The Rolls-Royce Trent Engine Michael Cervenka Technical Assistant

The Rolls-Royce Trent Engine Michael Cervenka Technical Assistant to Director - Engineering & Technology 5 October 2000

Rolls-Royce Today l World No 2 in aero-engines l World leader in marine propulsion systems l Developing energy business l Annual sales of over £ 4. 5 billion l Orders of over £ 13 billion

Newton’s 3 rd Law MV Equilibrium Reaction Thrust = Mass x Velocity (MV) Action

Propeller versus Jet Propulsion Propeller - moves LARGE MASS of air at low velocity Mvjet Mvaircraft Thrust = M(vaircraft - vjet) Thrust = m(Vaircraft - Vjet) m. Vaircraft m. Vjet Jet - moves small mass of gas at HIGH VELOCITY

Jet Engine Layout Compressor Combustion Chamber Exhaust Nozzle m. Vaircraft m. Vjet Shaft Turbine

Different Jet Engine Types Civil turbofan Trent Military turbofan EJ 200

Different Jet Engine Types - Mechanical drive Turboprop - AE 2100 Turboshaft - RTM 322 Marine Trent Industrial Trent

Piston Engine versus Turboprop Air intake Exhaust Piston engine Intermittent Compression Air intake Jet engine driven propeller (Turboprop) Combustion Continuous Exhaust

Pressure and Temperature 40 Pressure (atmospheres) 0 1500 Temperature (degrees C) 0

Axial Compressor and Turbine Operation

Axial Compressor and Turbine Operation Compressor Stages Rotating Rotor Row Turbine Stages Rotating Rotor Row Gas flow Airflow Stationary Vane Row Stationary Nozzle Row

Multiple Shafts - Trent 95, 000 lbs Thrust LP System 1 Fan stage IP System 8 Compressor stages 5 Turbine stages >3, 000 rpm 1 Turbine stage >7, 500 rpm HP System 6 Compressor stages 1 Turbine stage >10, 000 rpm

Combustor Operation

Combustor Operation Primary zone Dilution zone Intermediate zone Fuel spray nozzle

Reverse Thrust Net 25% to 30% thrust 85% thrust 15% thrust

New Product Introduction Process Stage 1: Preliminary concept defined for planning purposes Preliminary Concept Product definition stages Definition Stage 2: Full Concept Definition Full concept defined, product launched Stage 3: Product Realisation Product developed, verified and approved Stage 4: Production Capability Acquisition Product produced and delivered to customer Stage 5: Customer Support Product used by customer

New Project Planning Process BUSINESS MODEL MARKETING MODEL Market Size Selling Price Concessions Operating Costs Payload Range Maintenance Costs Fuel Burn Commonality Units sold Unit Cost Selling Price Concessions Sales Costs Development Costs Guarantee Payments Spares Turn Spares Price ENGINEERING MODEL Safety Unit Cost Weight Noise Emissions Geometry Reliability Operability Performance

102 Million Hours of Service Million hours RB 211 & Trent operating hours August 2000 -22 B -524 -535 Trent 90 80 70 60 26. 7 million hours 48. 5 million hours 25. 4 million hours 2. 2 million hours 4260 3592 103 100 engines ordered engines delivered customers currently flying with RB 211 or Trent engines Trent 800 Trent 700 50 -535 C -524 D -535 E 4 40 30 20 10 -524 -22 -524 H -524 G 0 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 Entry into service

Why 3 Shafts? Long / Medium-Haul Short / Medium-Haul (40, 000 -100, 000 lbs thrust): (8, 000 - 40, 000 lbs thrust): Range Fuel consumption Acquisition Cost Maintenance • Requires high: - Overall pressure ratio - Turbine entry temperature - Bypass ratio Three-Shaft Configuration • Simpler engine, hence moderate: - Overall pressure ratio - Turbine entry temperature - Bypass ratio Two-Shaft Configuration

Evolution of Trent Family Fan diameter - in. Trent 800 Trent 8104 Trent 900 Boeing 777 110 95, 000 lb Scaled 104, 000 lb Scaled 80, 000 lb core Trent 700 Trent 500 Trent 600 Airbus A 3 XX Airbus A 330 97. 5 72, 000 lb 56, 000 lb 65, 000 lb Boeing 747 RB 211 -524 G/H-T Airbus A 340 86. 3 60, 000 lb Boeing 767

Trent 700 & 800 Phase 5 low emissions combustor Single crystal HPT Single Crystal Uncooled IP turbine blade Fan diameter increased to 2. 8 m (110. 3 in. ) Trent 800 Fan diameter 2. 47 m (97. 4 in. ) Four-stage LP turbine Five-stage LP turbine Area of significant commonality Area of main geometric change 8 Stage IPC 3 Variables Trent 700

Trent 500 Scaled IP & HP Scaled combustor compressor with tiled cooling 3 D Aerodynamics Trent 500 Trent 700 HP & IP turbines have increased blade speeds High lift LP turbine blading

Material Strength Specific Strength Titanium Alloy Nickel Alloy Steel Aluminium Alloy Temperature

Engine Materials Titanium Nickel Steel Aluminium Composites

Fan Blade Technology Clappered + 4% efficiency Wide-chord fan

Wide-chord Fan Technology 1 st generation: 1984 Honeycomb construction 2 nd generation: 1995 DB/SPF construction

Fan Section

Swept Fans

Compressor Aerodynamics

Trent 500 Tiled Combustor Cold supporting wall l Tiles reduce wall cooling air requirements making more air available for NOx reduction l A significant cost reduction relative to conventional machined combustors is also achieved Thermal barrier coating Large primary zone volume for altitude re-light Large airspray injectors for improved mixing and smoke control Cast tile Small total volume for NOx control

Improvements in Materials Equiaxed Directionally Single Crystal Structure Solidified Structure

Turbine Cooling Single pass Cooling air Multi-pass Thermal Barrier Coating

Performance Trends Straight Low Medium High bypass jet 50 40 %sfc improvement (bare engine) 30 Propulsive efficiency Cycle efficiency 20 Thermal efficiency 10 Datum Avon Conway Spey 1958 1960 1963 Component efficiency -22 B -524 B 4/D 4 -535 E 4 -524 G/H 700 1973 1981 1983 1988 1994 RB 211 800 1995 Trent 500 2000

Electric Engine Concepts New Engine Architecture with reduced parts count, weight, advanced cooling, aerodynamics and lifing Air for pressurisation/cabin conditioning supplied by dedicated system Pylon/aircraft mounted engine systems controller connected to engine via digital highway All engine accessories electrically driven Internal active magnetic bearings and motor/generators replace conventional bearings, oil system and gearboxes (typical all shafts) Generator on fan shaft provides power to airframe under both normal and emergency conditions

Compressor Weight Reduction Conventional disk & blades Blisk - up to 30% weight saving Bling - Ti MMC - up to 70% weight saving

Metal Matrix Composites Specific Strength Titanium Metal Matrix Composite Titanium Alloy Nickel Superalloy Temperature (degrees C)

Future Emissions Improvements Main Pilot Double-annular combustor Main Pilot Pre-mixed double-annular combustor

Future Aircraft Configurations Large diameter duct Contra-rotating fan Gas generator Contra-rotating turbine Flying wing Blended wing aircraft may offer up to 30% reduction in fuel consumption - 40% if combined with electric engine concepts

Conclusion l The three-shaft concept is now recognised as a world leader l Customer-focused competitive technology is critical to its success l Success is a tribute to many generations of people l The RB 211 & Trent family has a long and secure future

Rolls-Royce