Clean Sky. The Joint Technology Initiative For Aeronautics & Air Transport. Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA

Transcription

1 Clean Sky The Joint Technology Initiative For Aeronautics & Air Transport Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA GRA ITD Overview & LWC enabling technologies F. Bianchetti R. Pinto (AleniaAermacchi) Brussels,

2 OUTLINE GRA - Main achievement and perspectives GRA - Team GRA 5 Technological Domains GRA High Level Objectives and Contents GRA Planning GRA Focus on LWC 2

3 Main achievements and perspectives GRA program was launched on 1 st September 2008 (GRA Kick-Off: October, 7 th - 8 th 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). 3

4 GRA Team : ITD Leaders ALENIAAERMACCHI EADS - CASA ALENIAAERMACCHI affiliate: SuperJet International Fraunhofer-Gesellschaft LIEBHERR ROLLS ROYCE SAFRAN THALES ROLLS ROYCE affiliate: Rolls Royce Deutschland SAFRAN affiliates: Snecma Messier-Dowty Hispano-Suiza THALES AVIONICS affiliate: Thales Avionics Electrical System 4

5 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 A sizeable amount of activities are reserved to Call for Proposals open to European Institutions and Industry ONERA 5

6 GRA ITD 5 Technological Domains Innovative structures (Low Weight Configuration) Lower weight Lower maintenance costs through multifunctional composites, advanced metallic materials, structure health monitoring 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 Innovative systems (All Electrical Aircraft) Lower fuel consumption through Bleed less architectures, Limited hydraulics, Energy management 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 6

7 GRA ITD - Contribution to environmental Targets ACARE Goals Reduced fuel consumption (CO 2 & NOx reduction) External noise reduction "Ecolonomic" life cycle Technology Domains 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 7

8 GRA High Level Objectives and contents To demonstrate technologies for future regional aircraft aiming at the reduction of: fuel consumption, pollution, external noise. 8

9 GRA High Level Objectives and contents 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) Electrical Generators & Controls ECS Electrical Compressor integration of such technologies in advanced aircraft configurations by interfacing new powerplants types. CDA profile FAF Area of noise benefit Cruise level Dive and drive conventional approach profile 9

10 GRA High Level Objectives and contents 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) 10

11 GRA High Level Objectives and contents Relation with other ITDs Electrical ECS (by Liebherr ) Electrical Generators & controls (By TAES) Innovative WIPS Elements (by Zodiacs) SGO ITD Optimized Trajectories & Mission for Regional A/C (by Thales) Management of A/C energy Mission & Trajectory Management TE ITD A/C Level and System Requirements A/C Requirements Systems test bench results AEA Architectures, EMAs Engines data Requirements SAGE ITD NC New Configuration AEA All Electric Aircraft GRA Core MTM Mission & Trajectory Management LWC Low Weight Configuration Electrical bench (by HS) Thermal bench (by FhG) ED ITD More green /light airframe GTF? (by MTU) OR & ATF (by Snecma/RR) LNC Low Noise Configuration ECO manufacturing process for composite Material ECO Surface Treatment for metallic Material 11

12 GRA High Level Objectives and contents 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. With reference to the generic regional aircraft type, the following Demonstrators will be produced: Electric WIPS Advanced Fuselage Panel 270 HVDC network demo channel Static and Fatigue tests on: Electric ECS Electrical Energy Management Fwd Fuselage Section Wing Box Section Cockpit Section (rear area, almost cylindrical) 12

13 GRA - Planning GRA Planning 13

14 JMS - Technological Studies & Demonstration 14

15 Demonstration: Milestones of the Full Scale Ground Demo & ATR In-Flight Demo 15

16 Focus on LWC LWC WBS & Members Involved LWC Flow Chart 1 st Down Selection Phase LWC Technology Development Goal 1 st Down Selection LWC Enabling Technologies involved in the 1 st Down Selection 2 nd Down Selection Phase LWC Technology Development Goal 2 nd Down Selection 2 nd 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 16

17 LWC WBS & Members Involved 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

18 LWC Flow Chart 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 Concepts Studies Coupons and large panels tests activities Flight Test Panel to be replaced Technologies development: req s, design, manufacturing, assembly & test Full Scale Ground Demo 1 st Down Selection 2 nd Down Selection 18

19 1 st Down Selection Phase 19

20 Technology Readiness Level (TRL) LWC Technology Development Goal 1 st Down Selection LWC enabling technologies: advanced composite structures, advanced metallic structures, structural health monitoring systems Static & Acoustic Coupon Test: First Down Selection Static & Fatigue Stiffened Panel Test: Second Down Selection Ground & Flight Test Demo TRL 7 TRL 6 TRL 5 TRL 4 TRL

21 LWC Enabling Technologies involved in the 1 st Down Selection ID Enabling Sensors Technology for SHM Optical fibre 1 Fibre Optics - FOBG 2 Fibre Optics - FOBR OBR 3 Fibre Optics - FOBR DSS 4 Acoustic Ultrasound AU-BB 5 Acoustic Ultrasound EMI Lamb waves 6 Lamb waves Acoustic sensors 7 Guided waves 8 AE-AU active and passive methods 9 Wireless Sensors Wireless sensors 21

22 LWC Enabling Technologies involved in the 1 st Down Selection ID Enabling Advanced Multifunctional Composite CFRP & Metallic wires interwoven 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 Multilayer multifunctional CFRP 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 Prepreg Nanocharged Nanoparticles in prepreg 22

23 LWC Enabling Technologies involved in the 1 st Down Selection ID Enabling Advanced Metallic Material and Process Al-Li Welded Compression Test 20 Al Li Laser welded Al-Li Intergranular corrosion ID Enabling Technology for Maintenance 21 Repair & Maintenance Resin infiltration repair 23

24 2 nd Down Selection Phase 2 nd Down Selection Phase 24

25 2 nd Down Selection Tests Tests to be performed on Large Panels Representative Fuselage panel architecture: 5 stringers 3 frames/dummies Size: about 1600 x 900 mm Representative Wing panel architecture: 3 stringers 2 ribs/dummies Size: about 900 x 400 mm 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 25

26 Call for Proposals Call for Proposals 26

27 GRA Call for Proposals To support GRA activities the following Call for Proposal launched in 2011 & 2012: For the Fuselage/Wing technologies: JTI-CS GRA : 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 GRA Design, manufacturing and impact test on selected panels with advanced composite material JTI-CS GRA Development of advanced Liquid Infusion Tecnology for regional wing structure: Numerical simulation and validation through an innovative test bench 27

28 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 ECO : Infusion system development for primary structure (activities started on 01/10/2011) JTI-CS ECO : Autoclave cycle optimization (for Liquid Infusion Process) (published in January 2012) 28

29 Full Scale Demo Full Scale Demo 29

30 Demonstrators on Ground 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. 30

31 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 Visor Conic Part Cyilindrical Area Dummy structure DEMONSTRATOR

32 Ground Demonstrators Cockpit Demonstrator 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 32

33 Ground Demonstrators Fuselage Section Test Article Fuselage Section Test article proposed tests: 1. Pressurization 2. Fuselage Bending: Static / Fatigue CURRENT BASELINE Material: CFRP. Process: cobonding OPTION #1 Material: Al-Li Alloy. Process: Laser welding on Al- Li alloy 33

34 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 34

35 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 35

36 Ground Demonstrators Wing Box Test Article Wing Box Test article proposed tests: 1. Up & Down Bending, Torsion (Static and Fatigue) BASELINE Prepreg composite with structural monitoring 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 36

37 Ground Demonstrators Wing Box Test Article - Baseline Ribs: CFRP Integrally stiffened via RTM and fastened UPR & LWR Skins: CFRP Co-infused skin - stringers via Liquid Infusion (LI) UPR Skin Ribs LWR Skin Rear Spar Spars: CFRP Integrally stiffened via RTM and fastened Front Spar 37

38 Thank You all indeed. 38 Clean Clean Sky Info - Harmonisation Day Ankara, workshop GRA, 13 th GRC, July SFWA, 2011 SAGE and EDA