Weight reduction of high performanceWeight reduction of high performance helicopter lubrication pumps by PM aluminium alloysR. Gradinger1, H. Kilian1, M. Schuller2, M. Tauscher2, P. Schäffler3

1 LKR Leichtmetallkompetenzzentrum Ranshofen GmbH, AIT Austrian Institute of Technology p , gy2 TEST-FUCHS GmbH 3 Alulight International GmbH

5th International Conference “Supply on the wings”2 4 Nov 2010 AIRTEC fair Frankfurt / Main Germany2-4. Nov. 2010, AIRTEC fair, Frankfurt / Main, Germany

Outline

Introduction of LKRGreening of aircraftWeight saving in generalWeight reduction of high performance helicopter lubrication pumps by PM aluminium alloyslubrication pumps by PM aluminium alloys

ConceptPM aluminium alloy selectionyPrototypingExperimental results

OutlookSummary

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LKR is a buiness unit of AIT’s MOBILITY department

AIT is one of Europe’s leading mobilityAIT is one of Europe s leading mobilityresearch centres

through efficient, safe and greenmobilty solutions

through extensive expertise in simulation coupled with a highly-d l d h i f t tdeveloped research infrastructure

through networking with sciencethrough networking with science and industry on a national and international level * LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

Most important research topicsMaterials development

• Development and optimisation of alloys• Optimisation of heat treatment parameter• Improvment of mechanic and dynamic characteristics• Optimisation of the microstructures of alloys

P d l t d ti i tiProcess development and optimisation• Development and improvment of casting processes• Evaluation and optimisation of metal forming processes• Simulation of process technologies• Evaluation and optimisation of processes in external production lines• Validation and prototyping

Materials based design• Design of light weight structures

C h i l ti f hi l t d t t• Crash simulation of vehicle components and structures• Optimisation of topology and structure• Joining technologies

Demonstration of prototyping• Demonstration of prototyping

LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

Greening of aircraft

The greening of aircraft is in the focus of European research activities e.g. the Joint Technology Initiative Clean Sky: large industrial players and EC committed themselves to big efforts concerning airframe, engines and systems. In the R&D g g , g yfocus are configuration, materials, weights, aerodynamics, energy efficiency, bio fuels et cetera.

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Weight saving in general

One main factor to increase environmental friendliness of aircrafts is mainly the reduction yof their weight. But “battle” of materials is not only daily business in largeonly daily business in large airframe structures (e.g. CFRP for A350WXB) or engines (γ-TiAl for low pressure turbinefor low pressure turbine application), also in smaller components.T i i tTo an increasing amount, material mix concepts with the best materials at the right place are chosen in aerospace asare chosen – in aerospace as well as in other sectors like automotive or mechanical engineering

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engineering.

Weight reduction of helicopter lubrication pumps

In aircrafts, fuel pumps are used for the continuous supply of the engines with fuel. Lube oil pumps are used for provisioning of p p p glube oil circuits of engines and gearboxes. In the field of aviation fuel and lube oil pumps there were few of innovations donepumps there were few of innovations done during the last years and decades. The need of lightweight construction, typically limited space in aircrafts and therefore highlimited space in aircrafts and therefore high specific power, respectively, lead to high rotational speed of the pump wheels, which causes a principal disadvantage of lowcauses a principal disadvantage of low efficiency by concept. The increasing importance of low emissions (CO noise) leads to an high potential of(CO2, noise) leads to an high potential of improvement of fuel and lube oil pumps as a contribution towards the environmental goals to be achieved

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goals to be achieved.

Weight reduction concept

The main concept for the weight reduction of high performance helicopter lubrication pumps was to substitute the standard steel p pmaterial of the inner and outer pump wheel by innovative powder metallurgical (PM) aluminium alloys in order to demonstrate a yreference for a weight saving of 25 % (of the typical mass of 2.2 kg of the basic lube pump).

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Selection of proven powder metallurgically produced alloys

Evaluation of PM alloys which are in industrial use, providing positive experience from automotive series parts:

AA 4041- AA 4041: - AA 6082

- AA 7020AA 7020

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General advantage of PM alloys

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Prototyping of pump wheels

PM alloyingCold isostatic pressingpressingExtrusionCuttingCuttingHeat treatmentWire-electro discharge machiningSizing*Sizing

* series production option

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Experimental results

After evaluating samples with mechanical and tribo-chemical tests as well as with pump-related test equipment the material AA 4041 is principallytest equipment the material AA 4041 is principally feasible for the usage in inner and outer pump wheels.Due to the unchanged geometry of the wheels (base: steel) an increased wear at the outer wheel can be observed due to the higher coefficient of gthermal expansion (CTE) of aluminium alloys. Without optimizing the geometry, a weight saving potential of 12% is feasible by combining outerpotential of 12% is feasible by combining outer wheels made of steel with inner wheels out of AA 4041.Through the change of the pump geometry it will be possible to use the innovative materials for the outer and the inner pump wheel and would result

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p pin a saving of weight of 24 - 25 %. Different coatings proved to be useful, too.

Outlook

Next R&D steps are being made in joint activities with different R&D and industrial partners e g in Austria in theindustrial partners, e.g. in Austria in the context of components for a range extender in hybrid cars.

The additional results for the PM materials under harsh internalmaterials under harsh internal combustion engine application will be used for the design of high performance helicopter lubrication pumps which willhelicopter lubrication pumps which will then take account of all material specific boundary conditions incl. ΔCTE.

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Summary

A weight reduction potential of high performance helicopter lubrication pumps was identified.Diff t PM l i i ll h iDifferent PM aluminium alloys were chosen in order to be evaluated as an substitute for steel in pump wheels.Suitable materials and coatings were selected and evaluated, production technologies were defined and parts for the qualification weredefined and parts for the qualification were produced.Further R&D is currently being done and these

lt ill b dd d t th i dresults will be added to the experiences made so far in order to find the best future series design.

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Acknowledgement

The funding granted by the Federal Ministry for Transport, Innovation and Technology via the Austrian Research Promotion Agency (FFG) for this research project “HPP” is gratefully acknowledged as well as the support of p j g y g ppinvolved project partners.

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AIT Austrian Institute of Technologyyour ingenious partner

Rudolf GradingerLKR Leichtmetallkompetenzzentrum Ranshofen GmbHLKR Leichtmetallkompetenzzentrum Ranshofen GmbHrudolf.gradinger@ait.ac.at