UltraFan 30: towards a turbofan with 30% lower emissions

An engine for the aviation sector’s energy transition

Aviation accounts for nearly 3% of global CO₂ emissions. To meet carbon neutrality targets, engine manufacturers are investing in innovative architectures, sustainable fuels, and hybrid propulsion. The UltraFan 30 turbofan is part of this transition.

What is a geared turbofan?

In a conventional turbofan engine, the fan and the compressor are driven at the same speed by a common shaft. This configuration limits fan size and reduces the bypass ratio, that is, the ratio of air flowing around the combustion chamber to the air passing through it. A geared engine uses an epicyclic gearbox positioned between the turbine and the fan, allowing the fan to rotate more slowly than the compressor. This optimization increases the bypass ratio, reaching more than 15:1, while reducing fuel consumption and noise. Rolls-Royce has already demonstrated mastery of this technology with its high-thrust UltraFan demonstrator, and UltraFan 30 adapts it to a mid-size engine.

Materials and innovation

UltraFan 30 incorporates fan blades made from carbon-fiber and titanium composite materials, offering strong resistance to impact and high temperatures. The casing and compressor blades also use metal-matrix composites to reduce weight. The engine features advanced cooling technologies and a module designed to reduce nitrogen oxide (NOx) emissions. Overall, it is expected to deliver a 30% reduction in greenhouse gas emissions and a significant decrease in noise compared with engines in service in 2020.

A European consortium

The UNIFIED project brings together Rolls-Royce, GKN Aerospace, MTU Aero Engines, Avio Aero (a GE company), the French Institute of Mechanics, and several universities. Each partner contributes its own expertise: GKN is working on composite structures, MTU on compressors and turbines, and Avio Aero on gear systems. The project is backed by €64 million in funding from the EU’s Clean Aviation partnership, which supports innovations for more sustainable air transport.

Next steps

Current work is focused on detailed design and digital validation of the engine. Manufacturing of the first components is expected to begin by 2027. Ground testing, scheduled for 2028, will be used to assess performance and reliability. If successful, UltraFan 30 could power the next generation of European single-aisle aircraft in the early 2030s.

Source : https://www.aerospacetestinginternational.com/news/rolls-royce-secures-eu-funding-for-ultrafan-30-testing.html#:~:text=The%20Rolls,Royce