Summary of the impact

Research in the University of Cambridge Department of Engineering (DoEng), which made it possible for the first time to design a 3D compressor blade as a single component, underpinned the design of compressors in Rolls-Royce civil aero engines. Blades designed using the research results yielded fuel efficiency improvements of 0.8% when deployed in Rolls-Royce Trent engines. The efficiency improvements in engines in service are estimated to have delivered savings of 460k tonnes in CO₂ emissions and USD 145 million in fuel costs during the assessment period. Rolls- Royce's outstanding order book for engines in which the technology made a significant contribution to efficiency is estimated to be worth GBP 27 billion at list prices as at 31 July 2013; orders received during the assessment period are estimated to be worth GBP 18 billion at list prices.

Summary of the impact

Cost savings in the order of £130M over the REF period have been achieved by Rolls-Royce through the improvement of engine reliability of civil and military aero-engines, industrial machines used for electricity generation and gas/oil pumping applications through the use of techniques and processes developed by the Vibration University Technology Centre (UTC) at Imperial College London.

Summary of the impact

Compressors developed at the Department of Engineering Science have formed a key component of the cryocoolers used to cool the infra-red sensors on satellites. Their low mass has trimmed almost $250k from the cost of individual satellite missions. Sixty seven have been sold to date, with sales totalling £2.8M between January 2008 and July 2013; three units are currently in Earth orbit with another nine planned to follow in 2014. A specialised version has been developed to achieve extremely low temperatures, with prototypes already built for the Mid Infra-Red Instrument (MIRI) that will form part of the James Webb Space Telescope.

Summary of the impact

Research carried out at the University of Southampton has enabled major players in the aerospace industry — among them Rolls-Royce, Airbus, and Boeing — to produce more fuel efficient, longer lasting engines and aircraft at reduced cost. The research has provided the aerospace industry with modelling tools and software enabling companies to explore complex new designs quickly whilst managing product risk in a competitive market. The research team has also developed new design processes for unmanned aircraft, which — as a result of strong media interest - improved public understanding of such new technologies through worldwide coverage. A spin-out company has achieved strong technological and economic impacts in its own right.

Summary of the impact

A unified design methodology for tuning gas turbine engine controllers, developed by researchers in the Department of Automatic Control and Systems Engineering (ACSE), is being used by Rolls- Royce across its latest fleet of Civil Aero Trent engines. Trent engines are used to power, for example, Boeing 787 Dreamliner and Airbus A350 aircraft that have been adopted by the world's leading airlines.

This new methodology has made economic impact through the introduction of a new process for tuning gas turbine engine controllers leading to the adoption of a significantly changed technology. Indicators of impact are:

i) a new control law and design practice, resulting in a unified approach for different projects;

ii) reduced development effort by shortening and simplifying the design exercise and rendering it suitable for modular insertion; and

iii) streamlined verification requirements.

Summary of the impact

Diffusion bonding (DB) is well-known for producing structured materials with fine scale features and is a critical technology for high efficiency reactors, e.g. heat exchangers and fuel cells, but currently equipment is slow and expensive (and there are size limitations to the `assemblies' that can be built). The University has researched and developed, with industry partners, a rapid affordable diffusion bonding (ADB) process involving direct heating to provide appropriate temperature and stress states and utilising flexible ultra-insulation (vacuum) for pressing titanium (and now aluminium) sheets together. The process operates at low stresses thus avoiding `channel' collapse. Investment is taking place in the partner companies to exploit the technology. A breakthrough has been achieved in the chemical machining of three dimensional structures for laminar flow technology assemblies in aluminium and titanium, that can be built by ADB.

Summary of the impact

Research from the Sheffield Department of Mechanical Engineering has led to major improvements in engineering analysis and design software for aerospace companies such as Rolls-Royce and Airbus. As a result of introducing new practices based on our research, the organisations have reported significantly reduced time input to design components as well as related economic benefits. For example: Rolls-Royce has reported an order of magnitude improvement in the time needed to mesh components. Similarly, by adopting our highly efficient computational aerodynamics solvers, Defence Science & Technology Laboratory has reduced the time its engineers spent evaluating concepts from many days to a few hours.

Summary of the impact

City University London's patented rack generation mechanism, the `"N" rotor profile', offers substantial improvements on the rotary screw compressors widely used in industry at present. It allows for an increase in compressor capacity and makes compressors more energy efficient. Significantly, it can be easily retrofitted to existing compressors, thereby delivering immediate benefit. The mechanism has already been licensed to 27 major manufacturers around the world, resulting in savings of 0.1% of global electricity consumption and an equivalent reduction in global CO₂ emissions. City academic staff have worked with an existing firm (Howden Compressors Ltd) to raise funds and train researchers for the development of this technology. In addition, a new spin- out company (Heliex Power Ltd) has been formed to build on research developed since 2009. Important examples of the impact include:

• An increase in annual turnover at Howden Compressors Ltd. from £15M in 2009 to £39M in 2011 and a 40 % increase in the number of staff employed.
• The spin-out company Heliex Power Ltd is valued at £15M and has employed an additional 23 people following investment of £7M from BP Alternative Energy and ESB Novusmodus. A further £3M will have been invested by the end of November 2013. Heliex has been named in the 2013 Global Cleantech 100 list.
• An estimated reduction in carbon dioxide emissions worldwide from energy efficiency improvements totalling 30 Mt (0.1% of total emissions).

This research has enabled companies that operate worldwide in air compression, refrigeration, air conditioning, oil, gas and process industries to improve their economic and environmental performance in response to demanding governmental demands.

Summary of the impact

Impact on the environment

• The adoption of cost effective CO₂ reduction technologies across a range of Ford vehicles reduced CO₂ emissions by an estimated 40,000 tonnes in 2012. This reduction applies pro rata for 2013 and becomes cumulative year on year.

Economic impact

• Improvements to vehicle engines have saved over €25M in fuel costs to the owners of Ford vehicles in 2012.
• Research has led to improvements that have been made to Ford products and processes; these improvements have been used to address upcoming legislation on CO₂ in a cost effective manner. Future penalties of up to €0.5bn have been avoided by these improved products and processes.

Impact on practitioners

• Improved monitoring processes, reducing variability in measurement of CO₂ from vehicles within Ford by 50%, facilitating the adoption of a range of new fuel saving technologies, which helped to justify a $50M investment in the Ford UK facilities.

Summary of the impact

This impact is the improvement of aircraft engine efficiency by the application of profiled endwalls to turbine blades. The technology was researched by Durham University and exploited by Rolls-Royce by deploying the technology on airframes. Engines with profiled endwalls include the Trent 900 (A380 airframe), Trent 1000 (787 Airframe) and Trent XWB (A350 airframe). This (as of April 2013) totals around 2000 aircraft engine orders with profiled endwall technology applied. A saving of 1750 litres of fuel per flight from Zurich to Singapore was estimated when profiled endwalls are applied. This gives a 4400 kg reduction in carbon dioxide emissions for such a journey with a fuel cost saving of over $1100. In addition to the environmental benefit and the obvious cash savings for airlines an economic benefit for UK industry has arisen as Rolls-Royce is able to sell engines with a reduced fuel burn as well.