GKN Aerospace delivers first UltraFan engine intermediate compressor case

GKN Aerospace in Sweden has successfully delivered the first intermediate compressor case (ICC) to the Rolls-Royce UltraFan engine demonstrator program. GKN Aerospace is a Rolls-Royce Core Partner in Clean Sky 2, with responsibility for design and manufacture of the ICC. The ICC is a structure between compressor cases, which carries the rotor gas loads to the engine casing and thrust mounts.

Development, manufacture, and testing of the ICC will demonstrate and validate a range of new technologies, including a low-cost and robust sectorized fabrication concept with castings. This makes use of an innovative welding method based on computer simulations; optimized bleed system aerodynamics and acoustics; shorter aggressive duct design and 3D printing of attaching parts; and model-based design methods.

Rolls-Royce's UltraFan next-generation engine family aims to improve fuel efficiency 25% more than the first-generation Trent engines. It features a new engine core architecture and introduces a geared design. The goal is full engine ground test during 2022, with flight-testing to follow.

Clean Sky 2 is the largest European aeronautics research program, developing innovative, cutting-edge technology aimed at reducing CO₂ emissions and noise levels produced by aircraft. Funded by the EU’s Horizon 2020 program and Europe’s aviation industry, Clean Sky 2 contributes to strengthening European aero-industry collaboration, global leadership, and competitiveness.

Henrik Runnemalm, Vice President of GKN Aerospace’s Global Technology Centre in Sweden, said: “We are excited to have implemented our latest sustainable technologies in the ICC’s development. We are extremely proud to be a partner of the Rolls-Royce team and to contribute to this energy efficient aero-engine of the future.”

GKN Aerospace’s development of innovative manufacturing processes for the ICC has been well supported in Sweden thanks to the Vinnova funded IntDemo-project and the Västra Götaland Region.