On the Design and Manufacture of Structures for Flightworthy Gas Turbines

by Apostolos Karafillis

Chief Consulting Engineer

Structures and Additive Design

GE Aerospace

Abstract

The design and manufacture of gas turbine components presents unique technical challenges that highlight the relevance and importance of the disciplines of mechanical and aerospace engineering. In this presentation, we will focus on describing the fundamental technical requirements for parts of flightworthy gas turbines and will then share examples of designs and innovations to meet these requirements. The talk will include the description of typical loading conditions and operating environments, and the description of how these requirements guide the selection of design features, materials, and manufacturing methods. We will discuss three specific examples: The selection of features and architecture of a bearing housing, the design of a turbine frame with a mix of metallic and composite materials, and the development of methods for characterizing the performance of components manufactured with non-traditional methods. Through these examples, it will be shown that successful hardware design requires the combination of robust design methods, rigorous implementation of the principles of mechanics of materials, and the development of design and manufacturing innovation.