Challenges and Opportunities for Future Aerospace Propulsion Systems

In the field of aerospace propulsion systems, economic demand and concern for the environment has stimulated advancements in aircraft system design.  Aircraft performance improvements depend largely on the engines.  Historically, engine fuel burn has improved at rate of about 1% per year.  With the cost of petroleum based fuels rising and no end in sight, the engine manufacturers must innovate to realize step change improvements to fuel burn, noise, and emissions. 

Materials have played an important role toward improving propulsion system performance by enabling operation at higher temperatures and pressures.  However, targeting improvements through material changes alone limits potential and may not fully address environmental demands.  Changes in system architecture, combined with continued advancement of materials, has opened up the possibility to game changing improvements.   Pratt & Whitney’s Geared Turbofan™ architecture has resulted in a double-digit percentage improvement in fuel consumption. 

To fully leverage advantages of new engine system architectures, advancements in material systems and integrated materials solutions, such as hybrid-material construction and rapid manufacturing methods, must continue.  The challenge now becomes the speed to develop and integrate new material technologies into the product as well as cost effectiveness of the technology.  An overview of the recent advances in propulsion system design will be presented along with a review of how materials and manufacturing methods are playing a critical role in the development, realization and deployment of new systems with unprecedented performance and durability.