material in jet engine production. The LSI production method has offered a much cheaper and faster way to produce CMCs than other methods. Plans to set CMCs into mass production have already started and show no signs of stopping soon. Currently, the NGS Advanced Fibers Company in Japan has the only plant dedicated to SiC ceramic fiber production, but GE Aviation is in the process of building two plants in Alabama to accommodate for the expected tenfold increase in demand of CMCs within the next decade [7]. One plant will be dedicated to producing SiC ceramic fibers similar to the NGS plant in Japan, and the other will be used to transform these fibers into the CMC material using liquid silicon infiltration. GE Aviation’s new plants will be built specifically to manufacture engine parts, as the engine is the most suitable use of CMCs due to high temperatures. Mass Production In aircraft jet engines, both the fiber and the matrix are made from SiC ceramics. The production process of SiC/SiC CMCs begins by adding a bond-altering coating to SiC fibers, 3 Brandt Miao Brendan Marani combustor liners [5]. While all these parts are static and do not move during operation, the goal of large aviation corporations is to reach a point where spinning components such as turbines and compressors can also be optimized for CMC production. Rotating engine parts benefit even more from weight reduction than stationary ones, because not only do they reduce the aircraft’s overall weight, the individual part’s rotational inertia is reduced. Since these parts will be spinning, the lighter weight means they will turn easier, allowing them to compress air more efficiently. CFM International’s promising start with turbine shrouds is a step in the right direction for large-scale implementation of CMCs in jet engines. Reaching the level of use planned for the GE9X and beyond could mean massive improvements in terms of engine efficiency. Corporal Pioneer: GE Aviation A joint venture between GE Aviation and Safran Aircraft Engines known as CFM International is the producer of the world’s most successful commercial aircraft engine, the CFM56. With over 22,000 installed engines delivered, the CFM56 is being used in almost twice as many aircraft than the next most popular engine [8]. CFM’s newest engine, the LEAP, aims to replace the CFM56. The LEAP engine introduces the use of a large ceramic matrix composite turbine shroud. While using only one CMC part may sound lackluster, its effects are easily observed. CFM International reports and guarantees the LEAP engine to have fuel savings of at least 15% over the CFM56, which uses no CMC parts [5]. Inspecting the prices of these engines, however, reveals one of the more negative sides of the LEAP engine. At a list price of $13.9 million, the LEAP exceeds the price of the CFM56 by $3.9M [9]. This should not be surprising however, as it is often the case to have to pay a premium for fuel efficiency. For example, a car might come in two trim levels; standard and hybrid. The hybrid model will tend to be more expensive upfront, but the real savings are observed in the long-run with reduced fuel costs. This same idea can be applied to the LEAP and CFM56 engines. The United States Aviation Research Group notes that a typical flight in a CFM56-powered Boeing 737-800 costs $3,326 in fuel per hour of flight [10]. Considering the use of two engines per 737-800 and the LEAP engine’s 15% fuel savings, this translates to $2,827 an hour, meaning it takes 15,631 hours of flight to pay off the premium of the two LEAP engines per aircraft. This is a relatively trivial feat, considering that the Massachusetts Institute of Technology’s Airline Data Project reports that the average 737-800 will surpass this amount within about 4 years of a 20+ year long life expectancy [11]. The primary goal of a company is to provide a good or service and make a profit from it. Looking beyond the initial four years of use proves why these CMC engines are such an economically sustainable investment for companies. After offsetting the initial cost, every four years a single 737-800 aircraft out of a company’s fleet will save $2.45M each year in fuel costs. Factoring in fleets of up to one hundred 737800s and around sixteen more years of operation, the savings reach well into billions of dollars. By saving companies such large amounts of money, CMCs are allowing airline companies to contribute to economic sustainability. With the saved money, companies are able to provide a better good or service, which is then more desired by customers. As a company’s customer base grows as a result of this, they incur even more profit, and the cycle repeats itself. Both parties are satisfied and the process is self-perpetuating, and therefore sustainable. The capabilities of ceramic matrix composites in jet engines are not defined simply by the LEAP engine alone. GE Aviation has plans to produce the GE9X engine in 2019, which will consist of five total CMC components including a shroud similar to the LEAP engine, and multiple nozzles and EXAMINING ENVIRONMENTAL IMPACT Understanding Aircraft Emissions Efficiencies through productivity and cost are not the only benefits CMC parts have to offer. Another dimension of the problem engulfing our world now is protecting the environment while retaining the brute power of technology. Currently, airplane emissions are a sizeable portion of what is tearing down the atmosphere. A report from the Center of Biological Diversity states that with aircraft usage continuing on the path it is now, 43 gigatons (43 trillion kilograms) of carbon dioxide are to be let off into the atmosphere, destroying ecosystems and the barrier that protects earth from cancerous UV rays. The United States itself released 200 billion kilograms of carbon dioxide in 2014 [12]. Carbon dioxide is one of the abundant greenhouse gases in the atmosphere. While greenhouse gases are important in keeping the Earth at a sustainably warm temperature, too many of them causes the phenomenon of global warming [13]. Carbon dioxide emissions also make oceans and bodies of water more acidic, disturbing the water’s pH balance and killing aquatic life. Aircraft pollution contains a dangerous compound called nitrous oxide in addition to carbon dioxide [14]. Nitrous oxide right now is the third strongest greenhouse gas in countries like the United Kingdom. It does not have a major impact on the local ecosystems; however, it does a great deal of damage to the Earth’s atmosphere. At this point, global aircraft emissions are growing to be equivalent to the emissions produced by an entire country’s worth of air pollution, from cars to factories. While automotive emissions unsurprisingly exceed them, aircraft emissions, if counted as the total emissions released by a single country, would rank seventh highest in the world, only slightly behind countries like Germany and ahead of countries like Sweden [12]. Aircraft emissions themselves have tripled in quantity over the last couple of years, and right now it seems there is no decrease in their destructive power. While the amount of emissions given off by aircraft has always been a great deal, they are growing 4 Brandt Miao Brendan Marani at alarmingly fast rates, and action must be taken in order to avoid the harmful effects. Recycling CMCs A distinct issue with CMCs is the difficulty in recycling them. While recycling the composites would not happen for a number of years due to their survivability and lesser need for corrosion treatment and other maintenance, the process must still be considered. When an aircraft is at the end of its lifespan, multiple waste management and environmental legislations, such as the EU-directive for End-of-Life Vehicles, agree that all engineering materials should be recyclable and sustainable in some way [16]. As with most other materials in existence, to remain powerful and practical, they must be sustainable in some way, whether it be in recycling old materials into new ones or converting old materials into energy. In the long term, almost all materials are limited. CMCs themselves are recyclable, but the process is costly and the remnants that are obtained from recycling are small in comparison to the quantity that is being initially recycled. Composites are not as easy to recycle as regular metals because with composites, homogeneous particles must be liberated in order to separate the CMC into its raw materials [16]. The fiber or matrix itself hinders the process as well because of the types of reinforcement that holds the material together. Recycling techniques exist that can take the composites and turn them completely into energy using combustion. While these processes are very good at producing energy, the ultimate goal in recycling these composites is getting material back for future use. The market itself for recycling CMCs is bare to say the least, because as seen, there is very little room for profit. The recycled parts that are created in recycling plants turn out to cost more than their newly created counterparts and are of a lesser quality than the newly created CMCs [16]. This brings up the question for many companies to consider whether it is worth it to look environmentally sensitive to settle the qualms of people preaching for environmental change and pay out, or simply pay for newly created, high quality material. Multiple legislations from the EU-directive for End-ofLife Vehicles and other types of waste management are allowing for increased demand in this field, however broad commercialization for the recycling market is still far off [16]. One specific organization that set out to help push this process along is the Aircraft Fleet Recycling Association (AFRA) [17]. Comprised of Boeing and multiple other aerospace companies, AFRA set an objective to state that retired aircraft are not to be simply disposed of; rather they should be recycled and be put to further use for the company. They have conducted research that pushes towards finding processes that can reinvigorate the used, old materials and give the created recycled materials the same properties that their virgin counterparts may have. AFRA does not only this, but it makes sure that the processes that happen are carried out in the proper manner. They conduct strict audits that make sure that all removal and recycling processes are held to high standard and are safe. This action helps keep all the recycling processes Linking CMCs to Emissions There are many different ways to address this problem in an aircraft. One such way is to use a different form of energy other than the primary environmental threat: fossil fuels. Other options available include solar and electric energy. However, while being implemented in cars and various other automobiles, transferring the technology from ground travel to air travel is a far-off prospect and has rarely been put into action. Safety issues must be considered first. Ceramic matrix composites are a way for aviation companies and manufacturers to approach this environmental issue, while also improving the aircraft itself and its cost. As specified previously, CMC parts in an airplane engine have enhanced features, like heat resistance and lower weight. Both of these properties help improve the impact on the environment, and reduce emissions. The lower weight of CMCs allows for a lighter aircraft in general. This means that the engine itself does not need to produce as much lift, reducing the amount of fuel that must be used and therefore reducing the amount of carbon dioxide emissions that are put into the atmosphere. The other big jump in efficiency, heat resistance, has a similar effect. An increase in heat resistance allows the engine to operate at higher yet still safe temperatures before the heat causes the engine to fail. The hotter the engine can be, it can produce greater levels of lift and thrust. This allows for the engine to take in less fuel and provide the same amount of power required to fly the aircraft to its destination. With less fuel expenditure comes less need to burn the fuel itself creating less production of harmful carbon dioxide and nitrous oxide gases. Adverse Effects While this technology does benefit the environment from its ability to decrease the amount of carbon dioxide and other harmful gases from entering the atmosphere, it does have downsides that cannot be ignored. While the efficiency of production has increased in terms of how long it takes to produce a substantial amount of CMCs, it does not make the process any more environmentally friendly than it was in the first place. The process itself requires large quantities of energy and leaves behind waste. During the processing and creation of the ceramic matrix composites, residual material and other gases may be given off depending on the process used. This means more waste and potentially toxic chemicals going off to various landfills. One such example is from the process previously mentioned, liquid silicon infiltration [2]. One of the big disadvantages of this method is that after the process is completed, there is residual silicon left over in the matrix of fibers. This silicon must be washed and cleaned thoroughly, and that residual waste must be disposed of. 5 Brandt Miao Brendan Marani from going unnoticed, or passed at below proficient standards. Ceramic matrix composites should be used for their superior efficiency and weight reduction, not for their recycling capability. As this material is partly experimental at the moment, extensive research into strong forms of recycling has not been fully accomplished yet. However, simply because ceramic matrix composites cannot be recycled well right now does not mean that they are not beneficial to the environment in the long run. As more research and development is put towards developing superior recycling methods, the usage of CMCs becomes increasingly more sustainable. produces 30% less nitrous oxide gases then the average large aircraft engine, 10% less fuel burn rate than the widely used GE90 engine, and a 5% better fuel consumption rate versus any twin-aisle engine available [18]. This engine is projected to come in 2019. In the future, more engines will be created with an increasing number of CMC parts. The GE9X already produces astounding results in its environmental capacity, reducing exhaust emissions by one third. As CMC parts are optimized and added to jet engines, continually increasing benefits can be yielded. A problem that needs to be addressed in the future is manufacturing cost. Production capabilities have already grown a great deal from what they were 20 years ago, and in our age of technology everything is being produced at high rates. As more companies see the advantage in this, the industry for CMCs will become more competitive, driving companies to want to lower their production price. With enhanced efficiency and power, CMC engines will save money for companies, through less fuel and less required maintenance. When these parts are worn through, enhanced recycling techniques will be used, possibly discovered from organizations like AFRA, so that these CMC parts can be repurposed at the same or greater efficiency that their virgin counterparts can produce. The future holds a promising position for ceramic matrix composites in the power of jet engines. With environmentally sound power and efficiency constantly being pushed to new heights, ceramic matrix composites will lead the aircraft industry into a new age of strength. Weighing the Benefits While these are distinct issues that need to be treated in the future for maximum adaption to the environment, the current state of power and efficiency of ceramic matrix composites overturn these disadvantages in many cases. In this sense, ceramic matrix composites are a bit like solar panels, a form of renewable energy. When creating the solar panels, multiple toxic gases are given off into the atmosphere. Regardless, solar energy is still considered eco-friendly because in the long term, solar panels prevent a lot more gases from being spilled into the atmosphere, opposed to coal and fossil fuel burning. In the creation of ceramic matrix composites, multiple gases and other chemical runoff may occur, but the efficiency that these CMC parts provide for airplane engines pushes a positive environmental impact in the long run. In this scenario, CMCs can be considered superior to solar panels, because the silicon runoff and leftovers that occur when creating ceramic matrix composites can be recycled, as they can easily be restored into usable silicon. More proficient engines created with CMCs reduces the amount of gases including carbon dioxide and nitrous oxide by up to 30% when compared to competitors in the commercial market [18]. The amount of exhaust an engine produces per flight is much more harmful than the waste that comes out of creating the singular parts. Not to mention these flights stack on top of each other, and within a few years, the aircraft is not only easily breaking even, but it will have far exceeded its initial environmental drawbacks. SOURCES [1] “Ceramic Matrix Composites- Manufacturing and Applications in the Automotive Industry.” University of Bristol. No date. Accessed 2.27.2017 http://www.bristol.ac.uk/engineering/media/accis/cdt/news/b racho-garcia.pdf [2] D. Kopeliovich. “Fabrication of Ceramic Matrix Composites by Liquid Silicon Infiltration (LSI).” Substech. No date. Accessed 2.25.2017 http://www.substech.com/dokuwiki/doku.php?id=fabrication _of_ceramic_matrix_composites_by_liquid_silicon_infiltrati on_lsi [3] “Evolution of Jet Engines.” D.J. Airways. No dat. Accessed 3.2.2017 http://www.dj-airways.com/evolution-of-jet-engines/ [4] N. Padture. “Advanced Structural Ceramics in Aerospace Propulsion.” Nature Materials. 7.22.2016. Accessed 1.25.2017 http://www.nature.com/nmat/journal/v15/n8/full/nmat4687.h tml [5] R. Lowden, K. More, J. Haynes, Y. Katoh, E. Lara-Curzio, R. Dinwiddle. “Ceramic matrix composites take flight in LEAP jet engine.” Oak Ridge National Laboratory. 1.3.17. Accessed 2.26.2017. https://www.ornl.gov/news/ceramic-matrix-composites-takeflight-leap-jet-engine THE FUTURE OF CMCS IN AIRCRAFT Right now, the most advanced CMC engine, the LEAP engine, is fitted with only one CMC part. This single component is part of what separates the LEAP engine from its standard nickel based superalloy counterpart by an efficiency advantage of 15% [5]. Currently, GE is creating the next generation engine, the GE9X, and it yields many impressive figures [18]. The GE9X, which is produced using five separate ceramic matrix composite parts, is the quietest engine ever created, has the lowest emissions from a GE engine, and has the best rate of fuel consumption. This 6 Brandt Miao Brendan Marani [6] R. Bowman. “Superalloys: A Primer and History.” TMS. No date. Accessed 2.25.2017. http://www.tms.org/meetings/specialty/superalloys2000/sup eralloyshistory.html [7] “GE Aviation breaks ground on CMC facilities in Alabama.” Gardner Business Media. 6.20.2016. Accessed 1.26.2017. http://www.compositesworld.com/news/ge-aviation-breaksground-on-cmc-facility-in-alabama [8] M. Morrison. “The power list: top 10 commerical turbofans.” RBI. 4.17.2015. Accessed 2.26.2017 https://www.flightglobal.com/news/articles/the-power-listtop-10-delivered-commercial-turbofan-411334/ [9] J. Jewell, R. Kennedy, Charles Soret. “2016 CFM orders surpass 2,600 engines.” CFM international. 2.14.2017. Accessed 2.26.2017. https://www.cfmaeroengines.com/press-articles/2016-cfmorders-surpass-2600-engines/ [10] “OPERATING COSTS.” ARGUS International. No date. Accessed 3.29.2017. http://compair.aviationresearch.com/pdf.aspx?action=print_a ircraft_report&id=523&document_id=3 [11] “Aircraft and Related Data.” MIT Global Airline Industry Program. No date. Accessed 3.29.2017 http://web.mit.edu/airlinedata/www/Aircraft&Related.html [12] “Airplane Emissions.” The Center for Biological Diversity. No date. Accessed 1.26.2017. http://www.biologicaldiversity.org/programs/climate_law_in stitute/transportation_and_global_warming/airplane_emissio ns/ [13] “Effects of Changing the Carbon Cycle.” NASA. No date. Accessed 3.2.2017. http://earthobservatory.nasa.gov/Features/CarbonCycle/page 5.php?src=share [14] “Nitrous oxide.” SEPA. No date. Accessed 3.2.2017 http://apps.sepa.org.uk/spripa/Pages/SubstanceInformation.a spx?pid=8 [15] C. Arnold, S. Alston. “Environmental Impact of Composites.” Swansea University. No date. Accessed 3.1.2017. http://www.welshcomposites.co.uk/downloads/environmenta l%20webinar.pdf [16] Y. Yang, B. Irion, D. van Heerden, P. Kuiper, H. de Wit. “Recycling of composite materials.” Elsevier B.V. No date. Accessed 3.1.2017. http://www.sciencedirect.com/science/article/pii/S02552701 11002029 [17] “The AFRA BMP.” AFRA. No date. Accessed 3.1.2017. https://afraassociation.org/accreditation/the-afra-bmp/ [18] “GE9X Commercial Aircraft Engine.” General Electric. No date. Accessed 3.2.2017. http://www.geaviation.com/commercial/engines/ge9xcommercial-aircraft-engine ADDITIONAL SOURCES “Ceramic Matrix Composites Improve Engine Efficiency.” General Electric. No date. Accessed 1.10.2017. http://www.geglobalresearch.com/innovation/ceramicmatrix-composites-improve-engine-efficiency D. Freitag, G. Mandigo. “A Primer on CMCs.” ACMA. 2.28.2015. Accessed 1.10.2017. http://compositesmanufacturingmagazine.com/2015/02/aprimer-on-ceramic-matrix-composites/ “GE Aviation and the Ceramic Matrix Composite Revolution.” GE Aviation. 10.29.2017. Accessed 1.9.2017. https://www.youtube.com/watch?v=is1BBilkyUM& “Jet Engine, How it works?” Learn Engineering. 1.11.2015 Accessed 1.10.2017. https://www.youtube.com/watch?v=KjiUUJdPGX0 K. Wood. “Ceramic-matric composites heat up.” Gardner Business Media. 1.11.2013. Accessed 1.9.2017. http://www.compositesworld.com/articles/ceramic-matrixcomposites-heat-up T. Kellner. “Ceramic Matrix Composites Allow GE Jet Engines To Fly Longer.” General Electric Company. 2.9.2015. Accessed 1.9.2017. http://www.gereports.com/post/110549411475/ceramicmatrix-composites-allow-ge-jet-engines-to/ ACKNOWLEDGMENTS We would like to thank our writing instructor Rachel McTernan for continually providing us with feedback on our progress. We would also like to thank Dr. Budny and the University of Pittsburgh Swanson School of Engineering for allowing us the opportunity to write this paper, giving us experience on the topic and exposure to feedback from professional engineers. Additionally, thanks to our Co-Chair Colleen Hilla for meeting with us and reviewing the various sections and areas of our paper and how we could improve upon them. 7
© Copyright 2026 Paperzz