According to Rolls-Royce, UltraFan™ will be significantly reduced in terms of weight, noise and fuel requirements. Compared with the first-generation Trent engine, the fuel efficiency will be 25% higher. UltraFan® will redefine jet engines.
3D printingIt is one of the innovative technologies used in the manufacturing of Advance3.3D printingThe parts originally combined by multiple components can be integrated to print, realizing the integrated structure of the parts.
New milestone
Recently, GKN Aerospace provided the first intermediate compressor housing for the UltraFan™ engine, marking a major milestone in the demonstration program of the Clean Sky 2 Rolls-Royce UltraFan™ engine. GKN Aerospace is the core partner in the UltraFan™ engine demonstration program led by Clean Sky 2 and Rolls-Royce, responsible for the design and manufacturing of the ICC. ICC is a structure between compressor housings that transfers the rotor gas load to the engine housing and thrust mount.
New engine core architecture
The development, manufacturing and testing of ICC will demonstrate and verify a series of new technologies, including low-cost and robust segmented manufacturing concepts with castings. This makes use of innovative welding methods based on computer simulations.The technical difficulties include optimized aerodynamic and acoustic performance design in the exhaust system; shorter active duct design and3D printingAccessory parts; and model-based design methods.
UltraFan™ uses a new engine core architecture and adopts a gear design. The goal is to conduct a comprehensive ground test of the engine in 2022, followed by a flight test.
Clean Sky 2 is Europe’s largest aviation research program, which aims to develop innovative cutting-edge technologies to reduce CO2 emissions and noise levels produced by aircraft. Clean Sky 2 is funded by the European Union’s Horizon 2020 program and the European aviation industry, which will help strengthen European aviation industry cooperation, global leadership and competitiveness.
Rolls-Roy’s Road to Additives
The early Rolls-Royce engine Trent XWB-97 used additive manufacturing/3D printingpart,3D printingThe nickel-metal structural part is a front bearing seat with a diameter of 1.5 meters and a thickness of 0.5 meters, containing 48 airfoils. The Airbus A350-1000 uses the XWB-97 engine. The XWB-97 looks very much like the XWB-84 engine of the A350-900, which can generate 97,000 pounds of thrust. The increased thrust is mainly achieved by the new high-temperature turbine technology, which combines the core technology of the updated engine and the fan with larger air volume.In the final analysis, the realization of all this is the use of advanced aerodynamics technology, and3D printingParts.
In addition to the application in the core machine Advance 33D printingTechnology, Luo Luo also applied advanced fully automated manufacturing technology and digital twins when manufacturing UltraFan® engines. According to 3D Science Valley market observations, Luo Luo uses advanced fully automated manufacturing technology to manufacture UltraFan® engine components in its composites center of excellence. The blades in the engine are all made by robots. The robot builds about 500 layers of carbon fiber material and then applies heat and pressure. Each blade has a leading titanium edge, which provides excellent protection against foreign objects and bird strikes for the engine.
Each blade of the UltraFan engine is equipped with a digital twin, that is, each blade has a virtual copy in the computer software. During engine testing, they will collect a large amount of data, which will be fed into the digital twin for engineers to predict the performance of each blade in service.
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