Sean Broderick's aviation career started in 1991, working for Airbus in Toulouse. His industry experience includes four years with an aviation consultancy, where he worked on the successful launch of a U.S. Part 121 carrier; 12 years with an airport association as a magazine editor and communications executive; and more than 15 years of full- and part-time work as a journalist, writing about air transport and business aviation. &nbsp;
&nbsp;

Writer

Sean Broderick

MTU Aero Engines, bolstered by the ramp-up of Pratt &amp; Whitney PW1000G Geared Turbofan (GTF) production, is projecting a 30 percent jump in revenues generated by its original equipment work this year. But even as one of its largest programs hits peak production, the company is looking ahead to its next set of platforms.

 


The Munich-based engine manufacturer and maintenance, repair and overhaul (MRO) provider specializes in low- and high-pressure turbines, high-pressure compressors, and turbine center frames. On the GTF, the company supplies the high-speed low-pressure turbine and the first four stages of the high-pressure compressor, and assembles some of the PW1100G-JMs that power Airbus A320neos. In 2017, it delivered 1,300 turbines, 750 compressors, and 250 turbine center frames across all programs, while assembling 150 engines.

 


The ramp-up of GTF production is expected to peak in 2018, and then normalize in what MTU calls part of&nbsp; a "consolidation phase," executives said. "After significantly increasing throughput in recent years, we expect growth to normalize during the consolidation phase,” said MTU COO Rainer Martens.

 


In 2016, MTU generated €4.7 billion (US$5.8 billion) in revenues, including €2.9 billion (US$3.6 billion) from its commercial and military original-equipment work. The rest came from its spare parts and MRO services businesses. Its 2017 revenue figure was expected to surpass €5.0 billion (US$6.2 billion), thanks in part to a third consecutive calendar year of MRO growth that approached or surpassed 20 percent.

 


Demand for work on some of MTU's key engines, notably the International Aero Engines V2500, has led the company to add repair capacity. Its MTU Maintenance Zhuhai shop, a 50/50 joint venture with China Southern, saw its capacity increase to 300 shop visits annually following a 2012 expansion. Plans call for adding another 50 percent in capacity at the center, which specializes in both V2500s and CFM International CFM56s.

 


<h2>Product-Development Efforts</h2>

 


Meanwhile, MTU is planning ahead on the OEM side as well. The company has more than 150 projects in its "technology portfolio," which focuses on big-picture goals such as reducing noise and emissions while developing more efficient engines, said Lars Wagner, MTU's COO. The portfolio focuses on three of MTU's primary products: the high-pressure compressor, low-pressure turbine, and turbine center frame. MTU is working on everything from developing new materials to perfecting manufacturing processes, including additive manufacturing (aka 3D printing).

 


"We have recently established a new center of competence with dedicated staff in order to walk this road map for additional additive manufacturing parts in an engine," said Wagner. "Our vision is to have 30 percent additive parts in an engine…in 2030."

 


Part of its product-development is being done under Clean Sky 2, the European Union's aviation technology development initiative.

 


“Under Clean Sky 2, we are paying special attention to the interactions of the components sitting on the low-pressure and high-pressure shafts,” said Stefan Weber, senior vice president-technology and engineering advanced programs.

 


Advanced inlet and exit case designs will help improve aerodynamics, while new materials—notably ceramic matrix composites (CMCs)—are being explored to both improve durability and reduce weight.

 


The company is configuring an MTU Turbomeca Rolls-Royce MTR390 engine to test some of its low-pressure turbine innovations. The demonstrator will include a newly designed power turbine for testing the advanced materials.

 


“Plans are to get the demonstrator up and running and tested by 2020. We expect the evaluation of the results to be concluded in 2021," said Gerhard Kahl, MTU's chief engineer, technology demonstrators and rigs. "An analysis of the behavior of the materials in an engine environment will then provide proof of the maturity of the technology."

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