Volvo Aero in Clean Sky Bengt-Olof Elfström Robert Lundberg

Clean Sky = JTI JTI = Joint Technology Initiative Ny typ av EU-program Public/private partnership (JU, Joint Undertaking) 7 år, 2008 - 2015 Budget 1600 M€ Stöttas av det svenska FLUD-programmet Clean Sky är en av flera JTIer Clean Sky tar fram demonstratorer inom sex teknikområden Ett av dessa är motorer (Sustainable and Green Engines, SAGE) SAGE leds av Rolls-Royce och Snecma SAGE budget 425 M€ Volvo Aero är Associate member => Identifierade som nyckelspelare för att projektet ska lyckas Ansvarar för större arbetspaket 21 M€ budget October 2010 Clean Sky

”Innovationsupphandling” från EU Det övergripande målet med Clean Sky är att ta fram teknologi som tar oss snabbare till ACAREs mål för år 2020: -50 % CO2 Halverat buller -80 % NOx October 2010 Clean Sky

October 2010 Clean Sky

Clean Sky – six areas October 2010 Clean Sky

Five engine demonstrators in SAGE October 2010 Clean Sky

Volvo Aero involved i four of the five engine demonstrators Volvo Aero focus on design, development and manufacturing of complex lightweight static and rotating structures. Advanced manufacturing and manufacturing process simulation technologies developed in FP5 and FP6 projects are a key to success. Manufacturing process simulation of welding Intermediate Compressor Case Complex rotating parts Rear Rotating Structure Mid Turbine Frame Intermediate Case Turbine Exhaust Case SAGE 1 SAGE 2 SAGE 3 SAGE 4 October 2010 Clean Sky

2025 New generation B737/A320 (NSA) Open rotor SAGE 1 & 2 2025 New generation B737/A320 (NSA) Open rotor SAGE 3 Large 3-shaft 2020 New B777, B747 (NWB) SAGE 4 Geared turbofan 2016 Re-engine of A320/B7373 (NSA) October 2010 Clean Sky

SAGE 1 Geared Open Rotor – Rolls-Royce Volvo Aero: Rotating structure High torque Critical part Hot environment Engine test in 2015 Engine challenges: Noise Pitch change mechanism October 2010 Clean Sky

SAGE 1 Geared Open Rotor – Rolls-Royce Mechanical testing of sub-element October 2010 Clean Sky

SAGE 2 Direct Drive Open Rotor – Snecma Volvo Aero: Rotating structure Short shaft Engine test in 2015 Engine challenges: Noise Pitch change mechanism Weight October 2010 Clean Sky

Open rotor - aircraft integration Noise Vibrations Certification Weight of installation Flight test of Open Rotor engine planned in SFWA-part of Clean Sky October 2010 Clean Sky

SAGE 3 large 3-shaft engine – Rolls-Royce Volvo Aero: Intermediate compressor case New high strength steel design Welding Validation by mechanical rig test October 2010 Clean Sky

SAGE 4 Geared Turbofan - MTU Turbine structure Volvo Aero: Hot structures Heat transfer HT materials Fairing design Seals Engine test in 2013 October 2010 Clean Sky

Innovationsdriven utveckling via ”sneda vågens princip” day month year Innovationsdriven utveckling via ”sneda vågens princip” 120 miljarder i beräknat ordervärde SAGE 4 SAGE 3 SAGE 1 & 2 GENx 2009 PW1000G 2012 Trent XWB 2012 Produkt- applikation Geared turbofan Large 3-shaft Open rotor TRL 9 Open Rotor Utvecklings- program ”Gröna” flygplan & motorer Verifierad Teknologi JTI ”Clean Sky” TRL 6 Internationella program FLUD Green&Sustainable Demo? Demon- Antle/Clean VITAL strator TRL 3 Nationella program NFFP 3 NFFP 4 NFFP 5 NFFP 6? Teknologi Time 2005 2010 2015 Dept. 9005, Ulf Högman

Clean Sky ger Volvo Aero möjlighet att deltaga i USA-demonstratorer NWA Airbus: NSA Open Rotor NSA upgrade Produkt- applikation GE (BWB?) -strukturer P&W (GTF) LP-kompressor P&W (GTF) –Mid-frame GE (NWB) –Komposit fan frame Demo- program SAGE 1 – RR, Open Rotor Clean Sky – 2 Värmeväxlad motor Gen 2 Open Rotor RR, Snecma, MTU SAGE 2 – Snecma, Open Rotor SAGE 3 RR 3-axlig SAGE 4 MTU – Geared TF FLUD Green&Sustainable Demo Time 2010 2015 2020 2025

“Make It Light” för att minska CO 2 day month year “Make It Light” för att minska CO 2 Volvo Aeros mål är att minska vikten på kalla och varma strukturer med 20%, vilket kommer att minska vikten på framtida motorer med nästan 3%. Det sparar 17000 kg i bränsle för ett normalstort passagerarflygplan. Om denna teknik användes i den nuvarande globala civila flygplansflottan, skulle CO2-utsläppen minska med 1,3 miljoner ton om året. Som jämförelse släppte flygtrafiken i Sverige ut 1,5 miljoner ton CO2 under 2005. The 20% reduction is Volvo Aero´s adopted technology target for hot and cold structures. From a recently designed engine the weight of the intermediate case, fan OGV and turbine exhaust case was estimated at 13.4% of the engine weight. 20% of this gives a 2.68 % saving on engine weight. For a next generation single aisle aircraft the engine weight was estimated at 2300 kg. This in turn gives a 61 kg saving per engine. By rescaling the aircraft for constant mission range and payload the aircraft mass decreases a total of 262 kg. This aircraft saves 0.255 % fuel compared to that with the baseline engines. The baseline aircraft uses 1720 kg fuel per average mission hour. For 4000 hours utilization this gives a baseline consumption of 6860 tons per year from which 17500 kg can be saved. The global commercial fleet (IATA) was estimated to use 161 Mtons of fuel 2006, which generated 507 Mtons of CO2. The potential improvement of 0.255% was applied to this quantity. SIKA (Statens institut för kommunikationsanalys) reports in "Civil aviation 2005" (SIKA 2006:17) that "Emissions in engine exhaust gases from air traffic in Sweden" contained 1455 thousand tonnes CO2. Company, Department, Name

Sammanfattning Viktigt med demonstratorer Teknologiutveckling TRL Validering i komponent-prov Validering i motorprov Dyrt Tillgång till motor/riggar Leder till affärer Viktigt att få möjlighet och finansiering att delta i internationella demonstratorprojekt Clean Sky ger möjlighet till att Volvo kan fira >100 år som ett framgångrikt företag i framtiden October 2010 Clean Sky

Clean Sky is the kind of project that will ensure that Volvo Aero can celebrate also >100 years as a successful company in the future October 2010 Clean Sky