GKN Aerospace’s Intermediate Compressor Case (ICC) of Rolls-Royce UltraFan® engine successfully tested at full power

Successful ground testing of UltraFan technology demonstrator engine at full power provided evidence towards validation of GKN Aerospace’s pioneering technologies in the ICC.

UltraFan™ aims to offer 25% fuel efficiency improvement since the launch of the first Trent engine.

Innovative design features include: optimized aerodynamics and acoustics for bleed system efficiency, a streamlined high curvature duct design, additive fabrication of attaching parts, and model-based design methods.

GKN Aerospace, a Rolls-Royce Core Partner in Clean Sky 2, recently achieved a significant milestone when Rolls-Royce successfully tested the UltraFan technology demonstrator including the innovative GKN-designed and manufactured ICC, at full power. The testing marks a pivotal moment for GKN Aerospace’s advanced sustainable aero-engine technologies.

The ICC, a critical structure between compressor modules, plays a vital role in carrying rotor loads to the engine casing and thrust mounts. GKN Aerospace's developmental efforts encompass pioneering technologies, notably a low-cost, robust sectorised fabrication concept integrating castings. This innovation includes an advanced welding method based on precise computer simulations, optimized aerodynamics and acoustics for bleed system efficiency, a streamlined high curvature duct design, additive fabrication of attaching parts, and model-based design methods.

Clean Sky 2 stands as the largest European aeronautics research programme dedicated to pioneering technologies aimed at reducing CO2 emissions and aircraft noise levels. Funded by the EU’s Horizon 2020 programme and Europe’s aviation industry, Clean Sky 2 fosters collaboration, global leadership, and enhanced competitiveness within the European aero-industry.

The recent successful testing of the UltraFan® technology demonstrator engine at full power, conducted at the Rolls-Royce facility in Derby, UK, marks a momentous achievement. Notably, the initial phase of the test utilized 100% Sustainable Aviation Fuel (SAF), underscoring a commitment to sustainable aviation practices.

The successful ground testing of the UltraFan engine signifies a significant milestone for our ICC. It underscores the success of the Clean Sky 2 collaboration and showcases our incorporation of cutting-edge sustainable technologies, such as additive fabrication, in ICC development. We take immense pride in partnering with the Rolls-Royce team to contribute to this energy-efficient aero-engine of the future.

Henrik Runnemalm Vice President of GKN Aerospace’s Global Technology Centre in Sweden

GKN Aerospace's strides in developing innovative manufacturing processes for the ICC have received substantial support in Sweden, notably through the Vinnova funded IntDemo-project and the Västra Götaland Region.