Advance3, incorporating around 20,000 parts in total, has achieved more than 100 hours on test. The aerospace giant says that initial results are showing excellent performance from 3D-printed parts and also those made from ceramic matrix composites (CMC). CMCs last longer in high temperatures and are lighter than metal alternatives.
Rolls-Royce reports that its engineers have downloaded millions of data points from the tests, which began last November and saw the engine achieve full power in July. Advance3 plays an important part in delivering the ‘IntelligentEngine’, Rolls-Royce’s vision for the future, as it builds on pioneering technology and digital capabilities to deliver important benefits for customers.
Ash Owen, Rolls-Royce, chief engineer, Civil Aerospace Demonstrator Programmes, said: “Testing so far has been completely seamless, which is an outstanding achievement when you realise that this is an engine incorporating a range of new technologies, as well as a brand new core architecture. We have completed our first phase of testing and analysing the results right now. We like what we see from the CMC and ALM [3D-printed] parts performance.”
Rolls-Royce has been at the forefront of innovation with 3D printing, flying the world’s largest 3D-printed aerospace structure within the Trent XWB-97 engine that was tested in 2015 - the front bearing made from titanium and 1.5 m across. The component was not made in a single piece; it contains 48 aerofoil-shaped vane components, which were also made by additive manufacturing.
The Advance3 demonstrator programme is co-funded through the Aerospace Technology Institute (ATI) in association with Innovate UK and the EU’s Clean Sky 2 programme.
