For Training Purpose Only DETAILED TRAINING
VAR Part 7 – Aircraft Maintenance Basic Cat B
TRAINING MANUAL
ATA 72
Issue: 01
Rev: 00
Date: 25/04/2014
© VAECO Training Center
Lufthansa Technical Training
M15 GAS TURBINE ENGINE EJAMF
Gas Turbine Engine
MODULE 15
M15.01 ENGINE CONSTRUCTION PRINCIPLES
FOR TRAINING PURPOSES ONLY
HAM US/F SwD 01.04.2008 ATA DOC Page 1
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M15.01 ENG. CNSTR. PRINC. (ATA 72) EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
CONSTRUCTION PRINCIPLES
NON - MODULAR CONSTRUCTION
The different methods of engine design are known as modular engine design
and non-modular engine design.
A gas turbine engine is made of many individual parts. In the early years of gas
turbine engine design, parts were made by using the best manufacturing
capabilities and engine materials of that time, so that the engine fulfilled its
main purpose.
Because of these factors, compromises were made which led to a very
condensed and difficult engine design.
A non−modular engine construction saved weight and was fully functional. It
therefore fulfilled the main aim of the engine design, but most parts were
matched individually.
This meant that the design was complicated and parts were difficult to access.
Often the engine was removed to gain access to a single part that had to be
replaced for maintenance purposes.
A non−modular engine construction is usually only found on older engine type
and on some APUs.
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HAM US/F SwD 01.04.2008 01|Non−mod Constr/A/B1 Page 2
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M15.01 ENG. CNSTR. PRINC. (ATA 72) EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
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Figure 1 Construction Principles
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
MODULAR CONSTRUCTION
A modular engine construction is used on all modern aircraft.
The whole engine is split up into a set of separate major modules. These
engine modules are pre−assembled and balanced. They are specially designed
to be removed and replaced more easily. The modules remain intact after
removal and do not fall to pieces.
Usually the major engine modules are further divided into individual
sub-modules. The number of modules depends on the manufacturer and on
the engine type.
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HAM US/F SwD 01.04.2008 02|Mod Constr/A/B1 Page 4
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
FOR TRAINING PURPOSES ONLY!
Figure 2 Modular Engine
HAM US/F SwD 01.04.2008 02|Mod Constr/A/B1 Page 5
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
Modular Construction cont.
There are many advantages to a modular engine construction for the engine
manufacturer and for the engine operator.
The advantages for the engine manufacturer are:
S the rotating module parts can be pre−balanced,
S less spare engines are needed in stock,
S there is more flexibility when changes are made to individual engine parts
S and finally the main engine modules can be easily stored and transported.
The advantages for the engine operator are:
S the modules can be removed and replaced with a minimum of disturbance
to other nearby engine parts,
S no re−balancing is required after a module change,
S most modules can be replaced while the engine remains on the aircraft,
S there is less need for spare parts and the modules can be easily
transported.
Another factor of the modular design is that very often the replacement of a
module is considered a minor repair and not a shop repair. This means that
work may be done by a maintenance organization and not by an engine
overhaul organization.
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HAM US/F SwD 01.04.2008 03|Mod Constr/A/B1 Page 6
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
Advantages for the Manufacturer Advantages for the Operator
FOR TRAINING PURPOSES ONLY!
Figure 3 Advantages of Modular Engine Design
HAM US/F SwD 01.04.2008 03|Mod Constr/A/B1 Page 7
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
ENGINE MATERIALS
The main design aim for engine materials is that they must be as strong as
required for their individual tasks, they must also be as light as possible and
they must be as cheap as possible.
Typical materials used on modern jet engines are
− aluminium alloy,
− ceramic material,
− composite material,
− cobalt base alloy,
− nickel base alloy,
− corrosion resistant steel alloy
− and titanium base alloy.
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HAM US/F SwD 01.04.2008 04|Engine Mat/A/B1 Page 8
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
Flow Path Liner
Outlet Guide Vanes
Fan Turbine Nozzle
N1 Shaft
Spinner Cone
Engine
Bearing
No.1
FOR TRAINING PURPOSES ONLY!
Low Pressure
Compressor High Pressure
High Pressure Turbine
Compressor
Diffuser Case Exhaust Case
Main Gearbox and Combustor
Low Pressure
Turbine
Fan Case Fan Exit Case
Figure 4 Engine Materials
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CONSTRUCTION PRINCIPLES Gas Turbine Engine
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Engine Materials cont.
Aluminium alloy is mainly used for gearbox housings, fan stator casings and
other low loaded parts of the fan module.
Composite materials are usually used in the fan module.
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HAM US/F SwD 01.04.2008 05|Engine Mat/A/B1 Page 10
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
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Figure 5 Engine Materials - Composites and Aluminium Alloys
HAM US/F SwD 01.04.2008 05|Engine Mat/A/B1 Page 11
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CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
Engine Materials cont.
Ceramic coatings are used in the combust and in the high pressure turbine.
These coatings serve as heat protection and corrosion protection.
Steel alloys are used for the N1 drive shaft, the engine bearings and also for
main structural frames on some engines.
On the PW 4000 engine in the graphic the intermediate case and the turbine
exhaust case are made of steel.
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HAM US/F SwD 01.04.2008 06|Engine Mat/A/B1 Page 12
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
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Figure 6 Engine Materials - Ceramic and Steel Alloys
HAM US/F SwD 01.04.2008 06|Engine Mat/A/B1 Page 13
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CONSTRUCTION PRINCIPLES Gas Turbine Engine
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Engine Materials cont.
Cobalt base alloys are very heat resistant. They can be found in the stator of
the first stage of the high pressure turbine.
Titanium base alloys are as strong as steel but only half as heavy. They can
withstand high centrifugal loads, but they are expensive. These materials are
mainly used in the fan, the low pressure compressor and the front stages of the
high pressure compressor.
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HAM US/F SwD 01.04.2008 07|Engine Mat/A/B1 Page 14
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
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Figure 7 Engine Materials - Cobalt Based Alloys and Titanium Alloys
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CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
Engine Materials cont.
Nickel base alloys can withstand high centrifugal loads at high temperatures.
Therefore these materials are used in the high pressure compressor, in the
combustion section and for the high and low pressure turbines.
Note that these examples are typical and depend on the engine manufacturer.
More and more engine parts will be made of composite materials in the future.
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HAM US/F SwD 01.04.2008 08|Engine Mat/A/B1 Page 16
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ENGINE CONSTRUCTION PRINCIPLES EJAMF
CONSTRUCTION PRINCIPLES Gas Turbine Engine
MODULE 15
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Figure 8 Engine Materials - Nickel Based Alloys
HAM US/F SwD 01.04.2008 08|Engine Mat/A/B1 Page 17
EJAMF M15.01#2 B1 E
TABLE OF CONTENTS
M15.01 ENGINE CONSTRUCTION PRINCIPLES 1
CONSTRUCTION PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NON - MODULAR CONSTRUCTION . . . . . . . . . . . . . . . . 2
MODULAR CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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TABLE OF CONTENTS
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EJAMF M15.01#2 B1 E
TABLE OF FIGURES
Figure 1 Construction Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2 Modular Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3 Advantages of Modular Engine Design . . . . . . . . . . . . . . . . . . . 7
Figure 4 Engine Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5 Engine Materials - Composites and Aluminium Alloys . . . . . . . 11
Figure 6 Engine Materials - Ceramic and Steel Alloys . . . . . . . . . . . . . . . 13
Figure 7 Engine Materials - Cobalt Based Alloys and Titanium Alloys . 15
Figure 8 Engine Materials - Nickel Based Alloys . . . . . . . . . . . . . . . . . . . 17
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TABLE OF FIGURES
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TABLE OF FIGURES
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TABLE OF FIGURES
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