Rolls-Royce starts manufacture of world's largest fan blades, made with composites, for UltraFan demonstrator
CFRP blades and fan case cut weight for twin-engine aircraft by 700 kilograms
Rolls-Royce (London, U.K.) has started manufacture of the world’s largest fan blades, for its UltraFan demonstrator engine that will set new standards in efficiency and sustainability. This milestone marks the official start of parts production for the demonstrator.
CFRP blades
The UltraFan engine will reportedly set new standards in efficiency and sustainability, offering a 25% reduction in fuel burn and emissions compared to the first generation of Trent engines. Part of that efficiency improvement comes from UltraFan’s composite fan blades and fan case, which cut weight on a twin-engine aircraft by 700 kilograms, the equivalent of seven people with luggage.
As a set, the composite blades have a 140-inch diameter, which is almost the size of a current narrowbody aircraft fuselage. They are being made at the company’s technology hub in Bristol, U.K.
The fan blades are made from 500 plies of Hexcel’s (Stamford, Conn. U.S.) HexPly M91 carbon fiber-reinforced, high-toughness and impact-resistant epoxy prepreg. Hexcel supplies the slit tape for automated layup. The blades are autoclave cured using heat and pressure, precision machined and then coated before a thin titanium sheath is bonded to the leading edge, which protects against erosion, foreign objects and bird strikes. The composite titanium (CTi) blades are inspected and measured using metrology and ultrasound testing.
Composite fan blade being scanned at Rolls Royce composites technology center using a GOM Metrology system.
Sourcing:Rolls-Royce