Rolls-Royce has unveiled its new initiative to enhance its Trent-series widebody engines, with a focus on increasing their durability and time-on-wing, particularly in hot and sandy environments.
Under the £1 billion technology insertion program, the company aims to introduce a series of improvements across the Trent XWB-97, Trent 7000, and Trent 1000 engines. These engines are utilized in popular aircraft such as the Airbus A350-1000, A330neo, and the Boeing 787.
Rolls-Royce group director of engineering, Simon Burr, highlighted that recent advancements in fuel-burn efficiency have led to a reduction in durability. Consequently, the company is prioritising addressing this balance by integrating matured technologies from the UltraFan demonstrator program in order to achieve a significant increase in engine durability.
Initial enhancements involve increasing the temperature margin on hot-section components and improving turbine case cooling, already in service. Subsequent phases will introduce CMAS-resistant coatings to high-pressure turbine seals for increased durability, particularly in the presence of sand. Additionally, Rolls-Royce plans to incorporate further modifications to the HPT components from 2028, promising substantial improvements in engine life.
Other upgrades include revised HPT blades for enhanced cooling, the addition of ceramic matrix composite material to the HPT seal, and updates to the combustor for a more uniform thermal profile, all contributing to increased longevity of the engines.
Rolls-Royce has rigorously tested these enhancements, including simulated dust-ingestion rig testing using sand matching the composition found in the Middle East. Despite the years of development behind these enhancements, the company continues to refine and improve the technology, with the aim of addressing concerns raised by industry leaders, such as Emirates Airline president Sir Tim Clark, at the Dubai air show.
In addition to the upgrades for new-build engines, Rolls-Royce is also focusing on further improvements to the Trent 7000 and addressing the durability concerns with the Trent 1000, aiming to regain its market share. The company is scheduled to commence flight-testing of the improved Trent 1000 version in August. Furthermore, certification for the Enhanced Performance version of the XWB-84, offering a 1% improvement in fuel consumption, is expected later this year.
Rolls-Royce also plans to introduce turbine discs made from a new proprietary superalloy, RR1073, to further enhance the durability of the engines. Components made from this superalloy have shown the ability to withstand higher temperatures and have a more predictable lifespan compared to the current material.
Overall, these technological advancements and upgrades by Rolls-Royce signify a significant step forward in enhancing the durability and performance of their Trent series engines, ultimately benefiting the aviation industry as a whole.