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Title
Innovation Takes Off
Title
Innovation Takes Off
AIRFRAME ITD
January 2020
Clean Sky 2 Information Day dedicated to the
11th Call for Proposal (CfP11)
From Clean Sky towards Clean Sky 2
Step changes in the “efficiency” of all airframe elements by the means of a systematic “re-thinking”
Re-think the a/c architecture
Re-think the fuselage
Re-think the wing
Re-think the control
Re-think the cabin
Smart Fixed Wing Aircraft
• Greener Airframe Technologies• More Electrical a/c architectures
• More efficient wing• Novel Propulsion Integration Strategy • Optimized control surfaces
• Integrated Structures• Smart high lift devices
3
Setup and Implementation
High Performance & Energy EfficiencyMore Efficient Airframes
High Versatility & Cost Efficiency Efficiency of the engineering &
manufacturing processECO
InnovativeA/C
Architecture
Advanced Laminarity
High Speed Airframe
NovelControl
Novel Travel Experience
(Cabin)
Next Generation Optimized
wing
Optimized high lift
configurations
Advanced Integrated Structures
Advanced Fuselage
Eco-Design
FRCBizjet
SAT
LPA
REG
• Many types of Demonstration
– Physical Demonstrators from small (Eco-design) to large (e.g. FRC tail)
– Virtual Demonstrators (e.g. laminar nacelle, novel configuration) integrating partial tests
– Validation of process or modelling tools
• Wide TRL range to cover short and long terms application (e.g. NLF and HLFC)
• Activity to be carried out mostly prior to IADP demonstrations
• Supporting strategy for 5 product types
• Further exploitation / analysis of CS SFWA results
AIRFRAME Work Breakdown Structure
5
Co-Leader: Airbus D&S (CASA)Leaders: AIB, LDO-VEL, LDO-SPA, LDO-Ltd, AH, FHG, SAAB, EVE, PIACP: NACOR, OUTCOME, ASTRAL, SHERLOC, OPTICOMS, PASSARO, SAT-AM, CASTLE, LIFTT
5 Technology Streams 4 Technology StreamsCo-Leaders: DAV, SAABLeaders: AIB, FHGCP: NACOR, GAINS, ecoTECH, CASTLE, MANTA, OUTCOME
M - Management &
InterfaceC - Eco-Design
TS A-1:
Innovative
Aircraft
Architecture
TS A-2:
Advanced
Laminarity
TS A-3: High
Speed Airframe
TS A-4: Novel
Control
TS A-5: Novel
travel
experience
TS B-1: Next
Generation
optimized wing
box
TS B-2:
Optimized high
lift
configurations
TS B-3:
Advanced
Integrated
Structures
TS B-4:
Advanced
Fuselage
WP M-1 WP A-1.1 WP A-2.1 WP A-3.1 WP A-4.1 WP A-5.1 WP B-1.1 WP B-2.1 WP B-3.1 WP B-4.1 WP C-1
Overall
Management
Optimal engine
integration on
rear fuselage
Laminar nacelle
Multidisciplinary
wing for high &
low speed
Smart mobile
control surfaces
Ergonomic flexible
cabin
Wing for
incremental lift &
transmission shaft
integration
High wing / large
Tprop nacelle
configuration
Advanced
Integration of
syst. in nacelle
Rotor-less tail for
Fast Rotorcraft
Eco-Design TA
Link
WP M-2 WP A-1.2 WP A-2.2 WP A-3.2 WP A-4.2 WP A-5.2 WP B-1.2 WP B-2.2 WP B-3.2 WP B-4.2 WP C-2 (ex A-3.4)
Business Aviation
OAD & config.
Mgt
CROR & UHBR
configurations
NLF smart
integrated wing
Tailored front
fuselage
Active load
control
Office Centered
Cabin
More affordable
composite
structures
High lift wing All electrical wing
Pressurized
fuselage for Fast
Rotorcraft
Eco-Design for
airframe
WP M-3 WP A-1.3 WP A-2.3 WP A-3.3 WP B-1.3 WP B-3.3 WP B-4.3 WP C-3 (ex B-3.6)
LPA
OAD & config.
Mgt
Novel high
performance
configuration
Extended
laminarity
Innovative shapes
& structure
More efficient
wings
technologies
Highly integrated
cockpit
More affordable
composite
fuselage
New materials &
manufacturing
WP M-4 WP A-1.4 WP B-1.4 WP B-3.4 WP B-4.4
RotorCraft OAD &
configuration Mgt
Virtual modelling
for certification
Flow & shape
control
More affordable
small a/c
manufacturing
Low weight, low
cost cabin
WP M-5 WP B-3.5
Regional a/c
OAD & config.
Mgt
Assembly for Fast
Rotorcraft
airframe
A - High Performance and Energy
EfficiencyB - High Versatility and Cost Efficiency
FHG,DAV, CASA, SAABCP: ecoTECH, PASSARO
DAV,CASA, SAAB,AIB, LDO-Spa, LDO-Ltd, A-H
CFP11 Overview of Call topics
6
• Indicative start date: 2020 – Q4
• Type of Agreement: Implementation Agreement
JU Ref. CfP TitleActivity
LineWP
RIA
or IA
Durati
on
(Mont
h)
Est.
budget
[k€]
ST
Leaders
Project HPEJTI-CS2-2020-
CFP11-AIR-01-46
Evaluation of NDT Techniques for
Assessment of Critical Process and
Manufacturing Related Flaws and
Defects for a Ti-alloy
HPE A-3.3 RIA 24 550 SAAB
JTI-CS2-2020-
CFP11-AIR-01-47
Additive Manufacturing
demonstration on test article for a
trailing edge application with a
sliding pad concept
HPE A-4.1.2 IA 26 500 ASCO
JTI-CS2-2020-
CFP11-AIR-03-10
Innovative light metallic and
thermoplastic airframe sections full
scale testing
ECO C-2.3 IA 24 1300 HAI
JTI-CS2-2020-
CFP11-AIR-03-11
Development and execution of new
test methods for thermoset panel
manufactured in an automated tape
layup of dry UD or NCF and
subsequent infusion
ECO C-2.3 IA 24 500 USTTUT
JTI-CS2-2020-CP11-AIR-01-46
7
• WP-ref.: A-3.3 “Innovative shapes & structure”
• Topic Manager: SAAB AB (Mr Niklas Eriksson)
• Title: Evaluation of NDT Techniques for Assessment of Critical Process and
Manufacturing Related Flaws and Defects for a Ti-alloy.
• Objective: The objective of this work is therefore quantitative assessment and
applicability of NDT methods such as ultrasonic inspection with immersion, eddy
current, 2D X-ray, etc. to AM parts in order to realize benefits offered by AM. The
project will cover manufacturing of test pieces made of Ti64 Grade 5 alloy by
laser powder bed fusion (L-PBF) AM process, characterization of AM parts by
various NDT methods, mechanical testing, fractography and micrography work,
modelling with prediction and validation.
• Duration of the action: 24 months
• Indicative Funding Topic Value: 550k€
AIR-01-46 – Testing
Figure 1: Fatigue test specimen design and dimensions
• The activity will begin with the review of the different NDT methods and selection of
the most promising NDT methods for detection of both internal and external defects
in regard to specimen designs and material used. The NDT techniques applicable
for the work include optical/visual inspection.
• The relevant NDT techniques will be applied on the specimens from Task 2 (This
task covers experimental set up and manufacturing of AM test specimens by L-PBF
AM technique se figure 1) prior and after the mechanical testing. In addition, a
number of fatigue tests will be interrupted to allow for crack assessment and
evaluation.
AIR-01-46 – Deliverables and Milestones
9
Deliverables
Ref. No.
Title - Description Type*
Due Date
D1 Consortium and implementation agreement in place
R T0+1
D2 Test and characterization matrix established R T0+3
D3 Delivery of AM test pieces HW T0+9
D4 Report regarding detection of internal and external defects with different NDT methods
R T0+18
D5 Preliminary failure and damage mechanisms investigation to inform modelling work
R T0+18
D6 Final report regarding effect of defects on fatigue life and potential for early detection in AM parts
R T0+22
D7 Final report regarding modelling and life prediction of defects in AM parts
R T0+24
D8 Lesson learnt with recommendations R T0+24
Milestones (when appropriate)
Ref. No.
Title - Description Type*
Due Date
M1 Test and characterization plan approval R T0+3
M2 NDT methods selected R T0+3
M3 Delivery of test and characterization specimens
HW T0+9
M4 Mid-term project review R T0+12
M5 Review of fatigue test results and modelling work
R T0+16
M6 Completion of planned NDT testing R T0+18
M7 Completion of planned mechanical testing R T0+22
M8 Final project review R T0+24
M9 Guide for the developed models R T0+24
*Type: R=Report, D=Data, HW=Hardware
• Capability to manufacture AM parts by L-PBF AM process.
• Capability to perform mechanical testing and material characterization of metal AM material including tensile testing, fatigue crack initiation and crack propagation testing.
• Capability to perform NDT analysis by using, for example, ultrasonic inspection with immersion techniques, eddy current, 2D X-ray, etc., for detection of both internal and external defects as a result of processing and manufacturing.
• Capability to perform surface roughness and residual stress measurements.
• Sample preparation and surface polishing facilities.
• Microstructural investigation facilities including light microscopy and SEM+EBSD.
• Capability to perform inspections with optical techniques and scanning electron microscopy.
• Experience in deformation and damage mechanisms of metallic materials and structural strength modelling.
• Capability to perform simulations using industry relevant models for fatigue life predictions.
• Expertise in fatigue life prediction analyses.
• Expertise in FE-analyses.
AIR-01-46 – Essential
JTI-CS2-2020-CFP11-AIR-01-47
• WP-ref.: A-4.2.1 “Smart mobile control surfaces – MANTA”
• Topic Manager: ASCO Industries
• Title: Additive Manufacturing demonstration on test article for a trailing
edge application with a sliding pad concept
• Objective: To develop a printing approach using Wire Direct Energy
Deposition (W-DED) for the Titanium alloy track, and to design sliding pads
to replace the roller bearings in order to reduce the operational
maintenance efforts.
• Duration of the action: 26 months
• Indicative Funding Topic Value: 500k€
AIR-01-47 – Additive Manufacturing demonstration on test article
for a trailing edge application with a sliding pad concept
Topic Leader: ASCO IndustriesIndicative Funding: 500k€
Short Description:The aim of this topic is to develop a printing approach using Wire Direct Energy Deposition (W-DED) for the Titanium alloy track, and to design sliding pads to replace the roller bearings in order to reduce the operational maintenance efforts.
Scope of work:A. Printing, testing and validation of a flap track structure manufactured via W-DEDB. Design, manufacturing and testing of sliding pads
Flap support concept - roller track and carriage
Special skills / Capabilities:• Experience in management, coordination, and development of testing methods and the execution of a test program;• To have workshop facilities (test equipment and manufacturing facilities) in line with the proposed deliverables and
associated activities;• Capability to manufacture additive manufactured components produced via one of the W-DED techniques;• Experience in the development and testing of wear surfaces in aerospace or other industries;• Solid knowledge in the manufacturing of wear surfaces
Tasks:
Ref. No. Title - Description Due Date
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
A-1 Printing simulation and trials T0 + 06
A-2 Post-printing actions and evaluation of the printing process T0 + 20
A-3 Validation of the finishing component T0 + 24
B-1 Design and manufacture sliding pad T0 + 12
B-2 Validate sliding pad wear T0 + 18
2020 2021 2022
JTI-CS2-2020-CFP11-AIR-03-10
13
• WP-ref.: C-2.3 “Eco-Design for Airframe – Demonstration”
• Topic Manager: HELLENIC AEROSPACE INDUSTRY (HAI)
• Title: Innovative light metallic and thermoplastic airframe section full scale testing
• Objectives:
– Demonstrate the ecological advantages of high strength and improved endurance properties of novel Al-Li
alloys and thermoplastic materials at aircraft fuselage panels
– Demonstrate the advantages of integrally stiffened structures by novel welding and joining techniques
– Test prediction and residual stress simulation of welded regions of novel Al_Li alloy
– Multi-Objective Test Requirements
• Employment of realistic aircraft fuselage load cases for static tests
• Performance of ultimate static test of metallic and thermoplastic panels.
• Explore the endurance behaviour of integrally stiffened Al-Li panels under realistic load spectrum
– Utilization of advanced simulation for test and post buckling prediction on structures with residual stresses
– Prediction of crack growth response of defects on Al-Li alloy
– Employment of novel measurement and defect growth monitoring techniques
• Duration of the action: 24 months
• Indicative Funding Topic Value: 1300k€
AIR-03-10 – Test Articles Definition
14
• Metallic Panel
– A full scale aircraft panel representative of business jet aircraft fuselage
– Stiffened panel with Laser Beam Welded (LBW) and Friction Stir Welded (FSW)
stiffening members
– Detail design of interfaces with the test machine to performed in cooperation with
the successful applicant
– Two identical panels should be accounted for testing.
• First for static tests
• Second for fatigue tests
• Thermoplastic panel
– A full scale static test will be performed on a curved fuselage panel with an
integrated stiffening structure
15
AIR-03-10 – Test Articles Definition
– The detailed design of the panel will be done in close cooperation with the
applicant as the panel interface has to be carefully designed in order to have well
defined load introduction into the panel skin and stiffening structure.
– The pictures below show an integrated stiffened flat panel tested at NLR. The
interface consists of tabs bonded to the skin (left) and metal frames connected to
the skin and test fixture
AIR-03-10 – Geometric configuration and Test Requirements
16
• Panel Geometric Characteristics
– Flexibility was allowed in panels dimensions due to required complexity of test
loading and limited availability of advanced full scale component test centers.
Indicative panel dimensions are as follows:
Length : 1-2.4m Peripheral length : 1-1.6m
Radius : 1.1-1.65 m
• Test cases
– Static Test – Metallic Panel
• A number of load cases for verification of buckling behavior in compression and shear and their
combination along with pressurization load are required
– Static Test – Thermoplastic panel
• A limited sequence of static tests need to be performed prior ultimate failure test of the panel
– Endurance Test
• Endurance test to demonstrate crack growth characteristics of welded regions under residual stresses
and areas at skin junctions with stiffeners
• Digital Image Correlation (DIC) will be performed to define panel deformations and
strains for both static tests
• Additional instrumentation (strain gauges, LVDT’s) will be applied to calibrate the strain
levels and panel deformations measured by the DIC system
AIR-03-10 – Deliverables and Milestones
17
• List of deliverables and planning of milestones
AIR-03-10 – Applicant Comparative Advantage
• Applicants with the following expertise will be highly preferred
– Proven experience in structural testing of large aircraft components
– Capability in application of combined multi-axial load conditions representative to
full scale fuselage section
– Proven expertise in novel measurement techniques (Digital Image Correlation) and
damage growth monitoring
– Capability of accurate simulation of residual stress field of welded joints and crack
growth prediction of metallic structures
– Experience in compilation, data reduction and post-processing of experimental
flight load spectrum conditions, especially relevant to commercial aircraft fuselage
structures
JTI-CS2-2020-CFP11-AIR-03-11
19
• WP-ref.: C-2.3 “Eco-Design for Airframe – Demonstration”
• Topic Manager: University Stuttgart
• Title: Development and execution of new test methods for thermoset panel
manufactured in an automated tape layup of dry unidirectional fibres (UD) or
non-crimped fabrics (NCF) and subsequent infusion.
• Objective: The topic addresses the validation of the structural behaviour of a
thermoset panel consisting of stiffeners and skins. The test results shall
demonstrate the competitiveness of the newly developed manufacturing
process and the potential of this technology. The response of the structure to
defined static loads will also sharpen the understanding of the chosen
manufacturing concept and design.
• Duration of the action: 24 months
• Indicative funding Topic Value: 500k€
JTI-CS2-2020-CFP11-AIR-03-11
20
• Thermoset panel demonstrator
– Demonstrator will be manufactured with the Advanced Ply Placement (APP) technology by the placement of dry
fibres directly into a 3D mould with subsequent infusion of the preform.
– Sketch of the demonstrator (geometries subject to change):
• Test Scope
– Quasi-static Level 2 (Structural details) and Level 3 (subcomponent) testing has to be conducted.
– Exact definition of tests for both levels will be done in close cooperation with the applicant, where it is expected
that applicant brings in innovative approaches in order to minimize test volume.
– For Level 3 compression and tension tests preliminary loads are about 200 tons and 150 tons respectively.
– Load cases to be tested are compression, tension, shear and possibly combinations of these. One load case will
be tested until failure.
– Level 2 test results should be analysed by the applicant with the aim of predicting the structural behaviour of the
demonstrator in Level 3. Level 3 test results will serve as validation for these predictions.
1000 mm
2000mm
35 mm
70 mm
30 mmR=5
JTI-CS2-2020-CFP11-AIR-03-11
21
• Deliverables and Milestones
• Targeted applicant:
The applicant is expected to be experienced and suitable equipped for level 2 and level 3 testing of aeronautical
composites parts. In addition to test planning and exact execution, an innovative approach is expected in order to minimize
the required test effort with new test methods.
• Required skills:
– Capability to realize this project in terms of expertise, manpower, test facilities
– Suited load cells, universal testing machines, strain measurement systems (among others: 3D non-contact strain
measurement, clip-on extensometer, strain gages), hydraulic actuators, flexible test field
– Installed and monitored quality system
– Access to a workshop for manufacturing of individual test fixtures, advanced NDT systems and expertise, design and
tools compatible to the standards of the aeronautical industry (e.g. Catia V5), data management system, data storage
system, high-speed camera systems, impactor
Deliverables
Ref. No. Title - Description Type* Due Date
D1Level 2 test plan proposal (in
collaboration with TM)
R T0+2
D2 Level 2 test report + LCA data R T0+9
D3Level 3 test plan proposal (in
collaboration with TM)
R T0+11
D4 Level 3 final test report + LCA data R T0+24
Milestones (when appropriate)
Ref. No. Title - Description Type* Due Date
M1 Kick off meeting R T0
M2Level 2 critical design review: tooling and
test set up
R T0+5
M3 Level 2 test report R T0+9
M4Level 3 critical design review: tooling and
test set up
R T0+13
M5 Level 3 test readiness review: tests start R / HW T0+15
M6 Final test report R T0+24*Type: R=Report, D=Data, HW=Hardware
Title
Any questions?
Innovation Takes Off
Last deadline to submit your questions: 13 March 2020, 17:00 (Brussels time)
Thank You
Disclaimer
The content of this presentation is not legally binding. Any updated version will be regularly advertised on the website of the Clean Sky 2 JU.
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