Preparing for takeoff: Breakthrough process innovation at Rolls-Royce

Since their first application in the 1980s, bladed disks (blisks) have become integral components in jet engines. In this case study we examine a technological advance in joining techniques by following the successful development of linear friction welded (LFW) blisks at Rolls Royce. Initiated in 1984 and spanning over 20 years of R&D activity, this advance represents a significant breakthrough in the blisk manufacturing process, as it provides further improvements to weight, aerodynamic efficiency and cost. Providing a historical account of this project, we describe how Rolls Royce drew on government funds to engage in exploratory collaborative research with TWI and MTU before a workshare agreement on the Eurofighter Typhoon allowed for entrepreneurially opportunistic behaviour. Engagement with lead users when developing blisks for the Eurofighter provided Rolls Royce with niche commercialisation, learning opportunities and the platform to demonstrate the capability of LFW blisks for adoption in the joint strike fighter (JSF). This episode highlights how successful breakthrough innovation in the aerospace industry derived from a long-term commitment to exploratory research and a strategic development focus prior to commercialisation.