Car|os 8ustamante

lngenlero Mecanlco l1P

ILS1C NLUMA1IC
(Sales and 1ech SupporL)
SAkGLN1 CCN1kCLS
ALkCSACL
(CL uSC8 PW S88)
GL AVIA1ICN
(LxLernals PuW Lnglneer)
"INGLNILkIA DL AVICNLS 1Uk8INAS
LANLACICN DL CAkkLkA
GL AVIACICN
CL Avlaclon lnlclo dando servlclos a moLores de avlon hace
mas de 30 anos y es uno de los llderes producLores de grandes
y pequenos moLores para avlones comerclales y mlllLares
CL Avlaclon es una subsldlarla de Ceneral LlecLrlc y su sede es
en Lvendale Chlo
Sus prlnclpales compeLldores en el negoclo de las Lurbo
maqulnas son 8olls8oyce and raLL WhlLney
Ch|na (C1C)
Shanga|
ULk1AS A8ILk1AS ULk1AS A8ILk1AS
NINGUN
AAkA1C
NINGUN
AAkA1C
AVISC
AVISC
llghL Mlsslon
06612 12 Sense llne lssue
8esulLs
2
7
3
.
2

H
z
2
4
5
.
0

H
z
2
2
3
.
5

H
z
1
9
6
.
7

H
z
MODE 1 = 196.7 Hz
MODE 2 = 223.5 Hz MODE 3 = 245 Hz MODE 4 = 273.2 Hz MODE 4 = 318.3 Hz
3
1
8
.
3

H
z
Failure A
*Vibration
Spectrum
for Configs
Hardware
Design
Failure C
Failure A Failure
Here
Failure
Here
P MCuL 230 Pz
1ube MaLerlal AMS3337/SS21
CperaLlng ressure 30 Sl
lnLernal 8adlous 006373 lnch
Wall 1hlckness 028 lnch
CperaLlng 1emperaLure 6
Mean SLress 117
AlLernaLlng SLress 12311
Failure A
AlrcrafL ueslgn
Aerodynamic
Design
Customers (Airliners, Army, Navy, Government, Private Businesses) state the required
perIormance/characteristics oI the aircraIts/airplanes (Range, Pax/Load Capacity,
Airport/Carrier/Aerodrome Facilities, Fuel Consumption, Noise, Weapons, Wheatear Instruments,
Sprayers, etc).
AirIrames (Boeing, Embraer, Piper,
Cessna, Lockheed Martin, an so on)
Engine ManuIacturers (GE, Pratt & Whitney,
Continental, Lycoming, Bristol, and so on)
Propulsion
Design
Structural
Design
Electronics
Wings
Fuselage
Empennages
Landing Gear
Aerodynamic
SurIaces Control
Civil Aviation
W Short, Medium and Large Range
AircraIts
W Cargo
W Executive, Aerobatic,
Agricultural, Rescue, Patrol, etc.
Military Aviation
W Fighters
W Bombers
W Reconnaissance
Wing Type
%ail %ype
Conventional Tail T-Tail V-Tail
Twin Tail
Triple Tail
Rudder Elevator Flaps Aileron Spoiler
Aircraft Components
LiIt
During take oII, what are the
aircraIt elements that produce
more drag?
Mach Cone
Tunnel Tests
#s Lnglnes roducL Llne
18
GE Aviation
August 23, 2010
GE Proprietary nformation
For nternal Use Only
Ilslon Ceneral
E
m
p
u
j
e
o

T
h
r
u
s
t

(
K
l
b
f
)
5.4-6.6
CF34-3
3809 engines
50M Hrs
42M Cycles
CFE738
494 engines
2.3 M Hrs
1.5 M Cycles
9
CF34-8C/8E
1852 engines
17M Hrs
13M Cycles
12-14
CF34-10E
734 engines
3.5M Hrs
2.4M Cycles
CF34-10A
ES 4Q 2011
17-20
L78
Plghbypass Lurbofan englnes bullL ln
parLnershlp wlLh Poneywell
CL owns hoL secLlon core
modules AuL PMu IC
AcLuaLors
lrsL verslon cerLlflcaLlon ln 199
Lxcluslvely uassaulL 8uslness !eL
AppllcaLlon
alcon 2000 alrcrafL
CuL of producLlon

uerlved from mlllLary 1

lrsL verslon cerLlflcaLlon ln 1982
LasL verslon cerLlflcaLlon ln 1993
Lxcluslvely 8ombardler alrcrafL appllcaLlon
0 8uslness !eL (hallenger)
60 8eglonal !eL (8!100/200)
8
30 lncreased LhrusL over
erLlflcaLlons beLween 1999 and 200
% uselage mounLed for 8 (8ombardler)
AlrcrafL 8!700/ 900/ 1000
% Wlng mounLed for 8L (Lmbraer)
AlrcrafL L170/ L173
10L
Scaled archlLecLure from M367
erLlflcaLlon uec 200
LlS nov 2003
Wlng mounLed for Lmbraer
AlrcrafL L190/ L193/ Llneage
10A
uerlved from 10L
80 Lo 90 common
uselage mounLed for CMA
lrsL alrframe A8!21
90 Lo 103 pax
hLLp//wwwyouLubecom/waLch?vCn0sIe1yeCk
onflguraLlon Pardware allure Modes
HCF LCF
Wear Leaks
Bladeout Rupture
Fire Prevention Over-temperature
Good Design Considers and Avoids Likely Failure Modes
The Better Your Design, the Easier Your Substantiation
Will Be
onflguraLlon aused leld LvenLs
FSD
Delays and
Cancellations
Pow uo l revenL leld roblems?
Know the potential failure modes
Design to avoid the failure modes
Substantiate to prove you won't
see the failure modes
t requires lots of
Engineering dedication!!!
P allure Lxample
CFM56-5C LPT cooIing tube Air France
Suspend a mass between supports, put a frequency
in the operating range, and do not be surprised if it
breaks
Mass between
support points
Fatigue crack
propagated in weld
HAZ until burst
L allure Lxample
LPT ACC PaneI GE90-94B
Cracks Propagated in LCF Due to thermaI gradient,
pressure cycIing and Kt of impingement hoIe
pattern
Wear
Fatigue
Cracks
Wear allure Lxamples
CF6-80 HPT ACC MANIFOLD INLET
Slip Joints Wear Out!
Wear allure Lxamples
Even Teflon Can't Last Forever Use Frequency
Avoidance!!
Wear allure Lxamples
CI680L W88 cab|e rout|ng near the fue| pump
So That is Why DP 6601 Says Not to Do That.
1hlnWall 8uckllng
CI6S0 8th stage a|r duct found buck|ed at A check
Thin Walls Can Do Ugly Things.
Cver1emperaLure allure Lxample
ause Cver LemperaLure
lssue found afLer runnlng speeds 176 1236 116
12776
Lnglne 00 AcLlon 8eplace wlLh same parL
1ype ueslgn AcLlon Add wear sleeves Lo Lubes replace
ushlon clamps wlLh noncushlon clamps
Locations showing distress
GEnx Vibration Endurance
Test
1yplcal SubsLanLlaLlon MeLhods by 8equlremenL
our Requirements May Be Different
Failure Mode Requirements Material property Risk to Prevent
Vibration
(HCF)
FAR 33.63
Avoid all damaging input frequencies
including NSV by 25% (analysis), or
Keep stress below minimum material
limit for HCF
Fatigue strength
with Kf=4 on
Goodman
diagram
Fluid leaks
Separated parts
Contact between
parts
Endurance
FAR 33
Functional life as long as the engine
Keep stress below minimum material
limit for LCF
Wear resistance
LCF strength
Fluid leaks
Loose parts
Burst
JAR 64
Keep stress below minimum material
limit (yield or ultimate) at specified
operating conditions
.2% yield strength
Ultimate strength
Fluid leaks
Undercowl fire
Fire indication
Strength
FAR 33
Keep stress below minimum material
yield strength
.2% yield strength Fluid leaks
Bladeout
FAR 33
No fluid leaks due to ruptured pipes,
flanges, etc.
Ultimate strength Fluid leaks
WhaL allure Mode ls AffecLed?
Failure Mode Consider Changes That
Affect
Red Flags
Vibration (HCF)
FAR 33.63
Span length
Stiffness
Mass
Center of Gravity
Attachment points
Longer span between supports
Reduced stiffness of span or supports
Higher mass between supports
Mass centered farther from supports
Reduced stiffness
Endurance - wear
FAR 33
Materials
Clearance
Displacement in contact
Softer, less wear-capable materials
Mismatched materials hard/soft, bad couple
Reduced clearance that could cause contact
Higher displacement could accelerate wear
Endurance - LCF
FAR 33
Stiffness
Material
Temperature
Attachment interfaces
Higher stiffness can increase mean stress
Material with lower LCF strength
Temperature change check thermal growths
Higher stiffness
Burst
JAR-E-640
Wall thickness
Diameter
Cross-section shape
Reduced wall thickness due to casting or forming
ncreased diameter check hoop stress
Less round, abrupt changes
SubsLanLlaLlon by Pardware 1ype
Type of hardware Most likely failure modes Design methods to
avoid failure
Recommended
substantiation
Tube, duct, tube
manifold
HCF - Resonant frequency
coincident with dynamic input
(1/rev or NSV)
HCF driven
Tensile overload - bladeout
Add bracket stiffness in
direction of modal
response
Shorten span,
eliminate bends
Modal analysis
mpulse test
Shake table test
nstrumented engine
test
Hose Fire prevention Add fire sleeve Comparative analysis
Fire test
Flexible joint LCF life
Over-temperature
Optimize kinematics
Add internal limiter
Material selection
Finite Element Analysis
Component test
Temperature tab or TC
on engine test
Fluid joint Mis-assembly
Thread loosening
Use standard parts
Triple-torque
Service history
Service history
SubsLanLlaLlon by Pardware 1ype
Type of hardware Most likely failure
modes
Design methods to
avoid failure
Recommended
substantiation
Structural bracket HCF
Bladeout strength
Stiffness to place
system above 1/rev
Avoid abrupt
changes in geometry
Reduce Kt's
Use nco 625
Soft mount valves
Add thickness
Use nco 625 or 718
System modal
analysis
mpulse test
(frequency)
Shake table test (Q)
nstrumented engine
test
Electrical bracket Assembly LCF
HCF
Avoid abrupt
changes in geometry
Reduce Kt's
Panels LCF Wear pads Thermal stackup
Fluid joint Mis-assembly
Thread loosening
Provide good access
Secondary retention
Physical mockup
N/A
GE Aviation
GE Proprietary nfo
EBU Architecture
EIec. Harnesses
HydrauIics
FueI
IDG CooIing
Drain System
Air System
Fire Protection
EBU: Systems required for engine to work with the aircraft
GE Aviation
GE Proprietary nfo
EIectricaI Harnesses
LS View
EIectricaI Harness route design
Connects components and sensors to the
FADEC and Aircraft
GE standard is "closed bundle: jacketed
wires surrounded by protective sheath
Cushioned clamps and spring clamps
support harnesses
Considered LRU by Maintainability Eng.
Harnesses routed by EBU Eng., but
designed by Components and Accessories
Eng.
GE Aviation
GE Proprietary nfo
HydrauIic SuppIy
LS View
Engine-mounted hydrauIic Iines
Moves fluid between the EDP (Engine-
Driven Pump) and the Aircraft
Pressurized fluid used for many aircraft
controls.
Not used to power engine systems
Three lines required: Supply (pressure),
Return (suction), Case Drain
EDP provides required 3000 or 5000 psi
steady state with undesirable high freq.
pressure pulsations
Has specific certification requirements per
FAR 25.1435
GE Aviation
GE Proprietary nfo
FueI SuppIy and Motive FIow
LS View
Engine-mounted FueI Iines
Fuel Supply line always required to pass
fuel from Aircraft to engine
Fuel Motive Flow line may be included to
allow fuel pump to pressurize aircraft fuel
tanks
Fuel Low Pressure Switch usually included
to sense low fuel pressure and prevent
hose collapse
Pressure is relatively low in normal
operation: < 60 psi
GE Aviation
GE Proprietary nfo
IDG CooIing
LS View
IDG (Integrated Drive Generator)
CooIing System
Cools DG oil (separate from engine oil)
Normally includes an ACOC (Air-Cooled Oil
Cooler)
Often contains an FCOC (Fuel-Cooled Oil
Cooler) for cooling at ground idle
Moderate pressure system: ~300 psi
GE Aviation
GE Proprietary nfo
Component Drains
LS View
Engine Drain System
Used to drain engine-mounted, fluid-filled
components and sometimes pylon
Also used to check for component leaks
without opening nacelle
Drains lines separated to allow ease if leak
source identification
Tubes are open to ambient air, so not
under pressure during normal operation
GE Aviation
GE Proprietary nfo
Component Drains
Collector
Lower
Bifurcation
Disconnect
Panel (Firewall)
GE Aviation
GE Proprietary nfo
Air Systems
LS View
AMS, NAI, Start, and Overboard
BIeed Air Systems
AMS (Air Management System) provides
pressurized air to aircraft for wing anti-ice
and cabin pressurization
NA (Nacelle Anti-ce) provides hot,
pressurized air to inlet lip skin
Starter Duct provides pressurized air to air
turbine engine starter, used to start the
engine
Overboard Bleed sends compressor air out
of engine and nacelle during engine start to
allow starter to turn engine rotors
Starter Duct
Overboard
Bleed
Anti-ice
10
th
Stage
Bleed
GE Aviation
GE Proprietary nfo
INLET
Starter
Valve
Starter
PRSOV
HPSOV
Check
VaIve
5th Stage
Bleed Port 9th Stage
Bleed Ports
Nacelle Anti-ce (NA)
position feedback sensor
FAN AIR INLET
PyIon Interface
Bleed Bias
Sensor
(BBS)
Fan Air
Valve
Pressure
Transducer
Core Compartment
Fan Compartment
Pre-cooIer
Fire
Barrier
Fan Air Discharge
(Overboard)
High Press.
Bleed to Aircraft
nlet Fwd
Bulkhead
Piccolo
Tube

Flow restrictor
CF34-10A Air Systems Schematic
GE Aviation
GE Proprietary nfo
Fire Detection
LS View
Fire Detection and Extinguishing
System
Fire detectors sense ambient high
temperature condition in engine fire zones
Two types of detectors available: electrical
and pneumatic
Detectors routed by EBU Eng. but
designed by fire detector supplier
Fire extinguisher often a nozzle at the pylon
firewall panel
Extension tubes may be added to
extinguisher if needed (may be required
around gearbox
Under-cowl Ventilation
Flow Direction
Flammable Fluid
Components
Detectors placed
"Downwind of fire sources
Burn-
through
Region
GE Aviation
GE Proprietary nfo
Fire Detection (GEnx-1B)
Electrical
Harness supports
Brazed bracket
connection
Bolted fire
detection
supports
Minimal weight and cost system
LPT mounted
brackets
LPT pipe serves as
fire det. support rail
Plan de Carrera
GE Aviation
GE Proprietary nfo
our career is a
JOURNE not
a
DESTNATON
GE Aviation
GE Proprietary nfo
GE's a HUGE, gIobaI company.this
means Iots of opportunities
to have a robust
career path
Other Associates
~95,000
Other Associates
~95,000
ProfessionaIs
~190,000
ProfessionaIs
~190,000
(LTB, PB, LPB) (LTB, PB, LPB)
Senior ProfessionaIs
~30,000
Senior ProfessionaIs
~30,000
Executive Band
~4,000
Executive Band
~4,000
Senior
Executive Band
~435
Senior
Executive Band
~435
Officers
~185
Officers
~185
CEO
5
TotaI Company EmpIoyment ~320,000
GE Aviation
GE Proprietary nfo
GE's Growth VaIues
GE >320,000
Employees
New
Leader
Execution
Developing
Leader
Strategy +
Advanced
Leader
Culture +
Executive
Leader
+ Vision
External focus
Clear thinker
magination + courage
nclusive leader
Expertise
S
P
EB
SEB/
VP
GE Aviation
GE Proprietary nfo
David L. Joyce's Six Key
Imperatives
1. Scale our business to current realities
2. Help our customers bring value to their customers in these
challenging times
3. Make selective investments in technology
4. Simplify the organization to deliver greater customer value
and productivity
5. Maximize deflation opportunities in both base and variable
cost productivity
6. Grow selectively where the payback is clear and
sustainable
GE Aviation
GE Proprietary nfo
demonstrated
+
potentiaI potentiaI
demonstrated
+
potentiaI potentiaI
GE Assessment ModeI
Competencies
Passion & Passion &
behavior behavior
Passion & Passion &
behavior behavior
Assessment
ActiveIy focus your deveIopment beIow the water in addition to the above
GE Aviation
GE Proprietary nfo
OUR Career Management ModeI
competencie
s
passions
organizationaI
needs
career best
career goaIs
personaI
brand
Ieadership
differentiators
Factors are constant but the weighting may change
.what are your desires?
.how is your "packaging"?
.what differentiates you?
GE Aviation
GE Proprietary nfo
competencie
s
passions
career goaIs
organizationaI
needs
our career goaIs are a baIance
between your competencies and your
passions
OUR Career Management ModeI
GE Aviation
GE Proprietary nfo
Think about your ideaI position
What IeveI of responsibiIity do you wish to attain
in your career?
What steps do you need to take to attain this
IeveI?
How much autonomy do you Iike in a roIe?
Do you prefer strategic vs. transactionaI roIes?
Do you enjoy a coIIaborative environment or
individuaI contribution?
How important is financiaI vs. non-financiaI
reward?
Do you need fIexibiIity? What do you need
to sacrifice?
GE Aviation
GE Proprietary nfo
Think about yourseIf
What's important to you?
What motivates you?
What is your "naturaI styIe"?
What do you enjoy doing?
What are your Iife priorities?
What is "free time" and how do
you spend it?
What have you Iiked/disIiked
about past jobs?
GE Aviation
GE Proprietary nfo
Life VaIue Ranking Assessment
Power & authority
Location - Iiving where you
want
Independence - freedom to act
Money - financiaI success
BaIance between work &
famiIy
ProfessionaI respect &
recognition
Job security - stabiIity
Working with smart peopIe
Rank order the importance of the foIIowing items to you
Working with peopIe you
Iike
Having fun - enjoying work
Working for a worId cIass
organization
ContinuaI chaIIenge &
growth
Excitement - sense of
adventure
Managing/Ieading others
Making an impact;
Achievement
GE Aviation
GE Proprietary nfo
competencie
s
passions
organizationaI
needs
our personaI brand is the
intersection of your passions and the
org need
personaI
brand
OUR Career Management ModeI
GE Aviation
GE Proprietary nfo
What sets you apart from your peers?
What quaIities or characteristics make you
distinct?
What do you want your name to be
synonymous with?
How weII & what are you known for?
What is your strongest Growth Trait?
What are you most proud of?
What is your personaI definition of
success?
Brand differentiation - seIf assessment:
Ask yourseIf.
GE Aviation
GE Proprietary nfo
competencie
s
passions
organizationaI
needs
our differentiators are the marriage
between your competencies and the org
need
Ieadership
differentiators
OUR Career Management ModeI
GE Aviation
GE Proprietary nfo
OperationaI
understanding
G&Os compIement
business strategy
Customer
orientation
TechnicaI skiIIs
Product/process
knowIedge
FunctionaI skiIIs
Process
Ieadership
Change
Ieadership
Enterprise-
thinking
AII eIements of the competency modeI are key to success
Competency ModeI
Leadership
Business
Acumen
FunctionaI/
TechnicaI
Expertise
TooI: skiIIs inventory TooI: G&Os
imagination -
incIusiveness
TooI: differentiator inventory
GE
VaIues
GE Aviation
GE Proprietary nfo
Product Knowledge
ndustry Knowledge
Specific Technical Skill welding, etc
Manufacturing Process CTQs
Product Quality CTQs
Marketing ntelligence
Supply Chain Management
Financial Management
Contract Management
Digital Communication/Work Flow
Role Required T System
Web Based Skills
Competencies
HighIy
SkiIIed
SkiIIed
DeveIopment
Required
Inventory the competencies necessary for the position(s) you are
interested in
Create & conduct a seIf-assessment against those competencies
Engage your manager & identify gaps
DeveIop an action pIan and incorporate into annuaI career discussions
FunctionaI SkiIIs Inventory
GE Aviation
GE Proprietary nfo
Career differentiator questionnaire
Driven process improvements for business resuIts
through a Lean or Six Sigma assignment?
Taken a gIobaI assignment; Ied a gIobaI/virtuaI team?
Taken a stretch assignment outside your function?
Managed a crisis or a turnaround?
Touched other areas of the business?
Led a business/cuIturaI integration?
DeIivered bottom-Iine resuIts for an organization?
Shared best practices across the Iarger enterprise?
DeveIoped a unique functionaI expertise?
Shown that you can be successfuI in muItipIe forums?
Have
you.
GE Aviation
GE Proprietary nfo
Enjoy your
JOURNE