ACE Awards - Best of Show

Best of Show
Sponsored by AOC and Composites One

This prestigious award, recognized as the highest composites industry award is presented to the entry that has the distinction of being the finest product, superior to all others in design, engineering, manufacturing, market significance, creativity, process innovation, and use of composites materials determined by a panel of industry judges.

Entry: GE 90-115B Aircraft Engine Composite Fan Blade

Submitted by: GE Transportation – Aircraft Engines; Cincinnati, Ohio

PRODUCT DESCRIPTION
The GE90-115B aircraft engine composite fan blade, made from a carbon fiber toughened epoxy matrix is one of 22 blades that make up the fan of this engine. The fan of an aircraft engine functions to provide thrust as well as conditioning air for the engine core (working medium for the machine).

The inherent qualities of composite material makes these blades extremely flexible, yet impact-resistant. Their spare blade acquisition rate is >80 percent lower than conventional Titanium blades. Only 3 blades have been removed from service in the first 6 million flight hours. Even if the blade does suffer cosmetic damage, it is easily repaired. Maintenance, too is vastly improved. The lighter weight and reduced number of blades coupled with the incorporation of a Teflon wear strip make removal and installation faster and reduces long term wear on the dovetail (base) of the blades. The size and shape of the blade has been designed to dramatically improve aerodynamic efficiency. Each blade performs more work which allows use of fewer blades versus conventional technology (22 vs. 36 on the GE CF6-80C2 engine).

The composite blade is created using a composite forming or draping process whereby the blade is built up by successive layers of carbon fibers joined with a polymer matrix. The blade features over 1600 individual ply shapes with up to 700 layers of carbon fiber. Blades are assembled by hand and consolidated in an autoclave under pressure and temperature.