Pratt & Whitney introduces AM solution for GTF engine repair
DED-based process expected to reduce repair times by over 60% with over $100M cost reduction
American aerospace manufacturer Pratt & Whitney (owned by RTX Corporation) has developed and launched a new additive manufacturing solution for repairing critical components on the GTF engine. The state-of-the-art repair technology is based on Directed Energy Deposition (DED) and is expected to reduce repairing times by over 60%.
Pratt & Whitney’s GTF engine is a geared propulsion system dubbed the “quietest and most fuel-efficient in its class”. The aircraft engine, engineered for greater sustainability, powers many single-aisle planes, including the Airbus A320neo Family, the Airbus A220 and Embraer E-Jets E2. Taking into account the efficiency of this engine, it is understandable that Pratt & Whitney is interested in making its repair processes more efficient as well.
The DED repair process was developed at the aerospace company’s North American Technology Accelerator in Jupiter, Florida in collaboration with the Connecticut Center for Advanced Technology and the RTX Research Center. The additive manufacturing approach has several benefits, including streamlining the repair process by eliminating tooling steps, minimizing machine changeovers and reduced heat treat cycles. The process will initially be used for repairing GTF structural case features, but will eventually also be rolled out to restore other engine components suffering from normal wear and tear.
“A more agile, additive repair process allows us to better serve our customers by improving turnaround time, while reducing tooling costs, complexity and set up,” commented Kevin Kirkpatrick, VP of Aftermarket Operations at Pratt & Whitney. “At the same time, it reduces our dependency on current material supply constraints. Additive technology has the potential to support a range of critical GTF part repairs and we’re actively working to explore additional opportunities for implementation.”
The DED technology is now being industrialized and Pratt & Whitney plans to introduce the process throughout its global GTF MRO network—which comprises 20 sites across four continents. The integration of this additive-based repair process will enable the company to recover $100 million worth of parts within just the next five years.
It’s worth pointing out that isn’t the first time Pratt & Whitney has leveraged AM for MRO applications: in 2020, the company (in partnership with Singapore’s ST Engineering) 3D printed a fuel system component one of its engine models with the aim of establishing a more agile aftermarket workflow. Much more recently, the aerospace company was awarded a $1.5 billion contract to sustain F119 engines for the U.S. Air Force’s F-22 fighter jets using additive manufacturing.
