Composites: A Multi-industry · PDF fileComposites: A Multi-industry Perspective ... Composite Properties ... systems are often the only solution for risers in dynamic environments

Imagination at work.

LCC 5th Anniversary Symposium September 11, 2014 Dr. Matthew Beaumont

Composites: A Multi-industry Perspective

© 2014 General Electric Company - All rights reserved

2

GE … a heritage of innovation

1892 FOUNDED

300,000 EMPLOYEES

WORLDWIDE

$150 BILLION IN

ANNUAL

REVENUE

1 COMPANY IN

DOW JONES

INDEX ORIGINALLY

LISTED IN 1896


3

GE today

Oil & Gas Power & Water Energy Management

Transportation Healthcare Aviation Home & Business Solutions

GE Capital

Aligned for growth


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Expanding our global presence

Global Research Headquarters Niskayuna, NY

Global Research Europe Munich, Germany

China Technology Center Shanghai, China

Advanced Manufacturing and Software Technology Center

Detroit, MI

1900 - 1999 2000 - 2009

Welch Technology Center Bangalore, India

Russia Japan

2X Size + Customer Innovation Center Israel

Brazil Technology Center Customer focused R&D Rio de Janeiro, Brazil

Software CoE San Ramon, CA

+ 3 Customer Innovation Centers

2010+

O&G Tech Center

Oklahoma


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GRC Composites Technologies

Niskayuna, New York

Munich, Germany

Design

Materials

Simulation Damage Tolerance

Testing

Manufacturing

Processing Inspection

Bangalore, India

Fan Blade

Composite Properties (60% Fiber Volume) Relative to Metal

0

1

2

3

4

5

6

7

Sta

inle

ss S

teel

Alu

min

um 7

075

Titani

um 6

-4

E-G

lass

S-G

lass

Kev

lar 4

9

Nex

tel 6

10

T700S A

S4

IM7-

6000

T800S

IM10

Sp

ec

ific

Mo

du

lus

0

5

10

15

20

25

30

35

Sp

ec

ific

Str

en

gth

Specific Modulus

Specific Strength

Carbon Fibers


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Aviation

Aviation Wind

Aviation Wind Oil and Gas

Evolution of composites use in GE

Fan Blade

Fan Case

Ducts

Nacelles

Thrust Reverser Off-shore

Riser Pipes

Wind Turbine Blades


Aviation


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GEnx composites use

Fan Blade

Platform

Acoustic

Panels

Bonded Vanes

Ducts Fan Containment Case


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Batesville, MS, USA Second composites plant announced for

Ellisville, MS, USA

Gloucester, UK

GE Aviation composite manufacturing

Middle River, MD, USA

San Marcos, TX, USA

Hamble, UK


Wind Energy


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Wind blade shell production

Outer Shell Layers Positioning of Prefabs Core Material

Inner Shell Layers Shell Infusion


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High volume serial production

Managing the supply chain for wind turbine blades

Making improvements to manufacturing processes

Increasing quality while decreasing cost

Maximizing the effectiveness of glass fibers


Oil & Gas


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What are flexible pipes used for?

Designed to have the strength and durability associated with rigid steel pipes, flexible

systems are often the only solution for risers in dynamic environments

Flowlines

Static pipelines used to

carry fluids on the sea bed

Risers

Pipes suspended in the

water column connecting

FPSOs to subsea infrastructure

Jumpers

Short lengths of pipe

connecting two fixed

structures either above

or below water

Transfer Lines

Tend to be large diameter

pipelines connecting two

structures which are

often dynamic


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Composite Armor Optimized fiber angles and

thicknesses to meet design requirements with minimum mass; fewer layers for easier inspection

Thermoplastic Matrix PVDF - qualified pipe material

Carbon Fiber Not susceptible to environmental stress corrosion; chemically resistant

Metallic Tensile Armor Straightforward means to attach mature end fitting technologies; stable dynamics; industry

experience; impact damage tolerance

Bonded Liner/Barrier PVDF - with high chemical resistance; reduced permeated gas risks; easier inspection

Smooth Bore Option For smaller diameter / lower

temperature applications – low pressure drop & improved flow assurance

Metallic Carcass High temperature collapse

resistance; well characterized performance

Hybrid flexible pipe design concept


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Replacing the tensile armour layer with thermoset composite profile

Tensile Test

Bend Test


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Gas turbine inlet plenum


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Composite inlet system initiative

Advantages of replacing a welded stainless steel inlet plenum with a glass fiber composite structure:

• Weight reduction

• Cost reduction

• Volume reduction

• Improved airflow

• Anti oxidation material


The Brilliant Factory


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Process informatics – 6 sigma tools

Data Information Knowledge Faster

Process Development

Yield and

Process Control

Yield Maintenance

Cost Reduction

Knowledge fusion across time-scales

• Increase capacity • Improved quality and

process capability • Cost reduction

opportunities

• Faster Root Cause Analysis • Robust Process Designs

Traceability


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Virtual Product

Design

Virtual

Manufacturing

Service/Repair Shop

Supply Chain

Network

“digital thread” forms 21st century Self-improving Manufacturing ecosystem

The brilliant factory

Smart

Factory


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GE-TU Munich Collaboration

GE-GRC and the TUM - LCC began a general agreement for research collaboration in 2010 with a pledge of €5M.

With this money, GRC has been sponsoring 6 doctoral theses with advisors from GE: • Fiber placement • Textile draping • Removable mandrel materials • Thermoplastic forming • Curing simulation • Composite-metal hybrid structures

Composites: A Multi-industry · PDF fileComposites: A Multi-industry Perspective ... Composite Properties ... systems are often the only solution for risers in dynamic environments

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