General Electric Catalyst
{{Short description|Turboprop engine model}}
| {{Infobox aircraft begin
|name= Catalyst |image= File:General Electric GE93.jpg{{!}}border |caption= }} {{Infobox aircraft engine |type= Turboprop |national origin = United States |manufacturer= GE Aerospace |major applications= Beechcraft Denali |developed from = |variants with their own articles = |developed into = }} |
The General Electric Catalyst (formerly Advanced Turboprop, or ATP) is a turboprop engine by GE Aerospace.
It was announced on 16 November 2015 and will power the Beechcraft Denali, it first ran on December 22, 2017, and was certificated in February 2025.
The {{cvt|850|to|1,600|hp}} engine aims for 20% better efficiency than its competition thanks to a 16:1 overall pressure ratio, variable stator vanes, cooled turbine blades, 3D printed parts and FADEC.
Development
After introducing the General Electric H80 in 2010 to improve the Walter M601, GE started analyzing its competition and devised a clean-design engine in 2014, then was selected for the Cessna Denali competition.{{cite news |url= http://aviationweek.com/future-aerospace/ge-sees-catalyst-engine-change-turboprop-push |title= GE Sees Catalyst As Engine For Change In Turboprop Push |date= Mar 19, 2018 |author= Guy Norris |work= Aviation Week & Space Technology}}
In September 2015, General Electric created a European turboprop development center, after the US-Exim Bank closure in June, investing over $400 million and creating 500 to 1,000 jobs.{{cite news |url= https://www.businessinsider.com/r-with-no-us-export-financing-ge-says-will-build-engine-center-in-europe-2015-9 |title= With no U.S. export financing, GE says will build engine center in Europe |agency= Reuters |via= Business Insider |date= Sep 17, 2015}}
The engine was announced on 16 November 2015 at the National Business Aviation Association's annual tradeshow.
In 2016, the gearbox, power turbine and combustor were to be made in Turin, the rotating components were to be supplied from Warsaw and the final assembly line was planned at Walter Engines in Prague. At the time, major components were split between GE-owned facilities in Poland and Italy, both belonging to Avio Aero. Avio Aero was acquired by GE in 2013.{{Cite press release |title=GE Completes Acquisition of Avio aviation business |publisher= GE|url=https://www.ge.com/news/press-releases/ge-completes-acquisition-avio-aviation-business|date=August 1, 2013}}
As of 2021, the Avio Aero website does not list any facility in Warsaw.{{cite web |url= https://www.avioaero.com/en/our-company/where-we-are |publisher= Avio Aero |title= Where we are}}
It was designed by GE in Europe,{{cite news |url= https://www.flightglobal.com/news/articles/ge-completes-first-ground-test-of-advanced-turboprop-444489/ |title= GE completes first ground test of Advanced Turboprop engine |date= 27 Dec 2017 |author= Stephen Trimble |work= Flightglobal }} and for the power and gas generator turbine, and the high pressure compressor, by the Engineering Design Center in Warsaw, an alliance between General Electric Company Polska and the Warsaw Institute of Aviation.{{cite news |url= https://www.aerospacetestinginternational.com/features/interview-marian-lubieniecki-leader-of-the-engineering-design-center-ge-poland.html |title= Q&A: Marian Lubieniecki, leader of the Engineering Design Center, GE Poland |author= Paige Smith |date= 16 April 2020 |work= Aerospace Testing International}}
In October 2017, GE received 85% of the parts, on track to deliver the first test engine by the end of the year.{{cite news |url= https://www.flightglobal.com/news/articles/nbaa-ge-nears-milestones-on-15b-bet-on-business-a-441992/ |title= GE nears milestones on $1.5B bet on business aircraft |date= 10 Oct 2017 |author= Stephen Trimble |work= Flightglobal}}
At this time, the axial-centrifugal compressor vehicle - stator, rotor and cold-section assemblies - was tested in Munich to validate its efficiency, performance and operability.{{cite news |url= https://www.ainonline.com/aviation-news/business-aviation/2017-10-10/ges-two-new-genav-engine-programs-set-soar |title= GE's Two New Genav Engine Programs Set To Soar |work= AIN |author= Curt Epstein |date= October 10, 2017}}
=Testing=
After two years of development, it completed its first test run in Prague on December 22, 2017.
After most of the component tested and the engine run, GE Aviation maintains its performance objectives and hope to exceed them.
It will begin certification testing in 2018, validating the aerodynamics, mechanics, and aerothermal systems.
It is expected to power the Beechcraft Denali first flight in late 2018 and will complete over 2000 hours of testing before the Denali enter service.
GE Aviation Czech, the development, testing and production headquarters, has recruited around 180 employees, with another 80 expected in 2018 among 500 others for the complete facility at full production rate.
It was developed over two years by 400 GE designers, engineers and materials experts in the Czech Republic, Italy, Germany, Poland, the U.S. and elsewhere.
Six test cells will open, 10 test engines will be built and it will be flown later in 2018 on a flying testbed, certification tests over 2018-2019 include altitude, performance and high-vibration testing.
In March 2018 the first sample ran nearly 40 hours before several years of health monitoring review.
The next engine is assembled and instrumented for altitude trials and will be tested in Canada from summer 2018.
From later in 2018, Cessna will receive three engines to prepare the first-quarter 2019 Denali maiden flight.{{cite news |url= https://www.ainonline.com/aviation-news/business-aviation/2018-03-07/ges-atp-engine-becomes-catalyst |title= GE's ATP Engine Becomes Catalyst |author= Kerry Lynch |date= March 7, 2018 |work= AIN}}
Its development is 30% faster than previous new GE projects as the development program has 10 engines, plus several rebuilds.
Over the next two years, 33 engine tests overall will happen including 17 certification tests.
The certification do not require a flying testbed but a modified King Air 350 may be used for flight safety clearance early in 2019, before Denali flight tests.
At the end of May 2018, 60 hours of testing were completed including at full power while second engine assembly was nearly complete for a summer first run, component certification was imminent and should be followed by whole-engine certification testing, starting with ingestion and altitude tests.{{cite news |url= https://www.ainonline.com/aviation-news/business-aviation/2018-05-29/ges-catalyst-readies-certification-testing |title= GE's Catalyst Readies for Certification Testing |work= AIN |author= Curt Epstein |date= May 29, 2018}}
By July 2018, the first engine ran over 100 hours while a second engine is running in Prague before being sent to Canada later in the year for altitude testing, performance is on target or better than predicted.{{cite news |url= http://aviationweek.com/farnborough-airshow-2018/testing-begins-second-ge-catalyst-turboprop-0 |title= Testing Begins on Second GE Catalyst Turboprop |date= Jul 17, 2018 |author= John Morris |work= Aviation Week Network}}
By May 2019, test engines ran up to {{cvt|41000|ft}} in an altitude chamber and over 1,000 h, simulating three years of operations, while the FADEC ran 300 h in the Denali iron bird.{{cite news |url= https://www.flightglobal.com/news/articles/ge-brings-catalyst-to-shake-up-turboprop-market-458302/ |title= GE brings Catalyst to shake up turboprop market |date= 20 May 2019 |author= Alan Peaford |work= Flightglobal}}
By October 2019, over 1,000 engine cycles logged 1,600h of tests: 1,200h in test cells and 400h in compressor rigs.
Altitude, endurance, vibration, durability and ingestion testing were complete, as integrated propeller controls tests and high-pressure compressor and gas generator turbine overspeed tests.
New icing tests requirements pushed back the first engine delivery to 2020, and Beechcraft Denali first flight even further.
Five engines were assembled by then, and two other should be completed before 2019 ends.{{cite news |url= https://www.flightglobal.com/news/articles/textron-delays-denalis-first-flight-due-to-ongoing-461659/ |title= Textron delays Denali's first flight due to ongoing Catalyst engine testing |date= 22 Oct 2019 |author= Jon Hemmerdinger |work= Flightglobal}}
First flight test aboard a King Air was delayed until spring 2020 and certification for autumn 2021, after a 18-month campaign, due to new FAA testing requirements, including icing tests.{{cite news |url= https://www.flightglobal.com/catalyst-turboprop-flight-testing-to-start-this-spring/136828.article |title= Catalyst turboprop flight testing "to start this spring" |author= Dan Thisdell |date= 19 February 2020 |work= flightglobal}}
By July 2021, 16 engines had been produced and completed 2,500h of operation; as 30% of Catalyst’s certification tests were completed including some icing tests.
Tests have shown more power at high altitudes than expected and a 1-2% more efficiency than anticipated for up to 16-17% more than competitors.
One turboprop was fitted to a Beechcraft King Air 350 in Berlin which completed some taxi tests, to achieve maiden flight in the coming months and certification by end-2022.
Another engine was installed on a Denali airframe to make its first flight before year-end and to achieve certification in 2023.{{cite news |url= https://www.flightglobal.com/ge-aviation-buttoning-up-catalyst-flight-approvals-eyes-applications-besides-beechcrafts-denali/144863.article |title= GE Aviation 'buttoning up' Catalyst flight approvals, eyes applications besides Beechcraft's Denali |author= Jon Hemmerdinger |date= 30 July 2021 |work= FlightGlobal}}
The Catalyst made its first flight on a King Air testbed on September 30, 2021 in the hand of BBA Chief Test Pilot Sigismond Monnet and Lead Flight Test Engineer Alessandro Ramazzotti.{{cite press release |url= https://www.geaviation.com/press-release/business-general-aviation/catalysttm-turboprop-engine-completes-first-flight |title= The Catalyst™ turboprop engine completes first flight |date= September 30, 2021 |publisher= GE Aviation}}
On November 22, the Denali made its first flight with a Catalyst engine, targeting a 2025 certification.{{cite press release|url=https://media.txtav.com/205380-beechcraft-denali-enters-flight-test-phase-with-landmark-first-flight|title=Beechcraft Denali enters flight test phase with landmark first flight|date=23 November 2021|publisher= Textron Aviation}}
In May 2023, Denali certification was pushed back to 2025 as the engine certification was delayed to 2024 by more-stringent standards like icing and engine ingestion requirements, having completed 16 of 22 planned engine certification tests and 26 of 37 component certification tests, hot-weather tests and cold-temperature trials.{{cite news |url= https://www.flightglobal.com/airframers/textron-aviation-delays-denalis-certification-until-2025/153170.article |title= Textron Aviation delays Denali's certification until 2025 |author= Jon Hemmerdinger |date= 8 May 2023 |work= FlightGlobal}}
In February 2025, the Federal Aviation Administration granted its certification after more than 8,000h of tests, clearing the Denali for a 2026 introduction as the three prototypes gathered over 2,700 flight hours in 1,100 flights.{{cite news |url= https://www.flightglobal.com/engines/faa-certificates-ge-aerospace-catalyst-engine-clearing-hurdle-for-2026-beechcraft-denali-approval/161996.article |title= FAA certificates GE Aerospace Catalyst engine, clearing hurdle for Beechcraft Denali approval |author= Jon Hemmerdinger |date= 27 February 2025 |work= FlightGlobal}}
=Market=
The GE Catalyst is intended to cover the market between the sub {{convert|850|hp}} General Electric H80 and the CT7. It is designed to compete with the Pratt & Whitney Canada PT6 which has led the small turboprop market for 50 years with over 51,000 units produced. The Catalyst has been selected to power the new Beechcraft Denali single engine turboprop aircraft, seating up to 12 passengers at over {{convert|280|kn|km/h}} for {{convert|1500|NM|km}}. GE plans to invest up to $1 billion in the project, including $400 million for a manufacturing center in Europe.
Design
The {{convert|1300|shp}} Advanced Turboprop could be extended in an {{convert|850|-|1600|hp}} range. Its 16:1 overall pressure ratio allow a 20% lower fuel burn and 10% higher cruise power than same size class competition with a 4000–6000 hour mean time between overhauls (MTBO). The compressor is derived from the General Electric T700 with four axial stages and a single centrifugal stage, with the same 3D aerodynamics design used in the GE9X. The engine includes variable stator vanes (VSVs) and 3D printed parts.
The reverse-flow single-annular combustor resembles the GE-Honda HF120 design. The two-stage single-crystal high pressure turbine will be the first in this class of engines to be fully cooled. The three-stage low-pressure turbine is contra-rotating. A FADEC integrated propulsion control system will govern both engine and propeller pitch as an entire system.
Twelve 3D-printed parts replace 855 parts: frames, combustor liners, sumps, exhaust case, bearing housings, stationary components in the flowpath, and heat exchangers. Overall weight is reduced by 5% and brake specific fuel consumption is improved by 1%. 3D printing is not used for rotating components such as blades, discs and rotors. 35% of the engine will be printed at GE, reducing the serialized part count to 35. They are printed from a titanium alloy.{{cite news |url= https://www.ge.com/reports/ge-fired-its-3d-printed-advanced-turboprop-engine/ |title= Fired Up: GE Successfully Tested Its Advanced Turboprop Engine With 3D-Printed Parts |date= Dec 27, 2017 |author= Tomas Kellner |work= GE Reports}}
The time between overhauls is 4,000 hours, 33% more than its leading competitor.
It is the first turboprop in its class with two stages of variable stator vanes.
It will feature a composite, five-bladed propeller system from McCauley, a subsidiary of Textron.
Turboprops now have to be certificated for high-altitude ice crystal icing: a compressor blisk has to survive an impact from an ice ball.
This would require a 2 lb (1.13kg) heavier first stage and would hamper the engine aerodynamics.
GE proposed channelling to the engine inlet hot oil from an accessory gearbox sump to avoid growing ice and will test this in a Canadian cold weather facility in summer 2018.{{cite news |url= https://www.flightglobal.com/news/articles/ge-renames-atp-engine-catalyst-as-test-plan-heats-446560/ |title= GE renames ATP engine 'Catalyst' as test plan heats up |date= 8 March 2018 |author= Stephen Trimble |work= Flightglobal}}
Cooled turbines allow over {{cvt|300|°F|-1|disp=flip}} higher operating temperatures.
Its FADEC, VSVs and a three-stage counter-rotating {{abbr|LP|low-pressure}} turbine generates 10% higher cruise power, maintaining peak efficiency at off-design conditions for better lapse rate and altitude power.
The one-piece sump replaces 45 conventional parts and will be printed in just four days down from 14 initially.
Applications
- Beechcraft Denali
- Eurodrone{{cite news |url= https://www.flightglobal.com/defence/avio-aero-to-supply-catalyst-engines-for-eurodrone-fleet/148054.article |title= Avio Aero to supply Catalyst engines for Eurodrone fleet |author= Craig Hoyle |date= 25 March 2022 |work= Flightglobal}}
- XTI TriFan 600{{cite news |url= https://www.flightglobal.com/news/articles/xti-selects-catalyst-engine-for-hybrid-electric-trif-459849/ |title= XTI selects Catalyst engine for hybrid-electric TriFan 600 |date= 23 July 2019 |author= Kate Sarsfield |work= Flightglobal}}
Specification
{{jetspecs
|ref=
|type=Turboprop
|length= {{cvt|71.6|in|mm}}{{cite conference |work=General Electric Global Research |title=GE turbines and small engines overview |publisher=ARPA-E |access-date=September 23, 2021 |url=https://arpa-e.energy.gov/sites/default/files/14_deBock_GE%20Turbines%20and%20small%20engines%20overview%20-%20ARPA-e%20INTEGRATE%20V2.pdf#page=8 |conference-url=https://arpa-e.energy.gov/2019-integrate-annual-meeting |first=Peter |last=deBock |conference=2019 INTEGRATE Annual Meeting |date=September 18, 2019}}
|diameter= {{cvt|20.00-20.13|in|mm}}
|weight= {{cvt|639.7|lb}}{{cite web |url= https://drs.faa.gov/browse/excelExternalWindow/DRSDOCID168944805920250307190803.0001 |title= Type certificate data sheet E00100EN - GE Catalyst 1300-CS1A |publisher= FAA |date= 7 March 2025}}
|compressor= four axial stages and a single centrifugal stage
|combustion= reverse flow single-annular combustor
|turbine= two-stage high pressure, three-stage low-pressure
|fueltype=
|oilsystem=
|power= {{cvt|1300|hp}} ({{cvt|850-1600|hp}} range)
|thrust=
|aircon=
|turbinetemp=
|fuelcon=
|specfuelcon= Less than {{cvt|0.5|lb/hph}}
|power/weight= {{cvt|{{#expr:1300/639.7round2}}|shp/lb}}
- Time between overhauls (TBO): 4000-6000 hours
- Core engine speed: 44,550 rpm
- Power turbine rotor: 23,533 rpm
- Propeller: 1,700 rpm
}}
See also
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References
{{cite press release |url= http://www.geaviation.com/press/business_general/bus_20151116.html |title= GE Aviation launches new turboprop engine |date= November 16, 2015 |publisher= GE Aviation}}
{{cite news |url= https://www.reuters.com/article/us-general-electric-textron-airplane-idUSKCN0T51EV20151116 |title= GE, Textron team up to make new turboprop engine, aircraft |publisher= Reuters |date= November 16, 2015}}
{{cite news |url= http://aviationweek.com/business-aviation/ge-takes-pt6-engine-advanced-turboprop |title= GE Takes On PT6 Engine With Advanced Turboprop |date= November 17, 2015 |author= Guy Norris |publisher= Aviation Week}}
External links
- [https://www.geaviation.com/bga/engines/ge-catalyst GE Catalyst turboprop page]
- {{cite news |url= http://www.gereports.com/czeching-in-ge-will-make-its-new-advanced-turboprop-engines-in-europe/ |publisher= GE Reports |title= Czeching In: GE Will Make Its New Advanced Turboprop Engines In Europe |date= January 20, 2016 }}
{{GE aeroengines}}