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
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
2
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
3
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
4
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
5
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
6
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
7
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
8
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
To demonstrate technologies for future regional aircraft
aiming at the reduction of:
fuel consumption,
pollution,
external noise.
GRA High Level Objectives and contents
9
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
GRA High Level Objectives and contents
Cruise level
FAF
“Dive and drive” conventional
approach profile
CDA profile
Area of noise benefit
10
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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)
11
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
GRA High Level Objectives and contents
Relation with other ITDs
12
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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)
GRA High Level Objectives and contents
13
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
GRA – Planning
GRA - Planning
14
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
JMS - Technological Studies & Demonstration
15
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
Demonstration: Milestones of the “Full Scale Ground Demo” &
“ATR In-Flight Demo”
16
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
17
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
18
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
19
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
1st Down Selection Phase
20
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
21
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
LWC Enabling Technologies involved in the 1st Down Selection
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
22
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
LWC Enabling Technologies involved in the 1st Down Selection
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
23
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
LWC Enabling Technologies involved in the 1st Down Selection
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
24
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
2nd Down Selection Phase
2nd Down Selection Phase
25
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
26
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
Call for Proposals
Call for Proposals
27
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
28
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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)
29
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
Full Scale Demo
Full Scale Demo
30
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
31
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
32
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
33
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
34
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
35
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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
36
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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)
37
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential
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)
38
Clean Sky - Harmonisation workshop GRA, GRC, SFWA, SAGE and EDA
Confidential Clean Sky Info Day – Ankara, 13th July 2011
Thank You all indeed.