GE is designing a new composite fan blade using next-generation carbon fiber composite material for its GE9X engine that will exclusively po...
GE9X will feature fewer and thinner composite fan blades than any GE widebody engines with improved aerodynamics that will enhance the airflow and make for a lighter and more efficient fan, improving overall performance and fuel burn.
The new material incorporates a higher stiffness carbon fiber and a new epoxy resin. The fan leading edge material will also be modified from titanium to a steel alloy to further enhance the blade's strength.
The fourth-generation GE9X composite fan blade design are built on the success of current GE90-94B and GE90-115B that powers 777 and GEnx engines that power 787 Dreamliner. In 2013, GE has performed material testing on full-sized GEnx blades, with positive results. The new GE9X blade design will be tested next year.
GE will spend $300 million in 2014 on technology maturation testing for the engine. Tests include the Universal Propulsion Simulator (UPS) fan performance tests as well as testing of ceramic matrix composite components in a GEnx engine.
The first full core test is scheduled for 2015. The first engine will test in 2016 with flight testing on GE’s flying testbed anticipated in 2017. Engine certification is scheduled for 2018.
The GE9X engine will be in the 100,000-pound thrust class with a 10 percent improvement in fuel burn over present GE90. Key features include a 133-inch diameter composite fan case and 16 composite fan blades; a next-generation 27:1 pressure ratio 11-stage high pressure compressor; a third-generation TAPS (twin annular pre-swirl) combustor for greater efficiency and low emissions; and ceramic matrix composite (CMC) material in the combustor and turbine.
GE's GE9X program partners include Japanese IHI Corporation, French Snecma and Techspace Aero (Safran) and German MTU Aero Engines AG.
IHI will be responsible mainly for the design and manufacturing of the low-pressure turbine parts. Techspace Aero will be in charge of the low pressure compressor global integration and the fan disk manufacturing.
Snecma having slightly more than 11% stake, will produce the composite fan blades via CFAN, its 50/50 joint company with GE, as well as design and produce the turbine rear frame and the forward fan case.
MTU will have manufacturing and design responsibility for the engine's turbine center frame.
