CFM International LEAP

LEAP
Mockup of a LEAP-X, the early code name of the engine
Type Turbofan
National origin France/United States
Manufacturer CFM International
First run 4 September 2013 (LEAP-1A)[1]
13 June 2014 (LEAP-1B)[2]
9 October 2014 (LEAP-1C)[3]
Major applications Airbus A320neo family
Boeing 737 MAX
Comac C919
Number built 20+
Unit cost $13,000,000 USD [4]
Developed from General Electric GEnx

The CFM International LEAP is a high-bypass turbofan engine. It is produced by CFM International, a 50-50 joint venture company between GE Aviation of the United States and Safran Aircraft Engines (formerly known as Snecma) of France. It is a modernized replacement for the successful CFM International CFM56, intended to compete with the Pratt & Whitney PW1000G in the single-aisle jetliner market.

Design

The LEAP's basic architecture includes a scaled-up version of Safran's low pressure turbine used on the GEnX engine. The fan has flexible blades manufactured by a resin transfer molding process, which are designed to untwist as the fan's rotational speed increases. While the LEAP is designed to operate at a higher pressure than the CFM56 (which is partly why it is more efficient), GE plans to set the operating pressure lower than the maximum in order to maximize the engine's service life and reliability. Currently proposed for the LEAP is a greater use of composite materials, a blisk fan in the compressor, a second-generation Twin Annular Pre Swirl (TAPS II) combustor, and a bypass ratio around 10-11:1. GE is using ceramic matrix composites (CMC) to build the turbine shrouds.[5]

These technological advances are projected to produce 16% lower fuel consumption.[6][7][8] Reliability is also supported by use of an eductor-based oil cooling system similar to that of the GenX, featuring coolers mounted on the inner lining of the fan duct. According to Aviation Week's article, "The eductor device produces a venturi effect, which ensures a positive pressure to keep oil in the lower internal sump."[9] The engine has some of the first FAA-approved 3D-printed components.[10][11]

Development

side view with cutaways

The LEAP ("Leading Edge Aviation Propulsion")[12] incorporates technologies that CFM developed as part of the LEAP56 technology acquisition program, which CFM launched in 2005.[13] The engine was officially launched as "LEAP-X" on 13 July 2008.[6] It is intended to be a successor to the CFM56-5B and CFM56-7B.

In total, 28 test engines will be used by CFM to achieve engine certification, and 32 others will be used by Airbus, Boeing and COMAC for aircraft certification and test programs.[1][14] The first engine entering the test program successfully reached and sustained 33,000 lbf (150 kN) of thrust, required to satisfy the highest rating for the Airbus A321neo. The same engine ultimately reached 35,000 lbf (160 kN) of thrust in test runs.[15]

General Electric carried out the first test flight, of a LEAP-1C, in Victorville, California, with the engine mounted on the company's Boeing 747 flying testbed, on October 6, 2014, the -1C version features a thrust reverser equipped with a one piece O-ring replacing a 2 piece door. The thrust reverser is deployed by the O-ring sliding aft, reducing the drag that was induced by the older design and improving efficiency.[16] In April 2015, it was reported that the LEAP-1B was suffering up to a 5% shortfall on its promised reduction in fuel consumption.[17]

Orders

The LEAP engine has attracted more than 5,000 orders and GE plans to produce 1,700 engines by the end of 2018.[9] The Commercial Aircraft Corporation of China (COMAC) has chosen the LEAP engine for its new COMAC C919 aircraft.[18]

The company expects to receive certification for the first LEAP, the LEAP-1C, for China's 150-seat COMAC C919 twinjet. The aircraft is due to begin testing in 2016.[19] The engine will also be deployed in the same year on the new Airbus A320neo variant.[20]

On July 20, 2011, American Airlines announced that it planned to purchase 100 Boeing 737 aircraft featuring the LEAP-1B engine.[21] The project was approved by Boeing on August 30, 2011 as the Boeing 737 MAX.[22][23] Southwest Airlines is the launch customer of the 737 MAX with a firm order of 150 aircraft.[24]

CFM International offers its support for the engine, and signed a 15-year Rate per Flight Hour agreement with Loong Air for 20 LEAP-1A at U.S $333 million, or $3039 per engine per day, in contrast with U.S. $138 million for 17 CFM International CFM56 over 12 years or $1852 per engine per day.[25] As a number of A320neo engine for ANA group of Japan was also ordered in 2014, there is a possibility to select the LEAP engine.[26]

Production

The LEAP entered service on the A320neo in 2016 and CFM should produce 100 LEAP this year, then 500 in 2017 with the 737 MAX introduction and 1,100 in 2018.[27] It should reach 2,000 by 2020, to be compared to the 1,700 CFM56 produced in 2016.[28]

To cope with the demand, CFM is duplicating supply sources on 80% of parts and even subdivide assembly sites, already shared between GE and Safran: GE assembles its production in Lafayette, Indiana in addition to its previous Durham, North Carolina facility. As more than 75% of the engine comes from suppliers, critical parts suppliers pass “run-rate stress tests” lasting two to 12 weeks. Pratt & Whitney acknowledges a production ramp-up bottleneck on its rival PW1100G geared turbofan including a critical shortage of the unique aluminium-titanium fan blade, hitting the Airbus A320neo and the Bombardier CSeries deliveries.[29]

Applications

Airbus A320neo prototype with Leap engines.
Model Application[30] Thrust range[30] Introduction[31]
1A Airbus A320neo family 24,500–35,000 lbf (109–156 kN) 2 Aug 2016[32]
1B Boeing 737 MAX 23,000–28,000 lbf (100–120 kN) 2017 (planned)
1C COMAC C919 27,980–30,000 lbf (124.5–133.4 kN) 2018 (planned)

Specifications

Model LEAP-1A/1C[33] LEAP-1B[34]
Configuration Twin-spool, high bypass turbofan
Compressor 1 fan, 3-stage LP, 22:1 10-stage HP[35]
Combustor second generation Twin-Annular, Pre-Mixing Swirler Combustor (TAPS II)[30]
Turbine 2-stage HP, 7-stage (-1B: 5-stage) LP[36]
Compression ratio 40:1[35] (50:1, Top-of-Climb)
TSFC ~ -15% (vs. current CFM56 engine)[30]
Fan diameter[35] 78 in (198 cm) 69.4 in (176 cm)
Bypass ratio (BPR)[35] 11:1 9:1
Length 3328 mm 3147 mm
Max. Width 2543-2533 mm 2421 mm
Max. Height 2368-2362 mm 2256 mm
Weight 2990-3153 kg (Wet) 2780 kg (Dry)
Take-Off Thrust -1A23, 24 : 10680 daN
-1A26 : 12064 daN
-1A30, 32, 33, 35 : 14305 daN 		-1B28 : 13041 daN
Max. Continuous -1A23 : 10458 daN
-1A24 : 10676 daN
-1A26 : 11868 daN
-1A30, 32, 33, 35 : 14096 daN 		-1B28 : 12762 daN
Max. rpm LP : 3894, HP : 19391 LP : 4586, HP : 20171

See also

Related development
Comparable engines
Related lists

References

  1. 1 2 "CFM launches a new era as first LEAP engine begins ground testing". CFM International. 2013-09-06. Retrieved 2013-09-07.
  2. ↑ "CFM International démarre le premier LEAP-1B du 737 MAX". Le journal de l'aviation. 2014-06-18. Retrieved 2015-03-05.
  3. ↑ "Leap 1C Engine Tests Continue as Comac's C919 Takes Shape". AIN-Online. 2014-11-10. Retrieved 2016-03-15.
  4. ↑ "Ryanair to Purchase 200 CFM LEAP-1B Engines at a value of more than $2.6B". CFM International. 8 September 2014.
  5. ↑ Norris, Guy, Hot blades, Aviation Week & Space Technology, April 27-May 10, 2015, p.55
  6. 1 2 "CFM Unveils New LEAP-X Engine". CFM International. 2008-07-13. Retrieved 2008-07-16.
  7. ↑ New engines: flurry of activity despite downturn
  8. ↑ LEAP-X: Redefining Turbofan Engines for Narrowbody Aircraft
  9. 1 2 Norris, Guy, Pressure testing, Aviation Week and Space Technology, October 28, 2013, p. 43
  10. ↑ Dalløkken, Per Erlien (21 April 2015). "Verdens største jetmotor får 3D-printet komponent" [World's biggest jet engine gets 3D-printed component]. Teknisk Ukeblad. Retrieved 22 April 2015.
  11. ↑ GE
  12. ↑ LEAP Turbofan Engine, History
  13. ↑ CFM Laying the Technology Foundation for the Future. CFM International
  14. ↑ http://www.flightglobal.com/news/articles/first-leap-powered-a320neo-moved-to-flight-test-team-411466/
  15. ↑ Norris, Guy, Pressure testing, Aviation Week and Space Technology, October 28, 2013, pp.42-43
  16. ↑ Norris, Guy, Boom time, Aviation Week & Space Technology, October 13, 2014, p.40
  17. ↑ "Engine problems aren't Propulsion South Carolina's problem".
  18. ↑ CFM International to provide engines for COMAC's C919
  19. ↑ CFM to finish Leap core testing by mid-May
  20. ↑ Airbus A320neo story FlightGlobal
  21. ↑ "Boeing and American Airlines Agree on Order for up to 300 Airplanes - Jul 20, 2011". Boeing.mediaroom.com. July 20, 2011. Retrieved May 31, 2013.
  22. ↑ Boeing Confirms Duopoly With Airbus Announcing Re-Engining Of 737. Forbes
  23. ↑ Boeing rendering illustrates major changes to 737NE. flightglobal.com
  24. ↑ "Southwest Airlines Will Become Launch Customer for the New Boeing 737 Max Aircraft - Southwest Airlines Newsroom". Swamedia.com. December 13, 2011. Retrieved May 31, 2013.
  25. ↑ "Zhejiang Loong Air signs RPFH agreement for CFM56-5B engines". Aviation News Ltd. 15 June 2015.
  26. ↑ "Zhejiang Loong Air signs Service agreement for CFM LEAP-1A engines". Aviation News Ltd. 15 June 2015.
  27. ↑ "CFM prepares for 'scary' production ramp-up on LEAP program". Aviation Week. Nov 11, 2016.
  28. ↑ Max Kingsley-Jones (November 15, 2016). "CFM quietly confident on Leap production ramp-up". Flight Global.
  29. ↑ "New GE plant highlights CFM ramp-up strategy on Leap". Flight Global. 16 November 2016.
  30. 1 2 3 4 "The Leap Engine". CFM international. Retrieved 14 November 2016.
  31. ↑ "CFM To Release A320NEO Leap Engine Final Design By Year-End". Aviation Week. November 7, 2012. Retrieved May 31, 2013.
  32. ↑ "Pegasus starts flying Leap-1A-powered A320neo". Flight Global. August 2, 2016. Retrieved August 3, 2016.
  33. ↑ "Type Certificate data sheet for LEAP-1A & LEAP-1C Series Engines" (PDF). EASA. 11 March 2016.
  34. ↑ "Type Certificate data sheet for LEAP-1B Series Engines" (PDF). EASA. 4 May 2016.
  35. 1 2 3 4 "LEAP Brochure" (PDF). CFM International. May 28, 2013. Retrieved May 7, 2014.
  36. ↑ "Comparing the new technology Narrow-body engines: GTF vs LEAP maintenance costs". Airinsight. November 9, 2011. Retrieved May 31, 2013.
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