FACC AG recently received the approval of the first article parts and the go-ahead for series production of bypass ducts for the new PurePower® PW814 and PW815 engines by Pratt & Whitney Canada, thereby reaching an important program milestone. The Austrian aerospace industry supplier is contributing innovative composite technology to the new engine family, with responsibility for development and production of the bypass ducts.

In mid-November, after more than two years of development work, FACC delivered the first article parts to Pratt & Whitney Canada (P&WC) in Quebec, where they were assembled with the engine. Following a successful test run and product release by P&WC, FACC is now commencing series production of the components at its Aerostructures plant in Ried (Austria). FACC's involvement in the PW800 program comprises deliveries throughout the service life of the engine family and a planned order volume of around 150 million US dollars. "FACC ranks among the global market leaders in the design and production of bypass ducts – thanks above all to the longstanding close collaboration with Pratt & Whitney Canada," explains Walter Stephan, Chairman of FACC AG. "We are constantly seeking new solutions to make aircraft engines even better, stronger, safer and lighter. So we are all the more pleased that we can play a significant role in the next generation of engines for business jets."

Composite innovations for primary engine structures

Bypass ducts are structural components that shroud the outer airflow of jet engines. They need to be extremely wear-resistant, while simultaneously reducing noise and being capable of bearing very high loads in extreme flight situations. All this with minimum possible weight.

Bypass ducts were formerly made of metal. FACC began very early with the development of engine structures made from high-quality, lightweight composite materials. The company's years of design experience and excellent production expertise were a decisive benefit in developing the PW800 program: The FACC engineering team devised an efficient and economical production concept for manufacturing high-strength bypass ducts with low weight and optimum acoustics, which also offer excellent reliability and safety. Specialized production technologies, state-of-the-art automation and process optimization combined with a global supply chain provide the main benefits in terms of cost-effectiveness. Günter Nelböck, Director of Engine Programs at FACC, stressed: "The years we spent building production expertise place us in a very competitive position for optimally meeting demanding customer requirements with regard to strength, weight, and reliability. Thanks to innovative composite technologies, we achieve the necessary functionality with far fewer components. We need fewer rivets, screws, bolts, and subcomponents. Unnecessary interfaces are avoided and the number of individual working steps is lower. Consequently, our integral composite concepts are also a cost-effective solution."

Alongside those for the PW800 engines, FACC also supplies bypass ducts for other engine families made by P&W Canada and P&W USA, as well as components for various Rolls Royce engine families.

Eco-efficient engines for new Gulfstream jets

The new PurePower® PW800 engine series is characterized by high fuel efficiency, lower emissions, and less engine noise. With 16,000 pounds of thrust, it is specially designed for fast, long-haul business aircraft flying at high altitudes. Gulfstream Aerospace also relies on this first-class performance: The American business jet manufacturer decided in favor of the PW814 and PW815 engines for its new, efficient Gulfstream G500 and G600 jets, as announced ceremoniously in mid-October at the market launch of the next generation of Gulfstream aircraft. Certification of the PW814 and PW815 engines that will power the Gulfstream G500 and G600 respectively is expected before the end of 2014.