This project will develop technologies that will allow rapid manufacture of components for future development rig and engine tests. This project will address the development of a range of manufacturing technologies that currently have long production lead times. The work packages will be developed by Rolls-Royce working in partnership with the Manufacturing Technology Centre the Advanced Manufacturing Research Centre and the University of Birmingham and using a UK supply chain.

Integrated Decision Support Systems The multi-physics simulations of detailed phenomena need to be coupled together into design and analysis systems capable of simulating product sub-systems and ultimately whole engines at variable levels of fidelity. Key enablers of this goal addressed in this project are: Coupling between models of differing fidelity; Integration of CFD and thermo-mechanical models; Effective use of high performance and massively parallel computing; Understanding and simulation of complex systems. The key Integrated Decision Support System capabilities developed by this project will address the innovations required to improve New Product Introduction (NPI) performance.

Recent years have seen increasing interest in the use of thick-section composites for safety-critical components in, for example, primary aircraft structure and fan blades in aero engines. All such components are required to undergo non-destructive evaluation (NDE) during manufacture; this is time consuming and NDE throughput is stretched to its limit internationally. Current composite Non-destructive Evaluation (NDE) is based on a qualitative empirical approach where a single normal-incidence ultrasonic probe is used to estimate the average ultrasonic attenuation from the amplitude of the back-wall reflection. While adequate for accepting or rejecting thin composite panels, this approach does not provide the level of defect characterisation and localisation necessary for the quantitative NDE of larger components.There is a clear and pressing industrial need for quantitative NDE techniques that can be applied to safety-critical composite components both at manufacture and in-service. An ultrasonic technique is the industrially preferred option for reasons of cost, safety and ease of deployment, but increased scanning speeds are required to speed up throughput. However, the conflicting demands of rapid scanning, high-penetration depth and accurate defect characterisation cannot be achieved with a single normal-incidence probe. Instead the data from multiple inspection directions must be combined. The necessary raw data can be rapidly and efficiently obtained using an ultrasonic array, but at present it cannot be exploited. This is due to the lack of (a) an appropriate forward model of oblique wave propagation and scattering processes, and (b) a suitable inversion scheme to turn the raw data into useful information. This is the motivation for the proposed research programme, the aim of which is to develop ultrasonic array data processing techniques based on physical reasoning for the characterisation of safety-critical aerospace composites. The programme requires advancement of the fundamental science of wave phenomena in composites, the solution of a challenging inverse problem and, crucially, the translation of the scientific findings into practical industrial solutions.

The SAMULET Project 3 programme is defined to develop transmissions and structures turbo-machinery technologies. This project will deliver novel technology enabling cost effective design for manufacture, component life analysis, part optimised manufacture and inspections. The overarching challenge within the lifecycle management activities within the project is to feed the design decision-making process with good quality, sufficiently accurate and timely information to maximise value, develop lifecycle knowledge and understand the environmental impact of the product. The project utilises the capabilities of the Rolls-Royce University Technology Centres (UTCs) coupled with Rolls-Royce’s expertise to develop transmissions and structures technology technologies to support the engine architectures of the future. These include new aerospace gear materials for increased engine duty; advanced aerospace structure manufacturing techniques and technologies; fluids system modelling of aero-engine bearing chamber performance; dynamic modelling of advanced sealing; lifecycle knowledge and environmental impact management systems.

Rolls-Royce Plc. will lead the FANTASIA (Future Noise Technologies And Systems Integration Analytics) project which seeks to develop, model and validate noise technologies to ensure integrated propulsion systems that will achieve the required noise levels for the novel UltraFanTM engine architecture as well as future hybrid-electric offerings. Multi-disciplinary optimisation techniques will be developed to design for the optimal noise, sfc and emissions levels. Computational fluid dynamics and source separation techniques will be enhanced to replace expensive testing and give early indications of design suitability. Project cost is £11.2m over 60 months, starting 1 December 2020 and completing November 2025.