JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 43
fan system for aero-engines
Hideo Morita, Doctor of
Engineering, Deputy Division Director,
tsutoMu MurakaMi, Manager, Engineering Dpt,
IHI Corp., together with its partners, recently developed an innovative
lightweight composite fan case and the first composite structural guide
vanes in the world. These technologies were applied successfully to the
Airbus A320neo, powered by the PW1100G-JM engine.
katsuyosHi Moriya, Manager, Engineering Dpt.
Civil Aero-Engine Division, Aero-Engine
& Space Operation, IHI Corporation
Significant weight reduction
The fan system, including the fan
case and SGVs, is a primary structural
part that typically increases in size
with an increasing bypass ratio. The
PW1100G-JM engine has a significantly higher bypass ratio than conventional aero-engines such as the V2500.
Applying composites effectively to the
engine components resulted in innovative advantages, including more than
20% weight reduction compared to the
V2500. In this project, a thermoplastic
material was selected for the SGVs and
it was the first time such a material was
applied to primary structural engine
parts. The thermoplastic parts for the
As part of this innovative project, the
materials were fully controlled by IHI
and IHI Aerospace as qualified materials
for aero-engines originally developed by
IHI and their partners.
The thermoplastic composites for the
SGVs showed extremely low delamination after testing at high velocity impact,
while the thermosetting composites for
the fan case exhibited superior impact
absorbing energy in high-velocity
impact testing, which was much better
than that of so-called toughened resins.
IHI manufactures these innovative
products at its own sites (IHI Soma
factory and IHI Aerospace). The SGVs
are processed by prepreg automated
cutting and laying up, press forming,
followed by machining, bonding,
painting and inspection processes.
The fan cases are produced by prepreg
automated winding, autoclave cure,
and then machining, bonding and
Flying in the sky
The PW1100G-JM engine was certified by FAA in December 2014, while
the Airbus 320neo was certified in
November 2015. Commercial flights
with the engine started in January
2016. These innovative composite fan
parts are now in production at IHI's
Soma factory and at IHI Aerospace.
Part of this technology research was
conducted as part of a contract with
Japanese Aero Engines Corporation,
partially funded by the Ministry of
Economy, Trade and Industry of Japan,
as a part of the project "Advanced
Materials & Process Development for
Next Generation Aircraft Engines".
It is the first time that thermoplastic composites are
selected for primary structure parts in aircraft engines.
No112 April - May 2017
/ jec composites magazine
his innovation reduces the
fan's weight by over 20%, thus
contributing to lowering the
fuel consumption of the PW1100GJM engine. It was developed by IHI
Corporation, IHI Aerospace and their
partners - the Industrial Technology
Centre of Fukui Prefecture, Mitsuya
Co., Shindo Co., Mitsubishi Rayon
Co, Ltd., and Toray Industries, Inc.
- and manufactured using IHI's own
materials, a thermoset for the fan case
and a thermoplastic composite for the
structural guide vanes (SGV).
SGVs are manufactured using a specially
designed and controlled manufacturing