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Key Milestone Achieved for GE’s New Turboshaft Engine for the U.S. Marine Corps.

Written by thomas · Filed Under Aeronautics News 

January 14, 2009

thomas

LYNN, Massachusetts  – January 13, 2008 – GE Aviation has completed on
schedule the Critical Design Review (CDR) of its new GE38 turboshaft
engine, clearing the way for full-engine testing in 2009.

A key component of GE’s growth strategy for turboshaft engines, the GE38
will power Sikorsky Aircraft Corporation’s next-generation CH-53K heavy
lift helicopter being developed for the United States Marine Corps.

In addition to powering the CH-53K, GE envisions the GE38 as the future
cornerstone for a new turboshaft/turboprop family, with a long-term
production potential of 7,000 engines for various commercial and
military applications over the next 30-plus years.

For the CDR, more than 50 representatives from the United States Naval
Air Systems (NAVAIR) command and Sikorsky Aircraft Corporation were
involved, covering all aspects of the engine program from test and
manufacturing plans to logistics support.

“We are extremely pleased with the CDR results, and we are excited to
support Sikorsky in delivering the increased capability CH-53K to the
Marine Corps,” said GE38 program manager Harry Nahatis.  “Successfully
completing this important milestone further validates GE’s investment in
technology for the GE38 and provides confidence the engine will meet
requirements for the CH-53K and other potential applications.”

Completion of the CDR concludes a busy 2008 for the GE38.  In June, a
thorough review of more than 100 design and program management criteria
led to finalization of drawings and release of parts for manufacture.
Engine component rig tests have been conducted throughout the summer and
fall.

Combustion system rig testing validated key performance parameters,
including cooling effectiveness, altitude starting, thermal efficiency
and exit temperature distribution.   Controls component tests verified
electrical interfaces and demonstrated functionality of the Full
Authority Digital Electronic Control (FADEC).   Lubrication system
simulator tests, designed to ensure the GE38 meets stringent military
requirements — such as pitch-and-roll operation — are scheduled for
early 2009.

Capable of producing more than 7,500 shaft-horsepower at sea level, the
GE38 draws upon technologies from the GE27 Modern Technology
Demonstrator Engine program for the U.S. military, which set world
records for low fuel consumption and power-to-weight ratio, and the T407
turboprop engine developed for the U.S. Navy.  A turbofan derivative of
the T407 engine, the CFE738, powers the Dassault Falcon 2000 business
jet.

The GE38 architecture is updated with new three-dimensional aerodynamics
for more efficient airfoil shapes, plus improved cooling schemes and
materials for added durability.  As a result, the GE38 can deliver
approximately 15-20% more power than the T407 engine–depending on the
application and the mission–plus significant advances in engine
performance and life-cycle cost.

The GE38 also features a more rugged compressor airfoil design to
increase durability.  To help reduce operation and support costs, the
GE38 also features a modular design popularized by the T700 engine
family.

In December 2006, Sikorsky selected the GE38 for its three-engine CH-53K
aircraft, which will replace the CH-53E SUPER STALLION(tm) helicopter
powered by GE’s T64 engine.  The GE38 provides 57% more power, 18%
better specific fuel consumption and has 63% fewer parts than the
similarly sized GE T64 powering the existing CH-53E helicopter.  Engine
deliveries are expected to begin in 2010.

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