Safran Aircraft Engines has recently achieved major milestones in the technological readiness of large-diameter fan blades developed for the Open Fan architecture of the CFM RISE technology demonstration program1.
As part of Research & Technology programs supported by the French Civil Aviation Authority (DGAC), Safran Aircraft Engines has recently tested three fan blade configurations to demonstrate the mechanical integrity of these critical components in an unducted architecture and validate improvements in aerodynamic and acoustic performance. Over 175 ingestion and endurance tests have been carried out in the test facilities at Safran’s Villaroche center, which were specially configured to accommodate large-scale components, in addition to the 300 hours of wind tunnel tests on a scaled-down Open Fan model at ONERA (France) and DNW (Netherlands), in partnership with Airbus.
The design of these fan blades, which are over 1.6 meter in length, leverages Safran’s expertise in advanced 3D RTM (Resin Transfer Molding) composite materials and processes, developed through its Safran Composites innovation platform. This composite technology, already in use on the LEAP engine’s fan blades and fan case, has proven its benefits in terms of weight reduction and durability, with more than 70 million flight hours logged by the CFM International engine since its entry into commercial service in 2016.
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Download free sample pages“Thanks to the R&T capabilities developed within Safran, we now have the cutting-edge processes and materials we need to address the technological challenges of the CFM RISE program,” said Pierre Cottenceau, VP Engineering and R&T for Safran Aircraft Engines. “In the last few months, we have conducted numerous test campaigns with full-scale fan blades at our Villaroche facility. The highly promising results from these tests are enabling us to expand our technology portfolio and help define the next generation of engines in line with our decarbonization objectives.”
The two rows of blades at the front of the Open Fan architecture play a key role in the engine’s energy efficiency. Launched in 2021, the CFM RISE program aims to improve fuel efficiency by more than 20% compared with current engines, by combining disruptive technologies with the development of an Open Fan demonstrator.
RISE is one of the most extensive technology programs in the aerospace industry, with over 350 component and module tests already completed to date, including major tests conducted by Safran on the low-pressure turbine and compressor, bearing systems and equipment for the new pitch control functions of the Open Fan. Safran Aircraft Engines has also advanced the development and readiness of hybrid-electric systems, leveraging synergies with other Safran companies to conduct a hybridization test campaign on a full-scale engine.
A new engine test facility is currently being built at our Villaroche center. Operational next year, it will boast an 8-meter-wide chamber and will be used to test large-scale modules as well as the pitch control systems for the Open Fan.
