Pioneering intelligent innovation
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1 Pioneering intelligent innovation Future Technology update Paul Madden Engine Emissions Expert 2016 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies. TotalCare is a registered trademark, Life, Term and Flex are registered in the European community. Trent is a registered trademark. Trusted to deliver excellence
2 World leading product evolution For a range of Civil Aerospace applications
3 Advance Advance 20% more efficient from 2020 A revolutionary design for a new jet engine family Engineered for business jets, narrowbody and widebody aircraft A New Era
4 Advance key technologies
5 UltraFan 25% more efficient from 2025 World s most powerful aerospace gearbox driven by our Advance core Engineered for narrowbody and widebody aircraft The Ultimate TurboFan
6 UltraFan key technologies
7 Our full-scale Technology programmes Underpinning our Vision strategy for Civil Aerospace
8 Full-scale Civil Aerospace demonstrators In collaboration with CleanSky, ATI, iuk, LuFo, Brandenburg & CLEEN
9 Full-scale Civil Aerospace demonstrators In collaboration with CleanSky, ATI, iuk, LuFo, Brandenburg & CLEEN
10 Maturing our CTi fan system 4 generations of blade & case with 250 blades manufactured to date 50+ bird strike tests completed, more planned Indoor and outdoor functional and noise testing complete in UK/USA Flight Test campaign completed in Tucson Design and analytical methods suite established Current test phase focused on maturing the design and proving certification criteria Larger blade >120 Full system interactions Environmental effects Back to back engine performance ALPS Manufacturing capability development progressing in parallel
11 Composite Fan Engine Testing Completed Indoor testing Blade untwist Tip clearance studies Indoor flutter mapping Nozzle calibration Back-to-back performance Outdoor ground testing Cross-wind testing Noise Outdoor flutter mapping Long blade tip rubbing test Ice testing ALPS
12 CTi fan system testing continues Also testing full engine (blade, case & annulus fillers) Currently on build in Derby to test later this year Testing performance & operability Flutter experiments with Ti rotor/composite case Tip clearance Damaged blade run on experiment ALPS Overall, testing is going well and meeting expectations
13 Advance3 overview Next generation large engine core architecture for Advance and UltraFan Demonstrates suite of technologies in addition to our Advance core architecture Also developing CMCs and ALM (3D printing) Utilises Trent XWB-84 fan system and Trent 1000 LPT Delivers design, process and product robustness validation Starts testing in Derby mid-year Advance XWB Supported by ATI, Clean Sky & iuk funding Advance3
14 Advance3 readying for test Advance3 Build progressing well at our facility in Bristol, UK
15 Advance3 readying for test Advance3
16 Advance Aero rig tests successfully complete IPC Rig at Anecom, Germany Proving the design, efficiency and stability of our new 4-stage IP compressor Successfully completed a number of experiments; tip clearance, vibration, noise HPC Rig at Anecom, Germany Proving the design, efficiency and stability of our higher PR 10-stage compressor Testing successfully completed Advance3 Will be deployed in Advance and UltraFan applications
17 Maturing our Lean Burn combustor Performed altitude relight exceeding the required envelope Showed good cold starting behaviour This rig has since successfully completed ground testing in Derby ALECSys Altitude rig testing at ILA Stuttgart successfully completed
18 Further rig, ground and flight testing planned ALECSys
19 High temperature technologies HT3 Deliver significant benefits for a typical Large Engine
20 HT3 demonstrator programme HT3 Trent XWB-97 based HT3 (High Temperature Turbine Technology) demonstrator continues the good work of the Trent 1000 based EFE vehicle Validates advanced high temperature technologies in a representative environment Advanced cooled metallic components made possible through Advanced Manufacturing CMC components Planned to establish drum beat of regular testing for high temperature components Technology delivers improved SFC through reduced cooling, reduced weight and lower emissions Engine build starts late 2017
21 Specialist turbine manufacture Advanced manufacturing technology enables highly effective & complex cooling schemes for metallic blades CastBond is an innovative manufacturing process unique to Rolls-Royce Allows more intricate features and reduced wall thicknesses Step change in cooling effectiveness significantly reduces cooling air Allows higher temperature smaller core Reduces SFC and fuel burn Facilitates NOx reductions Already demonstrated in Defence; further validation through Advance3 & HT3 HT3
22 CMCs creating new opportunities HT3 Ceramic Matrix Composites (CMCs) A continuous silicon carbide fiber reinforcement with a fiber-matrix interface coating, surrounded by a ceramic matrix consisting primarily of silicon carbide - 2 different CMC systems are commonly used - oxide/oxide (exhaust system hardware) and SiC/SiC turbine system hardware we are testing both Higher temperature capability Reduced cooling air use improves SFC Allows blades to run uncooled 1/3 the density of Ni-based superalloys Reduced system weight, improved SFC Applicable to combustor components and turbine seal segments, blades and vanes Hotter walls reduce cooling needs and emissions
23 Our new CMC facility in California HT3 $30m investment - 62,000 square foot R&D facility formally opened in 2016 For CMC processes and materials for a range of turbine components Production ready processes, manufacturing components for engine test programs to support certification Delivered components for the Advance3 demonstrator
24 Virtual Engine Digital
25 Analytical Capability Digital Analysis / test correlation is good
26 UltraFan Programme on track Major programme culminating in flying demonstrator of UltraFan technologies Demonstrator concept design freeze 2017 Flight Test 2021 Product EIS from 2025 Key enabling technology development underway Low Speed Fan Rig test completed Initial PGB testing underway more to come IP Turbine 2 nd Gen TiAl First trial blades cast PGB Manufacturing Joint Venture operating ATT, Aerospace Transmission Technologies GmbH First PGB started testing on attitude rig 1 st Sept 2016 Demo now in Stage 1 UltraFan Power rig will start testing in Q2
27 Bringing our vision to life An exciting year ahead
28 Intelligent innovation in everything we do
29
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