Periodic Reporting for period 4 - HEAVEN (Hydrogen Engine Architecture Virtually Engineered Novelly)
Período documentado: 2025-01-01 hasta 2025-12-31
Climate-neutral aviation will require the use of alternative fuels such as Green Hydrogen and Sustainable Aviation Fuel, combined with the power density of an ultra-efficient gas turbine engine for the Short and Medium Range (SMR) aircraft market, which corresponds to ~50% of the current share of air transport emissions. Rolls-Royce supported by key European & UK academia, industry and research partners are currently developing a new generation of very high bypass ratio geared engine architecture called UltraFan®. Since inception, this ducted engine architecture has been designed to be scalable and meet the needs both of widebody and SMR markets. To achieve the necessary 20% fuel burn reduction, HEAVEN aims to significantly evolve the UltraFan design by improving gas turbine efficiency, taking advantage of the properties of net zero carbon fuels, and combining this with hybrid-electric technology to reduce wasted energy. Numerous innovative enabling technologies will be incorporated into this new architecture. Together with work in Clean Aviation projects CAVENDISH (hydrogen) and HE-ART (hybrid-electric), in conjunction with activities in national and regional programmes, this will be synergistically combined to validate the highly innovative UltraFan design up to TRL6, in support of a 2035 EIS.
Propulsion System Architecture & Design: Cardinal product requirements have been confirmed, which will guide activities in a follow-on project to demonstrate ability and market readiness. Identification and integration of technologies requiring whole engine demonstration will be performed in support of the broader UltraFan demonstration programme. To support this, multiple architecture studies have been carried out in HEAVEN. The studies include the incorporation of hybrid-electric technologies. Completion of cycle design studies have confirmed the engine architecture and integrated enabling technologies have a credible path to meeting the 20% fuel burn reduction target at integrated platform level.
Inlet/Fan: Despite initial supply chain challenges, the final assembly of rig and test hardware is nearing completion, and commissioning is underway to support testing in 2026. Successful commissioning of a new aeromechanics test facility for fan flutter has been achieved, and measurement campaigns have started. Methods, tools, and design rules have been developed under the project, which will be leveraged through combination with experimental data from rig testing to further help optimise future fan blade designs. Key learnings have been published on flutter stability, measurement capability, unsteady aerodynamics, and aeroacoustics.
Power Transmissions: Building off the wealth of experience with design and test of large PGBs, the PGB design for SMR scale has progressed significantly, enabling raw material ordering, forging release, and rig facility adaptation. Manufacturing trials have been completed for the most challenging features at SMR scale, which includes production of fixtures needed for various manufacturing steps. Component scale rig testing has successfully been carried out in support of the optimisation of future transmission systems. A significant proportion of Arctic15 Material testing programs have been completed to fully characterize the material properties for engine use, with insights presented at ASTM Bearings conference. Assembly, commissioning, and initial testing of a novel damper rig has been achieved, and further testing continues in 2026 to explore multiple configurations across the full test rig design envelope.
Low-Emission Combustion: Various iterations of low emissions SMR-scale Fuel Spray Nozzles (FSNs) have been delivered to enable high TRL test campaigns looking at the impact of Fuel Spray Nozzle and cooling geometry on thermoacoustic and emissions performance. Through linked projects, flight testing has also been conducted with Low Emission Combustion System developed under HEAVEN. Novel combustion models have been developed, capable of predicting how flame response changes with operating conditions and the influence of complex geometric features of FSNs, and a methodology was established to match experiments which has not been achieved before. This will provide very valuable information for the development of future models and injector designs. Analysing and bringing together the data from the work package so far from all partners continues into 2026 to develop design rules for a future low thermoacoustic instability combustion system.
Turbine Technologies: The development and validation of a novel Intermediate Pressure Turbine (IPT) concept for the SMR market is essential in order to increase engine efficiency, while simultaneously reducing noise, emissions, and engine weight. Selection of best ITP concept has been achieved following completion of underlying design studies. The impact of high hade angle design of aerodynamics and noise has been characterised through completion of the first rig test campaign and post-test analysis. Testing has also been completed at component level to support the validation of novel IPT technologies, and preparations are underway for the final system level test campaign in 2026. A significant portion of the advanced manufacturing work programme has been realized with the successful pour of thin wall castings at single aisle engine scale. Multiple manufacturing trials have been carried out, and advanced joining methods developed to enable reduced losses and lighter design.
Inlet/Fan: Despite initial supply chain challenges, the final assembly of rig and test hardware is nearing completion, and commissioning is underway to support testing in 2026. Successful commissioning of a new aeromechanics test facility for fan flutter has been achieved, and measurement campaigns have started. Methods, tools, and design rules have been developed under the project, which will be leveraged through combination with experimental data from rig testing to further help optimise future fan blade designs. Key learnings have been published on flutter stability, measurement capability, unsteady aerodynamics, and aeroacoustics.
Power Transmissions: Building off the wealth of experience with design and test of large PGBs, the PGB design for SMR scale has progressed significantly, enabling raw material ordering, forging release, and rig facility adaptation. Manufacturing trials have been completed for the most challenging features at SMR scale, which includes production of fixtures needed for various manufacturing steps. Component scale rig testing has successfully been carried out in support of the optimisation of future transmission systems. A significant proportion of Arctic15 Material testing programs have been completed to fully characterize the material properties for engine use, with insights presented at ASTM Bearings conference. Assembly, commissioning, and initial testing of a novel damper rig has been achieved, and further testing continues in 2026 to explore multiple configurations across the full test rig design envelope.
Low-Emission Combustion: Various iterations of low emissions SMR-scale Fuel Spray Nozzles (FSNs) have been delivered to enable high TRL test campaigns looking at the impact of Fuel Spray Nozzle and cooling geometry on thermoacoustic and emissions performance. Through linked projects, flight testing has also been conducted with Low Emission Combustion System developed under HEAVEN. Novel combustion models have been developed, capable of predicting how flame response changes with operating conditions and the influence of complex geometric features of FSNs, and a methodology was established to match experiments which has not been achieved before. This will provide very valuable information for the development of future models and injector designs. Analysing and bringing together the data from the work package so far from all partners continues into 2026 to develop design rules for a future low thermoacoustic instability combustion system.
Turbine Technologies: The development and validation of a novel Intermediate Pressure Turbine (IPT) concept for the SMR market is essential in order to increase engine efficiency, while simultaneously reducing noise, emissions, and engine weight. Selection of best ITP concept has been achieved following completion of underlying design studies. The impact of high hade angle design of aerodynamics and noise has been characterised through completion of the first rig test campaign and post-test analysis. Testing has also been completed at component level to support the validation of novel IPT technologies, and preparations are underway for the final system level test campaign in 2026. A significant portion of the advanced manufacturing work programme has been realized with the successful pour of thin wall castings at single aisle engine scale. Multiple manufacturing trials have been carried out, and advanced joining methods developed to enable reduced losses and lighter design.
Assessment of the project’s impact has continued under the Clean Aviation impact monitoring framework, which provides a clear link between the project’s results, the impact on the environment, as well as the project’s contribution to the Clean Aviation High Level Objectives. The HEAVEN performance model has been optimized against aircraft requirements from linked project ACAP, with the engine data pack issued to DLR for fuel burn assessments. The results confirm that the project is on a credible path to meet the SRIA objective of 20% fuel burn reduction at propulsion system level.