Call 15 Infoday SAGE Topics - Clean Sky › sites › default › files › documents › calls › infoday2… · Prelim. DR March 2011 Concept DR Dec. 2009 Concept studies Technology

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Call 15 Infoday

SAGE Topics

Brussels, 16/07/2013 P. Trinchieri (Eco design Project Officer)

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SAGE (Sustainable And Green Engines)

AFHE

6 demonstrators with

evolutionary and revolutionary

technologies with challenging

environmental objective

Main Members and Affiliates: Rolls Royce

plc, Rolls Royce Deutschland, SNECMA,

MTU, Turbomeca, Volvo, AVIO, ITP, … Total budget > 420 M€

SAGE1

SAGE2

SAGE3

SAGE4

SAGE5

SAGE6

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Contra-Rotating Open Rotor – Concept Challenges

Power Turbine

Propellers

Pitch Change Control

Protective

Air Intake

Rotating

Nacelle Parts

Noise

& Vibration

Operability

& Power Management

Certificability

& Reliability

A/C Installation and

wake interaction

Counter-rotating

propellers, noise optimised

De-icing

Communications via

rotating systems

Power gearbox

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Technologies for

lightweight, efficient

intercase structures

Composite fan case

Composite fan

blades

Novel intake with

optimised aero and

acoustic liners

Advanced integrated

dressings

Lightweight, high

efficiency LPT

Improved controls

heat management

Advanced sealing

technologies

Lightweight annulus

fillers

Intake optimised to

composite fan

system

Large 3 shaft Engine – Concept Challenges

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Project launch

1 June 2009

Lightweight intercase

structures, material

characterisation and

manufacturing technologies

Trent 1000 core engine

Composite fan system

Integrated installations

Test programme

Low Pressure Turbine

and structures

Build 2

engine test

2013

Prelim. DR

March 2011

Concept DR

Dec. 2009

Concept studies

Technology

selection for

demonstration

Prelim. Design

Process

development

Partner selection

Detail design

Manufacture

Rig testing

Phased build and

technology

demonstration

Critical DR

August 2011

Build 1

engine test

2012

Large 3 shaft Engine – Participation & Schedule

http://www.itp.es/index.php

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August 2012: the first fan case engine build was achieved (advanced dressings)

More on Skyline October 2012

http://www.cleansky.eu/content/document/skyline-issue-8-october-2012

Large 3 shaft Engine - Achievements














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Advanced Geared Turbofan – Concept Challenges

New High Efficient High

Pressure Compressor Mid Turbine Frame with

aggressive Interduct

New High Speed Low

Pressure Turbine

New Lightweight

Exhaust Frame

Advanced Fan Drive

Gear System

Temps & Materials

Weight & Mech.

Integration Innovative Designs

& Mfg Processes

Efficiency &

Performance

Engine Control & Power

System

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Advanced Turboshaft – Concept Challenges

High efficiency HP

turbine

Innovative rear

support architecture to

reduce power losses

High efficiency

Compressor

Low weight

gearbox

One stage low weight

high efficiency BP

turbine

Low Emission

Combustion Chamber

Air intake acoustic

attenuation

Exhaust and plug

acoustic attenuation

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Advanced Turboshaft – Achievements

Turboshaft-engine demonstrator assembly started in August 2012.

The first rotation runs in March 2013.

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Lean Burn – Concept Challenges

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SAGE: Next plans and demonstrations

Large Three-shaft Engine Demonstrator

Lightweight fan system • Advanced external engine components and accessories

• Advanced ‘inter-case’ structures

• Lightweight and efficient Low-Pressure Turbine

Contra-Rotating Open Rotor Propeller Design

Pitch change mechanism

Gear Box

Rotating structure

Advanced Geared Turbofan Demonstrator

New highly efficient HP-Compressor • Light weight high speed Low-Pressure Turbine

• Advanced light weight and efficient Turbine Structures

• Light weight and reliable Fan Drive Gear System

• New systems for a more electric engine

Q4/2013

Q2/2013

Q4/2015

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SAGE: Calls for Proposal – Call 15

BudgetMax JU

contribution

JTI-CS-2013-02-SAGE-01-002 600000 450000

JTI-CS-2013-01-SAGE-02-032 500000 375000

JTI-CS-2013-02-SAGE-02-034 1000000 750000

JTI-CS-2013-02-SAGE-02-035 450000 337500

JTI-CS-2013-02-SAGE-02-036 450000 337500

JTI-CS-2013-02-SAGE-02-037 200000 150000

JTI-CS-2013-02-SAGE-02-038 550000 412500

JTI-CS-2013-02-SAGE-03-024 1750000 1312500

JTI-CS-2013-02-SAGE-03-026 1500000 1125000

JTI-CS-2013-02-SAGE-04-025 700000 525000

JTI-CS-2013-02-SAGE-06-003 1500000 1125000

JTI-CS-2013-02-SAGE-06-007 900000 675000

10100000 7575000Total

Call 15 SAGE Topics

Validated Design Methodology for Fuel Manifold Systems

Innovative instrumentation for rotating gauges

Effect of tolerance variation in high power density gears

Electric Pump for Safety Critical Aero engine applications

High bypass ratio fan capability acquisition

Development of materials, processes, and means to enable the application of

piezoelectric materials in aero engine controls.

Scouting high performance steels for gears and bearings

Fracture mechanic investigation of a new high temperature Ni-based casting alloy

Study and durability of electrically insulative material in aircraft engine chemical

environment

Non-rigid geometry variation simulation for fabricated aero engine structures

Health Monitoring -Wireless Captors

Non-intrusive Turbine Blade measurements

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SAGE-01-002: Fracture mechanic investigation of a new

high temperature Ni-based casting alloy

Objectives:

This topic intends to generate part of the necessary material property database and also contribute to the deeper understanding of important failure mechanisms and hold time effects by detailed fractographic and microstructural investigations for a new high temperature alloy

Main activities:

Casting of test material

Preparation of mechanical test specimens

Mechanical testing (Low cycle fatigue, creep, crack propagation)

Material characterization before and after test.

Special skills requested:

Mechanical testing laboratories should be ISO17025 ILAC approved for test specimen machining

Test results shall be reported as ISO17025 accredited.

Duration: 24 Months ; Topic value: 600 k€

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SAGE-02-032: Study and durability of electrically insulative

material in aircraft engine chemical environment

Background:

For the SAGE2 Open Rotor de-icing system, specific electrical machines have been designed with organic dielectric materials insulation. To enable long lasting reliability of the equipment, insulating material ageing behaviour in aircraft engine fluids such as hydrocarbide lubricant shall be investigated.

Objectives:

The main technical challenges are:

The identification of the organic insulating material ageing behaviour in aircraft engine fluids

The identification of the organic insulating material interfaces ageing behaviour in aircraft engine fluids

Main activities:

State-of-the-art of polymer aircraft engine fluids ageing

Insulating polymers and there interfaces initial state characterisation report

Insulating polymers and there interfaces ageing behaviour characterisation report


Experience in high temperature (above 200°C Tg or Tm) material testing and characterisation

Experience in polymer and their interfaces ageing in hydrocarbide and harsh industrial fluids ageing

Experience in polymer failure mode analysis

Experience in polymer interface testings

Experience in high performance polymer chemistry and synthesis

The applicant should have at disposal equipment and test means for high temperature polymer characterisation and testing


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SAGE-02-034: Health Monitoring -Wireless Captors

Background:

The SAGE2 Demonstration Project aims at designing, manufacturing & testing a Counter-Rotating Open-Rotor Demonstrator. It involves most of the best European Engine & Engine Modules & Sub-systems Manufacturers. Monitoring such an engine requires new technologies, new kind of surveillance and then new sensors. Removing wires is key driver if the number of sensors increases.

Objectives:

The aim of this Call For Proposal is to build wireless sensors prototypes adapted to aircraft engines and to demonstrate their ability to work in this harsh environment. 6 kind of wireless measures to be studied.

Pressure : [0 ; 10 bar] with 10 mbar resolution (objective – min requirement is 100 mbar)

[1 ; 30 bar] with 25 mbar resolution (objective – min requirement is 300 mbar)

Temperature: [-10°C ; 300°C] in a non rotating part, with a 3°C resolution

[-10°C ; 250°C] in a rotating part, with a 3°C resolution

Strain: [0 ; 400 MPa] with 4 MPa resolution

[-200 MPa:+200 Mpa] on a rotating element with a 4MPa resolution

Main activities:

State of the art; Preliminary study; Prototypes specifications; Prototyping; Integration;

Sage 2 prototype delivery; final technical reporting; test support.

Study of each kind of sensor is required but only 2 kinds of sensor prototypes are mandatory


Experience in sensors is mandatory

Experience in wireless technology is mandatory

Experience in Energy harvesting and storage is mandatory

Experience in aircraft engine instrumentation is an asset

Experience in sensors network is an asset

Duration: 30 Months ; Topic value: 1 M€

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SAGE-02-035: Non-rigid geometry variation simulation for

fabricated aero engine structures

Background :

Welded rotating frames will be manufactured (by the topic manager) as weld assemblies in order to accomplish the future targets of light weight, cost efficient and reliable open rotor engines. In these weld assemblies there are narrow offset requirements in the weld seams. This leads to narrow tolerance requirements on interfaces of parts in the assembly to make sure that final product requirements are fulfilled.

Main activities

3D geometry variation simulation for welded assemblies including castings and forgings together with sheet metal parts

Definition of tolerances on ingoing parts

Calculation of forces needed in fixturing

A virtual and a physical demonstration of a weld assembly of a complex geometry component shall be performed. The demonstration must comprise a fixture solution that can vary the fixturing/clamping force.

It is considered beneficial if the geometry assurance research can be complemented by weld distortion simulations.

The main deliverable is a 3D variation simulation methodology solving the stated problem above, verified to TRL 6 by a virtual and physical demonstration of capability.


Methods and knowledge considering non-rigid variation simulation

Experience in weld distortion simulation

Availability of equipment or a supply network for manufacturing of test specimens and fixtures used in physical test.

Experience in performing applied collaborative industrial research in international environment is considered as essential.


Rotating frames in an open rotor engine

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SAGE-02-036: Non-intrusive Turbine Blade measurements

Objectives: • To develop innovative technique for SAGE2 Turbine Bladed-Disk certification during the DEMO Engine Test

Non-contacting Instrumentation Full sample size characterization (All blade amplitudes and Frequencies) High measurement system reliability Low instrumentation Cost

• Potential Further Application in Diagnostic and prognostic for Bladed-Disks Interlocking wearing monitoring LCF - HCF monitoring FOD monitoring

Main activities:

Develop the algorithm and software in order to fit DEMO Turbine

specifications and requirements

Develop probes to be mounted on the DEMO Turbine

Validate the technology in a dedicated spin-test campaign

Mount the technology on the DEMO Engine

Acquired the vibration survey Ground-test data

Special skills requested: Extensive and proven experience in enhanced sensors (e.g non-contacting

measurement techniques), for aerospace products (in particular rotating

sub-modules), design, validation and manufacturing.

Proven experience in aircraft engine and rotating sub-modules instrumentation

(design, validation and manufacturing).

Availability of technologies at an high readiness level to minimize program risks is

an asset.

The Applicant needs to demonstrate to be in the position to have access to the test facilities

required to meet the Topic goals.

Experience in Supply Chain management. Experience in aerospace R&T and R&D programs.

Duration: 30 Months ; Topic value: 450 K€

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SAGE-02-037: Innovative instrumentation for rotating

gauges

Objectives: The Geared Open Rotor architecture introduces a decoupling between the turbomachine speed and the propellers

speeds to allow separate optimization of both systems, with overall efficiency gain of the whole engine, through the

use of a Power Reduction Gearbox (PGB).

There is the need of exploring the possibility of apply latest available instrumentation (e.g. optical strain gauges,

rotating acquisition systems, non-contact measurement) to maximize both learning from revolutionary application

testing and design verification opportunities.

The present Call for Proposal supports the identification and implementation of innovative/advanced instrumentation

into the Power Reduction Gearbox designed by the Topic Manager

Main activities:

Innovative Instrumentation Scouting

Scouting of potential solutions will be proposed about:

- strain measurement of gear body, gear teeth and structural rotating parts;

- metal temperature measurement of gear body, gear teeth and bearing races;

- on-line oil analysis for oil degradation monitoring and indirect monitoring of transmission health status;

- vibration measurements;

- noise emission;

Instrumentation Procurement and Validation

Special skills requested: Experience in:

Enhanced sensors (e.g non-contacting measurement techniques), for aerospace / transmission systems

products, design, validation and manufacturing is mandatory.

Supply Chain management is mandatory.

Aerospace R&T and R&D programs is a benefit.

Availability of technologies at an high readiness level to minimize program risks is an asset.

The Applicant needs to demonstrate to be in the position to have access to the test facilities required to meet the

Topic goals.


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SAGE-02-038: Effect of tolerance variation in high power

density gears

Objectives: The Geared Open Rotor architecture introduces a decoupling between the turbomachine speed and the propellers speeds to

allow separate optimization of both systems, with overall efficiency gain of the whole engine, through the use of a Power

Reduction Gearbox (PGB).

In order to answer the needs of proper design solutions for the PGB Module to be implemented in the SAGE 2 Engine

DEMO, the usage of a dedicated Design of Experiments (DOE) approach has been identified in support of specialized

calculation tools.

Main activities:

Test Plan Definition Validation of the design by component testing: definition of an experimental test campaign supporting DOE approach

validation. The test campaign detail requirements will be shared by the Topic Manager to the Applicant.

Test Articles Procurement Based on the agreed Test Plan and on the reference geometry for the Test Articles (issued by the Topic Manager)

the Applicant will be responsible for:

- Detail Design and Manufacturing Drawing

- Raw Materials Procurement (material specification and quality control on Raw Materials to be supported by the

Topic Manager)

- Test Articles Machining

- Test Article Heat Treatment.

Test Campaign & Results wrap-up


Gear design and LTCA (for T/As design)

Supply Chain management (for T/As procurement)

Experimental testing and Statistical Methodologies (for Test Plan definition and execution).


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SAGE-03-024: Electric Pump for Safety Critical Aero engine

applications

Objectives: The SAGE3 project aims at development and demonstration of a large 3-shaft bypass engine Demonstrator. RTD activities

are foreseen on developing an electrically driven pumps to replace traditional mechanically driven variants in engine

externals. The objective of the topicis to develop this technology and demonstrate to Technology Readiness Level (TRL)6.

Pumping applications can include fuel, oil and other fluidic substances depending on the engine application. For the

purposes of exploring the viability of electric pumping solutions, the oil system is chosen as the candidate fluid for this

demonstration.

Main activities:

Design and analysis of electrically driven oil pump Against the specification, the Partner will conduct the appropriate mechanical, electrical and electronic concept

and detail design of both feed and scavenge elements of an oil pump suitable for deployment in a safety critical

application within a large civil engine environment.

Electrically driven pump manufacturing and assembly Procure all materials and fittings and manufacture all material, test parts and components for rig testing necessary

to support validation of the pump and support design and manufacturing technology.

Electrically driven pump validation support Conduct and report on all testing as necessary to ensure that the unit meets the specification

requirements as appropriate to demonstrate compliance to engine environment TRL6

Special skills requested: Extensive experience in the detail design, development, manufacture and validation of electric drives and pumping

technologies. In-service operation of aerospace applications would be advantageous. Experience of suitable quality

control systems is essential.

Successful experience, with demonstrable benefits, of application of innovative manufacturing and material technologies

to reduce weight and cost of parts is an asset. Availability of technologies at an high technology readiness level to

minimise programme risks is an asset.

Experience in R&T and R&D programs. Experience of aerospace related research programs would be an advantage.

The Partner needs to be in the position to have access to the manufacturing facilities suitable for making an agreed set of

equipment suitable for system integration or engine test if required.

The Partner needs to have access to rig test facilities for vibration & thermal endurance testing.

Duration: 18 Months ; Topic value: 1.75 M€

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SAGE-03-026: High bypass ratio fan capability acquisition

Objectives: Low pressure ratio, high by-pass ratio turbofans are considered an optimum solution for higher propulsive efficiency, lower fuel consumption and lower noise turbofans. In order to de-risk the development of the SAGE3 demonstrator and to support engine data appraisal activities, test data from engine representative rigs is required. At a European level such test capabilities targeting the required pressure ratios and mass flows are currently not available. The scope of the proposal is to acquire the capability to test such high bypass ratio engines in engine representative rig facilities.

Main expectations:

To upgrade a rig facility to enable comprehensive fan performance and noise measurements to be acquired for engine representative low pressure ratio, high bypass ratio rigs

Main deliveries: Preliminary upgrade design study to increase rig test capabilities and achieve required mass flows and

pressure ratios Detailed design and make activities in line with the preliminary design Upgrade the facility, commission the facility and buy off the data from the rig facility

Special skills requested: Significant experience in testing fan systems under engine representative geometries, scales, fan blade tip relative

Mach number and non-dimensional mass flows.

Be able to demonstrate professional programme management, integration and technical supervision in design and

make activities with external suppliers.


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SAGE-04-025: Scouting high performance steels for gears

and bearings

Objectives: For a Power GearBox (PGB) design, one of the key Critical to Quality (CtQ) is the overall envelope (Power Density) to

enable optimal integration into the engine and therefore an overall optimal engine performance.

The project is aiming at scouting up to three innovative high strength materials when used for gears and bearings (e.g.

Pyrowear 675, CSS-42L,…), to be implemented into the SAGE 4 PGB for TRL6 validation

Main activities:

Specification and materials selection including surface treatment

Surface treatment and manufacturing trials

Bearings and gears specimen manufacturing

Bearings testing (endurance, contamination, low oil)

Gear testing (bending)

Results wrap-up


development of bearings for high performance aerospace application

testing of bearings for high performance aerospace application

application of bearing technologies to gears and integration of bearing design with gears.

testing of gears for high performance aerospace application

application of innovative technologies to gears.

Access to the test facilities required to meet the Topic goals

Experience in aerospace R&T and R&D programs

Experience in gear design and LTCA (for T/As design)

Experience in Supply Chain management (for T/As procurement)

Experience in experimental testing and Statistical Methodologies (for Test Plan definition and execution).


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SAGE-06-003: Development of materials, processes, and

means to enable the application of piezoelectric materials in

aero engine controls. Objectives: In order to achieve the benefits of the Lean Burn technologies, it will be necessary to employ radically different engine

control technologies. Piezoelectric technology has been identified as a potentially key technology in the implementation of

several different areas of functionality in engine controls. In addition, in order to fully exploit engine level benefits from these

novel controls piezoelectric components will need to be developed to be fully robust to these hostile, fluid wetted (and even

fully immersed) environments.

The topic will develop and demonstrate the materials, encapsulation methods and manufacturing processes required to fully

implement these piezoelectric sensing and control technologies. It supports the evolution of technologies emerging from the

Clean Sky SAGE Compact Aerospace Sensors and Effectors project.

Main activities:

Review and specification of appropriate controls functional, performance, and environmental

requirements

Materials and processes identification, development, and laboratory demonstrations

Accelerated and sustained environmental testing

Post environmental testing functional, performance, non-destructive testing, and destructive test

assessments.

Exploitation Plan delivery

Special skills requested: Strong aerospace background

Experience in manufacture of piezoelectric devices , electrical attach means, and environmental protection technologies

Availability of a range of environmental test facilities

Specialist metrology

Demonstrate access to the full range of design, manufacturing, process, test, and analysis facilities required to meet the

topic goals


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SAGE-06-007: Validated Design Methodology for Fuel

Manifold Systems

Present Status Rigid fuel manifold systems are complex and prone to vibration which can lead to fatigue

issues during development and service

Lean burn fuel delivery systems introduce considerably greater complexity and therefore risk

of vibration related issues

Objectives:

Main expectation: To execute a programme of vibration testing allied with the development of predictive Finite

Element approaches that enable the design and verification of fuel manifold systems with improved

robustness against vibration

Main deliveries: A report on the state of the art

A validated ‘toolbox’ of design and analysis predictive methods to be applied during design and

development

A suite of component, sub-assembly and full-assembly vibration test methods.

A low fidelity modelling approach to permit rapid assessment and optimisation of multiple deign

options during preliminary design

All of the above will be exploited during the design and verification phase of planned

demonstrator and production lean burn vehicles

Special skills requested: Demonstrated experience in experimental techniques to characterise and identify nonlinear dynamic

behaviour

Vibration test capability including a wide frequency range (20-2kHz), high amplitude (15g)

shaking facility

Full field Scanning Laser Doppler Vibrometer system for the contactless operating deflection shape measurements.

Capability and experience in 3D nonlinear dynamic FE predictions of sub-assemblies with contact interfaces

Access to the manufacturing facilities suitable to produce the required test rigs for the project.


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© 2013 by the CleanSky Leading Partners: Airbus,

AgustaWestland, Alenia Aeronautica, Dassault Aviation,

EADS-CASA, Eurocopter, Fraunhofer Institute, Liebherr

Aerospace, Rolls-Royce, Saab AB, Safran Thales and the

European Commission.

Permission to copy, store electronically, or disseminate this

presentation is hereby granted freely provided the source is

recognized. No rights to modify the presentation are granted.

Documents

Call 15 Infoday SAGE Topics - Clean Sky › sites › default › files › documents › calls › infoday2… · Prelim. DR March 2011 Concept DR Dec. 2009 Concept studies Technology