GE38 turbomoteur

Description: The General Electric GE38-1B is a turboshaft engine is based on the GE27 technology demonstrator and the US Navy's T407 turboprop engine. GE27 served as the basis for the CFE738 commercial turbofan engine which powers the Dassault Falcon 2000 jet. Developing more than 7,500-shp at sea level the new engine is provided with a similar architecture to the popular T700 engine. General Electric's main goals for the GE38-1B are: significant advances in engine performance, fuel efficiency and low life-cycle cost.

The GE38-1B has a five-stage axial compressor coupled with a single-stage centrifugal compressor. It has a low-emission, annular combustor, two-stage gas generator turbine, and three-stage power turbine. It features a dual-channel Full Authority Digital Electronic Control (FADEC) system with advanced health monitoring functions. The engine is highly resistant to sand erosion, salt-water corrosion and offers stall-free operation in all conditions - features ideal to withstand the Marine Corps' tough operating environments.

To date, the GE38-1B engine has been selected to power the US Marine Corps' CH-53K helicopter being developed by Sikorsky. CH-53Ks will supersede CH-53E helicopters which are powered by T64 engines. The GE38-1B features 60 percent fewer parts with longer component lives than its T64 predecessor. In addition, the new engine will offer excess power to meet current and future CH-53K mission requirements.

Key Milestone Achieved For GE's New Turboshaft Engine for the U.S. Marine Corps
January 13, 2009 -- LYNN, Massachusetts -- 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 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.

May 6, 2010
GE38 Completes First Engine to Test Program
--LYNN, MA -- The GE38 turboshaft engine has completed its First Engine to Test (FETT) phase, establishing a new shaft-horsepower (shp) record for the GE Lynn facility, exceeding production performance margins for fuel consumption and completing an initial 30 hour endurance test.

"We could not be more pleased with our FETT results," said GE38 Program Manager Harry Nahatis. "Rigorous testing has validated our design philosophy and reinforces a solid technical foundation for our upcoming qualification testing. We are on track to deliver as promised."

FETT, which focused primarily on design assurance testing, exercised the engine in some of the most demanding areas of operation. Data was accumulated on more than 600 parameters, including pressures, temperatures and vibrations.

Operability testing demonstrated excellent stall margin, indicating the throttle could be moved without impacting engine response. Engine vibrations were low, and all lube systems performed with temperatures in line with predictions. The Full Authority Digital Electronic Control system demonstrated outstanding operation, offering significant risk reduction.

The GE38 also established a turboshaft horsepower record for the Lynn facility, eclipsing 7,500 shp.

Completion of FETT sets the stage for qualification testing, scheduled to begin in 2Q2010, which will focus on engine durability, altitude performance and environmental compatibility. Testing is expected to run through 2012, concurrent with a full U.S. military qualification test program. In all, GE38 testing will include five ground-test engines that will accumulate more than 5,000 engine test hours, plus 20 flight-test engines for the Sikorsky CH-53K development aircraft.

The GE38 is the cornerstone for a new turboshaft/turboprop engine family, with a revenue potential of more than $4 billion including heavy-lift, turboprop and marine applications. Sikorsky selected the GE38 for its three-engine CH-53K aircraft, which will replace the CH-53E SUPER STALLIONTM helicopter powered by GE's T64 engine, in December 2006. The GE38 provides 57% more power and 18% better specific fuel consumption, and it has 63% fewer parts than the similarly sized GE T64 powering the CH-53E.

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.

GE38 architecture is updated with state-of-the-art aerodynamic features for more efficient operation, plus improved cooling schemes and materials for added durability. It can provide significantly lower fuel consumption for longer range and/or heavier payload compared to other engines in its class. Added power provides mission flexibility and enhanced hot/high aircraft performance, while its simplified design translates to improved reliability and a 50-80% operating and support cost advantage.

The GE38 also features a more rugged compressor design to increase durability, and is also highly resistant to sand erosion and salt-water corrosion -- features ideal to withstand the Marine Corps' tough operating environments.

GE Aviation, an operating unit of General Electric Company (NYSE: GE), is a world-leading provider of commercial and military jet engines and components as well as integrated digital, electric power, and mechanical systems for aircraft. GE Aviation also has a global service network to support these offerings.

Sikorsky Aircraft Corp., based in Stratford, Conn., is a world leader in helicopter design, manufacture, and service.

Sixteen years after development of General Electric's T407 turboprop was shelved following cancellation of the US Navy's Lockheed P-7 maritime patrol aircraft, Sikorsky has selected a turboshaft derivative of the 6,000shp-class (4,470kW) engine, the GE38-1B, to power the CH-53K heavylift helicopter.

The GE38 has been selected over the Pratt & Whitney Canada PW150 and Rolls-Royce AE1107 to power the triple-turbine CH-53K, which is under development to replace the US Marine Corps' Sikorsky CH-53E Super Stallions. Sikorsky was awarded the $3 billion contract to develop the CH-53K in April 2006.

The T407 turboprop never made it into production, but the GE38 core was used in the GE/Honeywell CFE738 turbofan, production of which is winding down as its only application, the Dassault Falcon 2000 business jet, is phased out in favour of a re-engined version.

The CH-53K's three GE38s will power a new rotor system with elastomeric hub and composite blades with advanced aerofoil and drooped tip. The helicopter is being designed to carry a 12,260kg (27,000lb) load to a distance of 200km (110nm), twice the hot-day lift capability of the CH-53E, which is powered by three GE T64s.

First flight of the CH-53K is scheduled for fiscal year 2011. A total of 156 new-build helicopters is planned. R-R's AE1107, which powers the USMC's Bell Boeing MV-22 Osprey tiltrotor transport, had been considered the favourite for the upgraded Super Stallion.

The GE38-1B is to power Sikorsky's Marine Corps heavylift helicopter

As of 15 February, GE had recorded 176 engine starts and 177 operating hours, he says. The engine had demonstrated sustained power of 7,760shp and peak power of 8,300shp, topping the CH-53K's requirement for 7,500shp

GE Aviation is excited to leverage the modern technology and proven performance of the GE38 into an ideal engine option for marine applications.

The GE38 is the most technologically advanced turboshaft engine in its class, and it has been selected to power the Sikorsky CH-53K helicopter in development for the U.S. Marine Corps. Compared to its T64 turboshaft engine predecessor, the GE38 provides 57% more power within the same envelope, 18% better fuel consumption and has 63% few parts.

The marine version of the GE38 is identical to its aircraft engine cousin with the exception of some control schedules in the Full Authority Digital Engine Controls (FADEC) software. GE is also looking to leverage this existing technology to offer the United States Navy maintenance commonality, smaller logistics footprint, as well as lower operating and support costs. GE Aviation believes the low-risk GE38 has ideal performance specifications for the U.S. Navy's Ship-to-Shore Connector (SSC) program and electric power generation for DDG-51-class destroyers.

GE38 development testing is well underway at its Lynn, Massachusetts, facility. The engine has established a facility turboshaft horsepower record, eclipsing 7,500 shaft-horsepower. Overall development testing features five factory test engines that will accumulate approximately 5,000 hours. To date, more than 300 hours have been logged on two engines. Overall engine performance is excellent and specific fuel consumption and power is better than predicted.