GKN Aerospace has agreed a long term agreement (LTA) with Rolls-Royce plc to supply components for the latest version of the Trent 1000 engine – a capability enhancement of the existing Trent 1000 engine for the Boeing 787. This LTA is estimated to be worth more than USD200m over the life of the agreement.

The agreement gives GKN Aerospace responsibility for the supply of the outer guide vane (OGV) mount ring and the rear fan case for the engine. Manufacture is taking place at the company’s sites in Newington, Connecticut, El Cajon, California and Mexicali, Mexico from where delivery of initial development units is already taking place. When in full production GKN Aerospace expects to supply up to 150 engine sets annually.

GKN Aerospace has optimised a number of advanced fabrication and assembly techniques to minimise the buy to fly ratio for each component, cut material wastage and limit exposure to material price fluctuations. Traditional ring forgings, which require extensive machining, have been replaced with near net shape materials which require minimal finishing. Techniques such as electron beam welding and plasma welding as well as optimised mounting solutions have reduced manufacturing and assembly complexity and cost. In addition, skilled chem milling of the rear fan case has lowered this component’s weight by more than 40lbs.

Mike McCann, Chief Executive, GKN Aerospace – Engine Systems comments: “We have been manufacturing these components for the Trent 1000 since 2005 and have been working with Rolls-Royce from the outset to develop this near net fabrication scheme. This agreement allows us to optimise a number of processes that will improve the performance of the Trent 1000 engine and simultaneously reduce the environmental impact of manufacture.”