Next Generation Fan System (SAM 2 P4)

Rolls-Royce is developing a composite fan system for deployment in future civil gas turbine engines. The primary aim of a composite fan system is to deliver a significant weight saving. The blades and associated composite engine casings will form part of the new CTi fan system that could reduce weight by up to 1,500lb per aircraft, the equivalent of carrying seven more passengers and their luggage. This enables substantial improvements in fuel consumption (SFC), thereby contributing to reduced emissions and achievement of the ACARE targets (ACARE Flightpath 2050 International Environmental Targets to significantly reduced aviation CO2, NOX, and Noise by 2050).

This ATI-supported project sought to develop, understand and demonstrate aspects of manufacturing technologies required for the production of composite fan blades ranging in length from 60” to 140”. Specific areas of research included: cost reduction; development of manufacturing methods for structural metalwork to very strict tolerances; and improvements to blade assembly techniques.

This project raised the Manufacturing Capability Readiness Level (MCRL) to 4, enabling improvements in composite laminate conformance and overall blade dimensional conformance, resulting in blades which offer improved aerodynamic performance and resistance to impact from foreign bodies.

Download the Next Generation Fan System (SAM 2 P4) case study
Short Title: SAM 2 P4
Project Number: 110103
Project Cost: £17,118,000
End Date: 31st Jan 2015
Time Horizon: Secure
Lead Partner: Rolls-Royce PLC
Attributes: Fuel Efficiency, Cost
ATI Value Stream: Propulsion of the future