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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
1
Lessons learnt, the way forward and
key partner contribution
ecoDESIGN ITD,
Clean Sky Closing Event Brussels, 22nd March 2017
John Simpson
Fraunhofer Gesellschaft
General Director Aviation
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Eco DESIGN a success story in green aviation
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CSJU footnote: “ecoDESIGN is in the essence of the Clean Sky DNA and design
philosophy, underpinning every project and initiative we undertake across all programme
areas, ITDs and IADPs
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ecoDESIGN/ Best value research through partner collaboration
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Key Material Innovation Integration
Key Specialist Eco Technology Integration
Key Technology Portfolio
Excellence in Detail
First Clean Sky Project: CORA
Clean Sky Awards Winner 2016: SENTRY
Accolade of CfPs, key words appended
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Example, Eco-Statements – Trade off lesson (s)
∆ = Partial
replacement
of petrol
based polyol
Global Warming Potential [kgCO2e/kg PUR foam]
∆ =
∆ =
No flame
retardant
1.4 – 2.4
↓ 7 % - 12%
Green PU seating cushion
A/c -seat 10-14kg, on the cushions ->
4
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Lessons, Implementation and more
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• The reduction of the manufacturing costs & time combined with decreased energy consumption, due to
higher integration of automated manufacturing processes
• The improvement of environmental aspects (e.g. substitution of noxious substances, less waste, reduction
of primary resource consumption, increased recycling ratios)
• The creation of customized LCA models for current and future aircraft, covering production maintenance
and end of life – CS Materials DataBase, BOM, BOP,
advanced Aeronautics Materials, Clean Technologies(Cr6 free etc.)
• Less fuel consumption through (clean approach) lightweight architecture (multifunctional materials, new
processes & more efficient use of resources) and efficient energy management which consequently results in
CO2 and NOx emission reduction
• New ecolonomic Machine Architecture potentials, keeping an emissions benefit margin, beckoning design
investigation sensitivity at high TRL for tomorrow
in key areas e.g. High Voltage and High Temperature (ElectricB and ThB)
with low SNR Disturbance and optimal Energy Management Sink
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• increased aircraft availability through more efficient maintenance
(repair, longer lifetime etc.)
• reduction of ground and flight tests during the design phase as well
as reduced buy to fly ratios through innovative concepts and
technologies
• benefits in recycling and corrosion resistance (innovative surface
treatment, reduced use of sealants by improved welded joint designs)
• clean manufacturing conditions: no dust, no chemicals..
process efficiency opportunities… advanced skills (socio-economic
impacts)
• less energy consumption due to “Out of Autoclave” processes
Lessons, Implementation and more
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AChSo Novel preforming of textiles (chemical stitching) ACID Advanced Composite Integrated Skin Panel structural testing
ADVANCED Advanced heating system and control for homogeneous high temperature curing of large composite repairs
AEROBEAM SLM and EBW for direct manufacturing of titanium stator vanes AiMeRe Recycling routes screening ALT
Aluminum alloys for high temperature applications AMICOAT Cromium free primers (fungus growth inhibition) APRIL
Advanced preform manufacturing for industrial LCM-processes BFCLeaner Borate free Cleaners for Aluminum Alloys
BIO_LCA_TOOL Simplified LCA Tool development BIFTTEC bamboo fibers BiMed Repair solutions (paint removal by
bicarbonate blasting) BME CS 27 Development of an innovative bio-based resin for aeronautical applications BRIGHT
Applications of bio materials to cabin interiors CF-THREAD Accelerated testing methodology (composites structures)
COMAG Conductive coatings for Mg sheets CONDUCTOR Repair solutions (flexible inductive heating device) Co-Proclam
Corrosion protective coatings on light alloys by micro-arc oxidation CoSPI Reduction and reuse of wet/dry composite materials
(infusion induction) CR FREE EPAINT Cr free coatings (anaphoretic paint) CHROMFREE Multi acid anodyzing (TSAA
cromate free sealing) DEFCODOOR Development of an eco-friendly final consolidation step using thermoplastic fibre
placement for a helicopter door DISACOP Disassembly of eco-designed helicopter demonstrators DIMAG Development and
implementation of magnesium sheets in A/C ECEFA Aluminum alloys for B2 demo ECO-FAIRS ecoDESIGN and
manufacturing of thermoplastic structural fairings for helicopters ENDAMI Industry LCA tool simplified and advanced
applications Extra-laser Extrapolation and Technical and economical study of a LBW technology FATIMA Accelerated testing
methodology (fiber reinforced laminates)
Accolade of partner projects I
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FIBIOSEAT Cushion polyurethane foams GELAIR Application of sol gel technologies on low weight green metallic fuselage
section HI-STA-PART High Strength Aluminium Alloy parts (Aluminium Scandium Alloy-Scalmalloy) by Selective Laser Melting
(SLM). Comparison with existing manufacturing methods. HiTemComFil Manufacturing of high temperature composite parts for
air cooling unit by filament winding HVRCFM Recycling into new fabric ILMAS Extrapolation to industrial condition of the
liquid infusion manufacturing process IMAGINE Processing for glass fibers reuse IRECE Extrapolation to industrial condition of
a cured composite and thermoplastic recycling process IRIDA Industrialisation out of autoclave polymerization for LR
ISINTHER Thermoplastic processes (in-situ consolidation) LAWENDEL Laser Beam Welding (LBW) approach LIBSAC
Identification and mapping for recycling (laser induced spectro) LCA-DATIM Life cycle assessment database improvement LEAF
Tool for ecoDESIGN Airframe simplified LCA LIGHTWELD Characterization of metallurgical joining technologies (through
Laser Beam Welding LBW) for Mg – Al and Mg – Al-Li joints LRI-HiT LRI and out of autoclave curing MAGNOLYA Advanced
environmentally friendly chemical surface treatments for cast magnesium helicopter transmission alloys preservation MIFACRIT
Methodology toolbox for Aacelerated fatigue testing of FRP materials: micro-structural failure criterion for multi-axial fatigue of
FRP structures NEMESIS Sustainability assessment for EcoDesign-Guideline OPTOCLAVE Design, implementation and
validation of an automatic learning cure cycle optimisation process for the eco-efficient autoclave processing of composite materials
PlasmaClean Surface mapping and control during atmospheric plasma treatments PLENOPTIMUM Manufacturing
optimization of a plenum with GFRP cyanate ester-based prepreg REMART Recycling of metallic materials from rotorcraft
transmissions SAA-Seal Multi acid anodizing (Sealing on SAA layer) SELFRAG CFRP electro dynamic fragmentation SENTRY
LCA of low weight green metallic fuselage panel(s) including physical dismantling and recycling
Accolade of partner projects II
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SPECIMEN Cyanate ester based composites SUPERBLEND Thermoplastic matrix (similar to PEEK) RASAC Identification
and mapping for recycling (raman spectro) SUSRAC Sustainable recycling of aircrafts composites SPECIMEN Cyanate ester
based composites SUSRAC CFRP recycling (waste filled compound process) TARTASEAL Chromate free and energy efficient
sealing of TSA anodic films for corrosion protection Thermoplastic scroll Manufacturing and optimisation of a PEEK scroll by
fusible core injection molding for E-ECS MTC TIFANManufacturing by Selective Laser Melting (SLM and bar machining) of
Titanium Fan wheels VALIDATE Validation of TSAA coating technology WISMOS Wireless integrated strain monitoring and
simulation
(EDS systems level)
AEGART Generator design and Construction AEROTHERMOPROP Thermophysical Properties Library for Relevant Fluids
AeroL-HP Heat pipes BESTT Development, Construction and Integration of Bench Systems for Ground Thermal Tests CORA
Sensor for Convective and/ or Radiative Heat Loss ELTESTSYS Electrical test bench drive systems: mechanical interfaces
EPOCAL Electrical Power center for aeronautical loads HEMAS Helicopter swash plate EMA High PMAAC Electrical
Test Bench Control System I PRIMES Intelligent Power regulation using innovative modules for Energy supervision MAS DE
NADA Modeling and advanced software development for electrical Networks in aeronautical domain analysis SEPDC Electrical
Test Bench Power Center SMART Saber model automatic translation tool SPLS Advanced programmable loads SUPREMAE
Software for saber models conversion to multi-systems simulation platforms
Accolade of partner projects III
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Dissemination & Communication Analyses, CFP/ GAP
[ JU 17. Dec. 2015,
I. Bitsios with 65 from 69 (Spring- 2016 wrapped- up)
GAPs]
GAM 2011*-15 Total 225 Final Report 2016
GAM 2008-15 Total 348 Fraunhofer Monitored
Weighted Mutiannual, JU,
2009-2016, Dissemination & C.
GAM: 216
GAP: 317
ecoDESIGN-GAM, Reference
technical delivery closure: Dec. 2015 317
* 2011 means 2008 - 2011 CSJU weakly accounted,
Advocacy up to 2008 and into 2009 NOT AT ALL
Numbers for
Deliverables Outputs/ Inputs are taken as duty
to the core GA purpose and are NOT INCLUDED
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CFP/ GAP, Leading, exploitable foreground cases
[ JU 17. Dec. 2015, I. Bitsios]
GAM : 53 Final Report dB/ 2011-15
GAP:
Total = 192
Environmental Benefit Technologies
infused to connected EDA components
Pathway-
Total = 176
139
Total 176
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Dissemination & Communication
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Events 2016
• JEC Europe, 8th to 10th March 2016, Paris, France
• 3rdEuropean Aircraft Recycling Symposium, 16th and 17th March 2016, Stuttgart, Germany
• Clean Sky Forum, 4th March 2016, Brussels, Belgium
• ILA Berlin Air Show, 1st to 4th June 2016,
Berlin, Germany (Fraunhofer booth)
• Farnborough Air Show, 11th to 17th July 2016,
Farnborough, United Kingdom
recent
procedings in analysis
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JEC Paris
The demonstrator EDA A3 at the JEC in Paris.
The demonstrator EDA I2 at the
JEC in Paris.
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Dissemination examples
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Highlights ongoing
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Award
eco DESIGN ENDAMI Tool for Sustainia
Eco DESIGN ENDAMI Tool
made it into the Top Ten in
the category IT.
Statement of the Jury:
ENDAMI addresses the
environmental impacts of
building new aircraft.
Implementation will add no
costs to traditional design
processes. The modular
and flexible structure is
readily adaptable to other
products and sectors.
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Highlights ongoing
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Symposium
Aircraft Recycling Symposium, Stuttgart
Implementation of the Symposium as yearly event since 2013
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News and Themes learnt for the Future?
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Global trends still valid
Globalisation and
Urban sprawl
Demographic
change
Informational
society and
new technologies
Increasing mobility
and transportation
Energy consumption
and resource depletion Climate change
2008 View - Generality
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Boundary conditions 2016?
-> more circular and inclusive thinking is necessary
“Clean Sky is not only an Initiative in the Air”
& “ecoDESIGN is not only a land fill topic for Aircraft Retirement”
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Eco-Innovation (secured creativity) Concerns?
• Emerging standards, awareness on
REACh, primary energy cost risks etc.
are firmly with us, resource scarcity and economic/
material flow competition &
skill flow competition
• If European services/ techn. Labour is not assisted by new
business approaches/ technologies
it will be outsourced from Europe
Staying in Charge of Connectivity
• Europe has to consider which products
it wants to commercialise in the future,
Creativity for that, the outset design domain
[Competitiveness! difficulty for the average-BAU]
2025
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Eco-Design Charta - to date
Eco-Design has key Materials, Processes and Resources impact and a strong relevance from the
Flight Path 2050, European eco-Innovation Agenda and the HORIZON programme.
This goes well beyond full green recyclability and pristine life cycle guidance: Eco-Design serves as synergy
and motivator for partnership in new business strengths, in
the aeronautics manufacturing base of excellence, in new supply chain services (even more
than MRO + Financial Systems) -interactions, advanced material cycles and opening synergies in
innovative technology streams [with ITD/IADPs]
CS2 Regulation[incl. CS delivery] Art. 2
Part III societal-challenge roof top priority and Horizon Regulation annex 1
eco-Innovation chap 4, 5 – & circular connection to part I and II
2(a) supply chain excellence
2(b) contribution to NOx and CO2 reduction
(advanced MPR manufacturing
….. e-learning, future factory, LCA,
connected (circular) productivity,
societal inclusive, „Industry 4.0“
…(real) Free Material Optimisation
additive/ intrinsic quality deployment
… Human-, Information
business connectivity
…. Digital Economy,
(Smart) Mega Trends
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ecoDESIGN future building on Clean Sky foundations
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Where are we in conceptual DESIGN Methodologies ?
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Range
BFL
Ma
FL
PAX
„Life Cycle Derivative“
Basic Conceptual Parameters
New Processes„ Derivatives
Services
Economic end to end drivers
Flight Physics
Innovative Configurations/ Vehicles
Innovative Productivity Models Life Cycle Engineering Value
Integrated Product Policies
-> added supply-chain value
EDS Systematic capability to upscale focus inside -out problems: e.g. 7000GWP - factor Halon Replacement Yes/ NO? Introduction of legacy or new Components, ecolonomic/reliability risk controlled, to free AEA concept Investigations, definition capacity for exploitable hybrid electric, fluidic concepts;
Life Claims (IPR, Marketability/Redundancy/ Re-Use)
Socio-Economic Deriv.
(SED)
EDA
Data Bases connected high TRL – cluster Demonstration (s) Production Phase Impact- Eco Statement; LCA monitored, Environmental Stewardship, Relevant CS Collaboration Scale
Objectives
Academic DOC
or
User Benefit, LCC…
Requirements, Certification Ease
Life Cycle Inventories(LCI) ->
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AP
POCP
EP
Coupling and snow-ball, collective
effects
are a challenge, yet closer, magnitudes higher
ISO 14040..ILCD collaborative application and
communication discourse
value compared to 2008 Status
(just three of the CS1 widely implemented
Potentials, considered impact routes)
[Lindner/ Hauser]
Around 12 SOA solid Environmental Impact Potentials
are now in widespread aeronautics „understanding“ , in high TRL applications
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The inclusive effect of ecoDESIGN
Inputs
Endpoints
Ground Pollution Action Frame,
Sustainability &
Productivity
Empowerment
User Satisfaction/
friendliness – security-
Health/
Working Environm., skills and
process change opportunities
Ecolonomic
differentiators, Connectivity
IPR, Societal-;
Information
Inclusiveness
Energy
Matter (Resources)
Water
Impacts Potential
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[A]: LIFT,
Identification
strategy, Life
scoping
[B]: Materials,
Processes &
Resources
(MPR)
[C]:
Manufacture/
Production
[D]: Services to
component and system
(MRO, financing,
accounting, storage, inside-
outside gate processes, alt.
Parts/ COTS…. Material
Flow Logistics)
[REUP]:
Re-Use
[EoL]:
End of life
[ADS]:
Integration/ Field
Assembly-
Disassembly-
Separation
[ASA]: alt.
sectorial
applications
[UP]: Use
Phase (
partial, socio-
economic
evaluations
derivative)
vertical/ horizontal activity,
ecoDESIGN Themes
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Global Clean Sky eco DESIGN Key Performance Indicators @ 2016
• The RE-cycle, RE-use quota (RRQ),
• The equivalent ground pollution
potential (GPP)
• An “advanced” Eco Statement (ES)
with the socio-economic statement
(SES), owning an Eco Design socio-
economic derivatives set.
Summed,
Bottom-up
micro-economic contributions
State of the art
Life Cycle portfolio
of environmental factors-equivalent
not „just“ GWP
Avoiding waste, reducing GWP
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Eco-Design Guidance
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Reaping ecoDESIGN added values for 2024 and beyond
will probably mean the challenge
of completely new tools and capabilities,
joint and several open mindset to Dissemination and Exploitation,
new partnership experiments to that cause,
building beyond
legacy aeronautical, industrial programmes„ experience
and past decades„ changing R&D networks,
some steps of the ITD-ecoDESIGN-phase 2008-2016;
But luckily we have the community tenure,
pool of innovative connections and resources
through the Clean Sky JTI
to tempt and evolve transversal change
ecoDESIGN Clean Sky Framework Prospectus
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Aknowledgement to the
CSJU ecoDESIGN Core Team Partnership
Recommended