MTU Aero Engines, working alongside strategic partners GKN Aerospace Sweden and the German Aerospace Center has focused on enhancing the LPT and HPC components to influence the next generation of geared turbofan engines.
MTU Aero Engines, Germany’s leading engine manufacturer, has unveiled significant advancements through its participation in the Clean Sky 2 research program. Working alongside strategic partners GKN Aerospace Sweden and the German Aerospace Center (DLR – Deutsches Zentrum für Luft- und Raumfahrt), MTU has focused on enhancing the low-pressure turbine (LPT) and high-pressure compressor (HPC) components. These developments are expected to influence the next generation of geared turbofan engines, marking a substantial leap towards cleaner and more efficient aviation.
“We focused on how our components work with their neighboring modules, and we especially want to optimize their interactions. In our collaboration with GKN and the DLR, we perfectly integrated the strengths of each partner: GKN’s competence with large structural components and DLR’s experience in the area of testing, as well as MTU’s expertise with compressors, turbines, and systems,” said Dr. Claus Riegler, Senior Vice President Technology & Engineering Advanced Programs, MTU Aero Engines in Munich.
Specifically, MTU examined the inlet and exit case for the LPT, and the low-pressure compressor and inter-compressor duct (ICD) for the HPC. The overarching aim was to improve aerodynamics and develop new, lightweight, and temperature-resistant materials alongside innovative manufacturing processes.
The Clean Sky 2 technology program, initiated in 2014 under the EU Framework Program Horizon 2020, is nearing its conclusion this year. Its mission: to make aviation greener and more efficient. Dr. Stefan Weber, Senior Vice President Engineering and Technology at MTU, expressed satisfaction with their contributions.
“What we have achieved shows that we can significantly support the initiative and the EU’s efforts toward clean aviation, as well as the lasting success of the European aviation industry,” concludes Dr. Stefan Weber, Senior Vice President Engineering and Technology, the Munich engine manufacturer. “We were the lead party,” he further added.
EMVAL Engine Demonstrator
To validate the LPT technologies, MTU developed the EMVAL (Engine Material Validation) engine demonstrator. Built and tested in Munich, this test vehicle was an MTR390 engine, typically used in Tiger helicopters and provided to MTU by the German Army. Integrating the new technologies required redesigning, building, and attaching a complete power turbine to the core engine.
The comprehensive testing program yielded impressive results. The analysis of material behavior under engine conditions demonstrated the readiness of these technologies for operational use. The focus was on optimizing innovative, highly heat-resistant materials, such as fiber-composite ceramics, and advancing manufacturing processes for heat-resistant disc materials and additively manufactured components. GKN Aerospace contributed the turbine exhaust case for this project, showcasing their collaborative strength.
Two-Shaft Compressor Rig
Concurrently, the two-shaft compressor rig was developed to validate new compressor technologies, constructed at DLR in Cologne. GKN Aerospace played a crucial role here as well, designing and manufacturing the low-pressure compressor and the inter-compressor duct.
This expanded compressor rig comprises a low-pressure compressor, inter-compressor duct, and HPC. A critical step was measuring flow conditions in short, steep inter-compressor ducts. To facilitate this, a wind canal rig, known as the ICD rig, was built at DLR in Cologne, the MTU Center of Competence (CoC) for engine systems. Various ICD configurations were tested to ensure comprehensive validation.
The final test series for the two-shaft compressor rig is now underway, with results expected by the end of the year. The focus is on validating the designs of individual components and the performance of the entire compressor system. These advancements promise to significantly enhance the efficiency and environmental sustainability of future aviation technologies.
Looking Ahead
MTU Aero Engines’ progress within the Clean Sky 2 program highlights the company’s commitment to innovation and sustainability. By refining critical engine components and collaborating with esteemed partners, MTU is driving the aviation industry towards a greener future. The outcomes of these initiatives not only align with the EU’s environmental goals but also reinforce MTU’s position as a leader in aerospace engineering.
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As the aviation industry continues to evolve, the integration of these advanced technologies will play a pivotal role in shaping more efficient, eco-friendly engines, ensuring a cleaner and more sustainable future for air travel.
