the joint technology initiative for aeronautics & air ... · 3 clean sky - harmonisation...

Clean Sky - Harmonisation workshop GRA,

GRC, SFWA, SAGE and EDA

GRA ITD –

Overview & LWC enabling technologies

Brussels, 26-01-2012 F. Bianchetti – R. Pinto

(AleniaAermacchi)

Clean Sky

The Joint Technology Initiative

For Aeronautics & Air Transport

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Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA

Confidential

OUTLINE

GRA - Main achievement and perspectives

GRA - Team

GRA – 5 Technological Domains

GRA – High Level Objectives and Contents

GRA – Planning

GRA – Focus on LWC

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GRA program was launched on 1st September 2008 (GRA Kick-Off:

October, 7th- 8th 2008), and will allow future regional aircraft to obtain weight

reduction, aerodynamics efficiency and an higher level of operative

performance w.r.t. “year 2000” technology level.

In order to achieve these so challenging results, the aircraft will be entirely

revisited in all of its aspects. In fact GRA consists of five technological

domains: Low Weight Configuration (LWC), Low Noise Configuration (LNC), All

Electric Aircraft (AEA), Mission & Trajectory Management (MTM) and New

Configuration (NC).

Main achievements and perspectives

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ALENIAAERMACCHI

EADS - CASA

Fraunhofer-Gesellschaft

LIEBHERR

ROLLS – ROYCE

SAFRAN

THALES

ALENIAAERMACCHI affiliate:

SuperJet International

ROLLS ROYCE affiliate: Rolls Royce Deutschland

SAFRAN affiliates: Snecma

Messier-Dowty

Hispano-Suiza

THALES AVIONICS affiliate: Thales Avionics Electrical

System

GRA Team : ITD Leaders

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GRA Team: Associates

AIR GREEN Cluster with following members:

Piaggio, Italy, single-voice Cluster's representative Polo delle S&T, Univ. Naples, Italy Centro Sviluppo Materiali (CSM), Italy IMAST, Italy (technological district) FoxBit, Italy Sicamb, Italy Politech. Turin, Italy Univ. Bologna/Forlì, Italy Univ. Pisa, Italy

ATR

CIRA PLUS Cluster with following members:

CIRA, Italy, single voice Cluster's representative Dema, Italy Aerosoft, Italy INCAS, Romania Elsis, Lithuania

HELLENIC AEROSPACE INDUSTRY

ONERA

A sizeable amount of

activities are reserved to

Call for Proposals open to

European Institutions and

Industry

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Innovative systems (All Electrical Aircraft)

Lower fuel consumption through

Bleed less architectures, Limited hydraulics,

Energy management

Advanced aerodynamics (Low Noise Configuration)

Improved aerodynamic efficiency

Drag reduction

Lower Airframe external noise through

innovative solutions for wing and high lift devices and landing

gears

New aircraft configurations (NC)

Lower fuel consumption

NOx & CO2 reduction through

Integration of Advanced turboprops, Open

Rotors, Advanced turbofan

Evaluation of new avionics architecture in

MTM domain for

Fuel & noise reduction

Lower Maintenance costs through

Upgraded capabilities for MTM

Innovative structures (Low Weight Configuration)

Lower weight

Lower maintenance costs through

multifunctional composites, advanced metallic materials,

structure health monitoring

GRA ITD – 5 Technological Domains

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Reduced fuel

consumption (CO2 &

NOx reduction)

External noise

reduction

"Ecolonomic"

life cycle

Power plant

Loads & Flow Control

New Aircraft Configurations

Low Weight

Aircraft Energy Management

Mission & Trajectory

Management

Power Plant

Mission & Trajectory

Management

Configurations

Rotorcraft Noise Reduction

Aircraft Life Cycle

GRA ITD - Contribution to environmental Targets

ACARE Goals Technology Domains

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To demonstrate technologies for future regional aircraft

aiming at the reduction of:

fuel consumption,

pollution,

external noise.

GRA High Level Objectives and contents

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By means of :

1 - LWC (Low Weight Configuration):

advanced structures and materials.

2 - LNC (Low Noise Configuration):

mature, validate and demonstrate advanced aerodynamics.

3 - AEA (All Electric Aircraft):

more electric Aircraft architectures.

4 - MTM (Mission & Trajectory Management)

advanced avionics architectures.

5 - NC (New Configuration)

integration of such technologies in advanced aircraft configurations… by

interfacing new powerplants types.

Electrical

Generators &

Controls ECS Electrical

Compressor


Cruise level

FAF

“Dive and drive” conventional

approach profile

CDA profile

Area of noise benefit

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…by interfacing new powerplants types and through the integration with other Clean

Sky technical platforms, using a multidisciplinary approach to integrate, in the

Demonstrators of the Green Regional Aircraft, technical solutions from:

SGO – (Systems for Green Operations)

energy management, mission & trajectory management

ED - (Eco Design)

more green airframe and systems test bench results

SAGE - (Sustainable And Green Engines)

Engines

TE - (Technology Evaluator)

Aircraft Simulation Model (ASM)

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ED ITD

More green /light airframe

LWC Low Weight

Configuration

LNC

NC

GRA

Core

AEA All Electric

Aircraft

Low Noise

Configuration

New

Configuration

MTM Mission & Trajectory

Management

SAGE ITD

Optimized Trajectories & Mission for Regional A/C (by Thales)

Mission & Trajectory Management Management of A/C energy

ECO Surface Treatment for metallic Material

ECO manufacturing process for composite Material

Electrical bench (by HS)

Thermal bench (by FhG)

Systems test bench results

GTF ? (by MTU)

OR & ATF (by Snecma/RR)

Engines data

SGO ITD

Requirements

TE ITD AEA Architectures, EMAs

A/C Level and

System Requirements

Electrical ECS (by Liebherr )

Electrical Generators & controls

(By TAES)

Innovative WIPS Elements (by Zodiacs)

A/C Requirements


Relation with other ITDs

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With reference to the generic regional aircraft type, the following Demonstrators

will be produced:

Demonstration Advanced technologies will be assessed through a cost effective mix of

ground and flight tests covering the technical solutions of integration of

airframe, systems and engines at aircraft level.

In this respect, full scale structural ground tests, large scale

aerodynamic and aero-acoustics wind tunnel tests, and flight simulators

have been considered.

Electric

ECS

Electrical

Energy

Management

270 HVDC

network

demo channel Electric WIPS

Advanced

Fuselage Panel

Static and Fatigue tests on:

Fwd Fuselage Section

Wing Box Section

Cockpit Section (rear area,

almost cylindrical)


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GRA – Planning

GRA - Planning

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JMS - Technological Studies & Demonstration

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Demonstration: Milestones of the “Full Scale Ground Demo” &

“ATR In-Flight Demo”

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Focus on LWC

LWC WBS & Members Involved

LWC Flow Chart

1st Down Selection Phase

LWC Technology Development Goal – 1st Down Selection

LWC Enabling Technologies involved in the 1st Down Selection

2nd Down Selection Phase

LWC Technology Development Goal – 2nd Down Selection

2nd Down Selection Tests

Call for Proposals

GRA and EDA Call for Proposals

Full Scale Demo

LWC Technology Development Goal – Full Scale Demo

Demonstrators on Ground

Demonstrator in Flight

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Alenia Aeronautica

EADS Casa

Fraunhofer

ATR

Air Green Cluster

Cira Plus Cluster

Hellenic Aerospace Industry

Onera

Red highlighted boxes are the WP’s started

in 2009

Green highlighted boxes are the WP’s

started in 2010

LWC WBS & Members Involved

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Flight Test Concepts Studies

Full Scale

Ground Demo

Panel to be replaced

Coupons and large panels tests

activities

1st Down

Selection

LWC Flow Chart

2008 2009 2011 2012 2013 2014 2010 2015

Technologies development: req’s, design, manufacturing, assembly & test

2nd Down

Selection

Objective: to demonstrate the applicability of advanced CFRP, metallic alloys & process and structural health

monitoring systems to achieve the expected structural weight reduction for Regional A/C

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1st Down Selection Phase

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LWC Technology Development Goal – 1st Down Selection

TRL 6

2008 2009 2010 2011 2012 2013 2014 2015

TRL 5

TRL 4

TRL 3

TRL 7

Static & Acoustic

Coupon Test: First Down

Selection

Ground & Flight Test

Demo

Te

chnolo

gy R

ead

iness L

evel (T

RL)

LWC enabling technologies: advanced composite

structures, advanced metallic structures, structural

health monitoring systems

Static & Fatigue Stiffened

Panel Test: Second Down

Selection

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ID Enabling Sensors Technology for SHM

1 Fibre Optics - FOBG

2 Fibre Optics - FOBR OBR

3 Fibre Optics - FOBR DSS

4 Acoustic Ultrasound – AU-BB

5 Acoustic Ultrasound – EMI

6 Lamb waves

7 Guided waves

8 AE-AU active and passive methods

9 Wireless Sensors

Lamb waves

Optical fibre

Acoustic sensors

Wireless sensors

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ID Enabling Advanced Multifunctional Composite

10 Prepreg with metallic wires interwoven

11 Prepreg cocured with metallic mesh

12 Prepreg with thermoplastic layer cocured with microwave

13 New Composite Prepreg with damping layer

14 Monolithic laminates with acoustic damping material inserted

15 Sandwich with acoustic core

16 Prepreg nanocharged

17 Nanomaterial for electromagnetic protection

18 Nanoparticles in prepreg for RTM applications

19 Nano-materials for innovative ice protection systems

CFRP & Metallic wires interwoven

Multilayer multifunctional CFRP

Prepreg Nanocharged

Nanoparticles in prepreg

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ID Enabling Advanced Metallic Material and Process

20 Al – Li Laser welded

ID Enabling Technology for Maintenance

21 Repair & Maintenance

Al-Li Intergranular corrosion

Al-Li Welded

Compression

Test

Resin infiltration repair

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2nd Down Selection Tests

Static and Fatigue tests:

Test 1: Undamaged

configuration - Static

Compression

Test 2: Damaged

configuration (BVID) - Fatigue

test + Static Compression

Test 3: Damaged

configuration (VID) – Static

Compression

Functional tests:

Lightning-Conductivity test

Fire

Acoustic

Hail impact

Tests to be performed on Large Panels

Representative Wing panel architecture:

3 stringers

2 ribs/dummies

Size: about 900 x 400 mm

Representative Fuselage panel architecture:

5 stringers

3 frames/dummies

Size: about 1600 x 900 mm

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Call for Proposals

Call for Proposals

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GRA Call for Proposals

To support GRA activities the following Call for Proposal launched in 2011 &

2012:

• For the Fuselage/Wing technologies:

JTI-CS-2011-1-GRA-01-037: Advanced fuselage and wing structure based

on innovative Al-Li alloy – Numerical trade off study and experimental

stiffened panel validation

• For the Wing technologies:

JTI-CS-2011-2-GRA-01-038 - Design, manufacturing and impact test on

selected panels with advanced composite material

JTI-CS-2012-1-GRA-01-045 -Development of advanced Liquid Infusion

Tecnology for regional wing structure: Numerical simulation and validation

through an innovative test bench

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EDA Call for Proposals in synergy with GRA activities

Thanks to the synergies created, in EDA ALA launched the following Call for

Proposals to analyze and improve the ecological aspects of the processes

developed in GRA.

• JTI-CS-2010-5-ECO-01-014:

Infusion system development for primary structure (activities started on 01/10/2011)

• JTI-CS-2011-3-ECO-01-042:

Autoclave cycle optimization (for Liquid Infusion Process) (published in January

2012)

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Full Scale Demo

Full Scale Demo

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The goal is to test on Ground Full Scale: 1. Fuselage section

2. Wing box section

3. Cockpit

Pressure, Static and Fatigue tests will be performed.

No end-life demonstration (e.g. dismantling, recycling) are foreseen.

Demonstrators on Ground

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Ground Demonstrators – Cockpit Demonstrator

Cockpit Demonstrator initial Forecast 1. Foreseen demonstrator geometry is only a section of this cockpit including the rear area (almost

cylindrical and the visor) (EADSCASA)

2. The component has to be closed by forward dummy structure to enable pressurization (ALN)

3. Dummy structure must conform (ALN)

• Nose LG well + attachments

508640787

Cyilindrical

Area

Conic

PartVisor

2615

411370

Dummy structure DEMONSTRATOR

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Eads-Casa is involved in advance cockpit design architecture for

maximum weight saving

Following aspects should be proved in demonstrator

Design

Forward CFRP integrated frames to reduce installation process

Windscreen installation to provide interface loading representation

Installation of nose landing gear bulkheads to check pressure effects

Installation and development of CFRP bulkhead with non pressure area interface.

Floor structure and interface attachment details

Manufacturing:

Full fiber placement laminate of cabin with conic geometry and double curvature

surface.

Test:

Pressure and nose landing gear loads (including fatigue)

Acceptable simulation of loads distribution at structural interfaces

Ground Demonstrators – Cockpit Demonstrator

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Ground Demonstrators – Fuselage Section Test Article

CURRENT BASELINE

Material: CFRP.

Process: cobonding

OPTION #1

Material: Al-Li Alloy.

Process: Laser welding on Al-

Li alloy

Fuselage Section Test article proposed tests:

1. Pressurization

2. Fuselage Bending: Static / Fatigue

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Ground Demonstrators – Fuselage Section Test Article –

Skin & Stringers - Frames & Shear Ties

Skin & Stringers:

CFRP-UD Tape Skins and omega stringers.

Acoustic damping material and a copper

mesh (for lightning protection) are integrated

into the CFRP skin.

Frames & Shear Ties:

CFRP UD Tape reinforced Z

shape that integrates the shear

tie

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Ground Demonstrators – Fuselage Section Test Article –

Window Frames - Pax floor

Window Frames:

RFI of stitched preforms in

close mould

Floor Beams:

Thermoplastic, Roll Forming

Seat Rails:

Extruded, Al alloy

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Ground Demonstrators – Wing Box Test Article

OPTION #1

Material: CFRP (dry preform + resin)

Process: LI

Liquid Infusion process could become the baseline if

the results after the second down selection (mid 2012)

are excellent

BASELINE

Prepreg composite with

structural monitoring

Wing Box Test article proposed tests:

1. Up & Down Bending, Torsion (Static and Fatigue)

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Ground Demonstrators – Wing Box Test Article - Baseline

UPR Skin

LWR Skin

Front Spar

Rear Spar

Ribs

Spars:

CFRP Integrally stiffened via

RTM and fastened

Ribs:

CFRP Integrally stiffened via RTM

and fastened

UPR & LWR Skins:

CFRP Co-infused skin - stringers via

Liquid Infusion (LI)

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Confidential Clean Sky Info Day – Ankara, 13th July 2011

Thank You all indeed.

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