Engines: what are the challenges?
Working towards radical engine architectures and new engine technologies to power the aircraft of the future, Clean Sky’s Engines Integrated Technology Demonstrator (ITD) activities all have a common goal: to increase fuel and energy efficiencies of the engine and reduce environmental impact. This ambition should be achieved regardless of whether the engine is powering a large airliner or a small utility aircraft, meaning more thrust while burning less fuel and emitting less CO2, NOx and noise.
The European engine sector currently represents about 40% of the global market and Horizon 2020 and Clean Sky 2 is contributing to that share. The Engines ITD programme is not starting from scratch: it builds on the achievements of a previous Clean Sky 1 programme, the Sustainable and Green Engine (SAGE) ITD.
The challenge for the participants in the Engines ITD Programme of Clean Sky 2 is to advance aero-engine technologies to a state of eco-compliance and technological readiness that can take to the skies between 2025 and 2050, delivering a combination of benefits which will result in more affordable air travel and cleaner skies.
This requires unprecedented capacity for foresight, imagination and innovative thought, for the efficiencies required – as the race against climate change heats up – are almost unimaginable.
To deliver substantial improvements in engine technology, the following challenges are addressed:
- Development of technologies at system level that are a step change from current state-of-the-art engine architectures and that are capable of delivering substantial reductions in emissions.
- An incremental approach to increasing the maturity of the technologies, utilising design studies and rig tests to explore and understand the technologies under development, their system interactions and the risks associated with their implementation.
- Ensure the participation in the programme of both large tier 1 suppliers and more specialised companies as well as academia and research organisations.
Read more about the ENG ITD and the CS2 Programme here
Overview
The Engines programme of Clean Sky 2 is building on the success of SAGE to validate more radical engine architectures. Validation of new engine architectures will be performed by taking a step-by-step approach to progressing the technology’s maturity or "Technology Readiness Level" (TRL), utilising design studies and rig tests to explore and understand the technologies under development, their system interactions and the risks associated with their implementation. The ultimate goal of the project is to achieve TRL5 on a number of key enabling technologies required for these new engines architectures.
The platforms or demonstrators of these engines architectures are summarised below:
- Ultra-High Propulsive Efficiency (UHPE) demonstrator addressing short / medium range aircraft market
- Business aviation / short range regional turboprop demonstrator
- Advanced Geared Engine Configuration (High Performance Compressor (HPC) and Low Pressure Turbine (LPT) technology demonstration)
- Very High Bypass Ratio (VHBR) middle of market turbofan technology
- Very High Bypass Ratio (VHBR) large turbofan demonstrator
- Light weight and efficient jet-fuel reciprocating engine for general aviation
- Reliable and more efficient operation of small turbine engines
Demonstrators
Seven demonstrators are planned, catering to the full spectrum of aircraft in commercial operations – from 4-19 seater aircraft in the SAT category – to the largest wide-body aircraft:
Ultra High Propulsive Efficiency (UHPE) demonstrator addressing short / medium range aircraft market, 2014-2023
A scale 1 integrated propulsion system (IPS) demonstrator is being built to validate the new engine architecture, the low pressure modules and associated systems and nacelle technologies. The technology is being matured through modules and rigs ground demonstrations that will feed into the main demonstrator.
The IPS demonstrator will consist of new low-pressure modules and engine multifunctional cowls integrated around an existing or adapted High Pressure (HP) core in order to build the ground demonstrator. One part of the project aims to deliver specific technologies dedicated to an Ultra High Propulsive Efficiency concept to TRL 5 by the end of the Clean Sky 2 programme.
Business aviation / short range regional turboprop demonstrator, 2015-2022
Safran Helicopter Engines leads the design, development and ground testing of an Integrated Power Plant System (IPPS) dedicated to short range turboprop applications. The IPPS demonstrator is based on the thermal core of the ARDIDEN3 turboshaft engine. Safran Helicopter Engines will coordinate the development and integration of the various IPPS modules (power and accessory gearbox, propeller, air intake and nacelle). In parallel, developments for gas turbine components will be conducted (compressor, combustion chamber and turbine). Design, development and ground testing of a new turboprop engine demonstrator is underway. The demonstrator will be also exploited for development of engine technologies/components towards “more electrical aircraft”.
Advanced Geared Engine Configuration [High Performance Compressor (HPC) and Low Pressure Turbine (LPT) technology demonstration], 2015-2023
This will include design, development and ground testing of a new demonstrator to validate key enablers to reduce CO2 emissions and noise as well as engine weight. Key elements are: improvement of efficiencies, reduction of parasitic energy flows, innovative lightweight and temperature resistant materials, low pressure turbine and exhaust noises reduction. Design, development and ground testing of a new demonstrator to reduce CO2 emissions and noise as well as engine weight is led by MTU.
Very High Bypass Ratio (VHBR) Large Turbofan demonstrator, 2014-2023
Design, development, build and ground test of an engine to demonstrate key technologies at a scale suitable for large engines. The Rolls-Royce Advance 3 engine core will be demonstrated and this will provide the core gas generator used for the demonstrator.
Very High Bypass Ratio (VHBR) Middle of Market Turbofan technology, 2014-2021:
The trend towards Very High Bypass Ratio engines requires technology development across a broad range of complex gas turbine systems, from fan inlets to the complete compression, combustion and turbine to exhaust. Rolls-Royce will lead the development and demonstration of technologies in low-speed low pressure-ratio fan, aerodynamic and structural design of high efficiency multi-stage intermediate pressure turbines, integration of novel accessory and power gearbox.
Lightweight and efficient jet-fuel reciprocating engine, 2014-2019:
For the small aero-engine demonstration projects related to Small Air Transport (SAT): An alternative 6-cylinder engine architecture was developed, integrated and optimised for aircraft installation. Technology improvements were made to the core engine (power density), turbocharger, propeller and engine control system. A ground test of an engine demonstrator was completed.
More Advanced European Small TurbopROp (MAESTRO):
For the small aero-engine demonstration projects related to SAT [Small Air Transport]: Development and demonstration of technologies in each area will deliver validated compression, combustion and power turbine systems for small turboprop engines, as well as an optimised propeller. A new stream on hybrid electric application has started.
Read more about CS2 Demonstrators here
Latest Progress and Results
In 2020, the Engines ITD progressed significantly towards the end of the master plan. The initiative on lightweight and efficient jet-fuel reciprocating engines completed its R&I programme and is now concluded. The ‘Turboprop Integrated Power Plant System’, which is in its final stage, continued testing on the ground (TechTP demonstrator) and the entire testing activity is scheduled for completion by the end of 2021.
Further progress was made in the following areas:
- Progress continued regarding the key technologies: Ultra-High Propulsive Efficiency, Very High Bypass Ratio (VHBR) middle of market turbofan technology and VHBR large turbofan demonstrator.
- In 2020, work continued on technology bricks for core engines in order to prepare the engine ground test demo. This engine demonstrator is addressing the segment for short and medium range passenger aircraft. Multiple maturation studies have also continued to consolidate the architecture for the ground test demo (GTD) of the future installed propulsive system (IPS). Several significant milestones were achieved despite the Covid-19 crisis.
- For the advanced geared engine configuration, the design of the two-spool rig, as well as the engine technology demonstrator activities, passed their preliminary and critical design reviews respectively. This progress makes the delivery of the technology evaluator target engine deck (data) possible, in line with 2nd Technology Evaluator Assessment planning.
- The VHBR large turbofan demonstrator continued, making significant progress regarding the key technologies and manufacture of components. The first engine will be ready for test at the end of 2021.
- Work progressed on the reliable and more efficient operation of small turbine engines. After achieving the objectives for loop two (improvements in a conventional turbo-prop engine), the programme has entered its third loop (hybrid-electric powerplant).
- Activity on the eco-design engine has been consistent with the work programme.
Read more in the latest CS2 Annual Activity Report (3.28 MB) "pdf" and Highlight Report
CS2 Members in Engines ITD
Leaders Engines ITD
- Airbus
- Deutsches Zentrum Fuer Luft - Und Raumfahrt Ev - DLR
- Fraunhofer-Gesellschaft zur Foerderung der Angewandten Forschung E.V
- MTU Aero Engines Ag
- Piaggio Aero Industries Spa
- Rolls Royce Plc
- Safran
Core Partners Engines ITD
- Akira Technologies SARL
- ANSYS UK LTD
- Egile Corporation XXI SL
- GE Aviation Czech s.r.o
- GE Aviation Systems Limited
- GE AVIO Srl
- GE Marmara Technology Centre
- GKN Aerospace Sweden AB
- ITP Industria de Turbo Propulsores S.A.
- MT-Propeller Entwicklung GmbH
- OFFICE NATIONAL D'ETUDES ET DE RECHERCHES AEROSPATIALES - ONERA
- Stichting Nationaal Lucht- en Ruimtevaartlaboratorium (NLR)
- University of Nottingham
CS2 GAPs in Engines ITD
In total, 74 Grant Agreements for Partners were awarded in the Engines ITD, representing a total EU contribution of €80.38 m.
Clean Aviation Annual Forum 2024: Aviation as a major contributor to the European Green Deal
Clean Aviation’s flagship event took its way back in a fully in-person format, welcoming over 400 attendees in Brussels on 5 and 6 March to explore how we can collectively overcome the hurdles to climate-neutral aviation.