future defence programmes and key enabling technologies · future defence programmes and key...

1

Future Defence Programmes and Key

Enabling Technologies

Conrad Banks

C fChief Engineer – Research and Technology

Rolls-Royce Defence

©2012 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.


Future Platform Evolution 2

Future ISTAR and Combat UAVs

Existing UAV

platforms

Future Transport

and Heavy Lift

Future Concepts

NPI Combat and

Transport

Hi-Mach

Transport


Future Manned Combat – LRS and 6th Gen Fighter

Power System Trends and Requirements

Increasing Electrical Power Demands Advanced Propulsion and Open Rotors

Advanced Heath Monitoring, Lifing and Repair Techniques

Enhanced Survivability

Smaller, Lighter and more Efficient Gas Turbines

yThermal Management


4

Future Gas Turbine Trends and Technology


5The Future Gas Turbine – Smaller, Lighter and More Efficient

Avon 20

T/W (Thrust to Weight) = 4:1Spey 202

T/W = 5:1T/W = 5:1

RB199

Rolls-Royce Power System Advances

T/W = 7:1

‘Current

Technology’

Engines scaled to

the same dry thrust

‘Next

Generation’

ec o ogy

EJ200

T/W = 9:1

• High stage loadings (advanced 3D

d i i t d f il )T/W = 15:1 aerodynamics, aspirated aerofoils)

• Compact, high pressure ratio cores

• Advanced materials (high temp, lightweight)

• Composites, Blisk/Bling Technology,

Significant scope for technology insertion


p g gy

Vaneless Turbines, Variable Cyclesremains

Advanced Gas-Turbine Technology

Advanced Materials Architecture and Aerodynamic Affordable

Advanced 3D Aerodynamics

Advanced Hollow

Bli kBlisks

Aspirated aerofoils

Innovative Low Cost

Manufacturing Processes

Metal Matrix

Composite Blisks

Precision Laser Drilled

Vaneless Counter-Rotating Turbines

PrecisionSand Cast

LaserDeposition

5-axi CNC Machining

Laser DrilledComponents

Ceramic Composites

High Temp Super –Alloys


Air and Magnetic Bearings Variable Cycles

Metal Matrix Composites

Titanium Metal Matrix Composite

Specific Strength

Titanium Alloy

Nickel SuperalloyNickel Superalloy

Temperature (degrees C)

Compressor Weight Reduction

Conventionaldisk and blades

Blisk – up to 30% weight saving

Bling – Ti MMC

up to 70% weight saving


weight saving

8

Advanced Heath Monitoring, Lifing and Repair Techniques


9Blisk Repair

Without the capability to easily replace blades, the ability to repair blisks is critical to

acceptable life cycle costs.

Blending of damage is first option, if beyond blending limits, blisk would be scrapped.

Rolls-Royce has developed a ‘Material Addition’ process which uses laser and titanium

powder to build up damaged areas

Laser in position

Damaged material removed

Laser in position

Material deposited


Blisk Repair10

p


11

Advanced Propulsion and Open Rotors


12

Typical installation and benefit

© 2009 Rolls-Royce plc© 2009 Rolls-Royce plc

Typical contra rotating open rotor installationTypical contra-rotating open rotor installation

Benefits relative to small business jet type turbofan in a typical MALE UAV (All engines sized to the same top of climb thrust)Rolls-Royce wind-tunnel testing


Next Generation Helicopters - Power System Technology

Inertial Particle Separators

Infra Red Suppressors

Heat Exchangers

- lightweight recuperator cells


14

Integrated Electrical and Thermal Management


Integrated Power SystemsIntelligently combining propulsion, thermal management and

15

electrical power provision

PROPULSION

SYSTEMS

ELECTRICALCOOLING

OPTIMISATION

and

CONTROL

ELECTRICAL

SYSTEMS

COOLING

SYSTEMS

Powering the g

Latest Unmanned

Demonstrator

Aircraft


Mantis UAV Demonstrator Taranis UCAV Demonstrator

16

Enhanced Survivability


Unmanned Combat Air Vehicle (UCAV)

‘Intelligent, Low Observable and More Electric’

Obscuration Vane

Low Observable Installations

Distortion tolerant Autonomous Control Systems and Engine Health Monitoring

Key Requirements

Compact, high power density gas turbineAd d i t ll ti C l t d d t RAM Ad d C li

compressors

Variable Cycle Technology

Advanced installations – Convoluted ducts, RAM, Advanced CoolingElectrical systems (embedded generator) and intelligent power management and storage.Intelligent ‘performance seeking’ controls

Future Technologies

Fuel Deox (small, flight weight units – stored fuel at elevated temperatures without coking)Thermoelectric power generation (reduced IFR signature and


Thermoelectric power generation (reduced IFR signature andincreased electrical power provision)

Conclusions

Air Domain Propulsion will continue to be dominated by the Gas Turbine –

unrivalled power density.

Advanced Research and Technology programmes will continue to enhance

gas turbine capabilities (smaller, lighter, more efficient, more affordable and

more reliable).

In parallel to the Gas Turbine, system level improvements will become

increasingly important

Integrated Power Systems intelligent autonomous and more electricIntegrated Power Systems – intelligent, autonomous and more electric

Heat Exchangers and Thermal Management

Propulsive efficiency (e.g. Ultra high bypass ratio / prop fans and Open Rotors).

Stealth and High Machg

Emerging niche requirements (e.g. Ultra-high endurance surveillance UAVs)

will start to benefit from alternative propulsion solutions (Electric, Hydrogen,

Solar etc)Solar etc).

Future consolidation and greater co-operation of the Propulsion Industry will

be essential to delivering effective future solutions and capability


be essential to delivering effective future solutions and capability

future defence programmes and key enabling technologies · future defence programmes and key...

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