Innovation Takes Off Not legally binding
Clean Sky 2 Information Day Lisbon, 28 November 2013 Innovation Takes Off AIRFRAME ITD Alain Bouillon, Dassault Aviation Chargé d affaires Clean Sky 2 Direction de la Prospective Miguel Llorca Sanz, EADS CASA Head of Clean Sky 2
From Clean Sky towards Clean Sky 2 Greener Airframe Technologies More Electrical a/c architectures More efficient wing Novel Propulsion Integration Strategy Optimized Smart control Fixed surfaces Wing Aircraft Integrated Structures Smart high lift devices Re-think the wing Re-think the a/c architecture Re-think the cabin Re-think the fuselage Re-think the control Step changes in the efficiency of all airframe elements by the means of a systematic re-thinking
High-level Objectives Not legally binding
From the From the Impact Perspective Expected Impacts Environmental Perspective More resource efficient aircraft : challenging targets for up to 30% cumulative CO 2 10 EPNdB Eco responsible industrial capabilities Smart & Efficient Mobility Perspective Industrial Leadership Perspective Increased operational flexibility (flight domain) Access to dense populated areas : low noise and low speed performances Access to remote areas performances : short take off and landing, reduced a/c ground infrastructure, remote repairing Travelling Time not as a wasted Time : passenger well-being Sustainable traffic growth Cost efficient Products Strong Product Differentiators Cost efficient engineering, manufacturing & life cycle support processes (up to recycling) Reduced time to market Sustainable industrial capability
Key Objectives Validate through demonstration of integrated technologies : To introduce innovative airframe architecture To introduce techonogies for more efficient airframe : drag, weight, cost, environmental impact, passager well-being, maintenance, servicing, To enhance the efficiency of the engineering & manufacturing process : timeto-market and competitiveness against low-cost labour countries, To fully address a technology issue from modeling to certification ability Serve maturity up to TRL 6 of airframe technologies De-risk novel generation product in the prospect of a next game changing step by 2030+ Support next generation bizjets and general aviation directly Support Large a/c, regional a/c and rotorcraft directly and through IADPS Create Product differentiators Supporting a 5 Product s Segments Strategy Base
Setup and Implementation Not legally binding
The Leadership : who are we? Key world player in the aerospace industry. More than 8,000 aircraft delivered, RAFALE FALCON representing some 28 million of hours of flight. 1900 Falcon in operation. Omnirole BizJets Only group in the world to design, manufacture and support both combat aircraft and business jets. neuron UCAV Demonstrator Saab serves the global market of governments, authorities and corporations with products, services and solutions ranging from military defence to commercial aeronautics. The product portfolio includes the Gripen combat aircraft, Unmanned Aerial Systems (UAS) and large aero-structures for OEM s such as Airbus and Boeing. More than 70 years in business and more than 4000 aircraft manufactured, among them 500 airliners. World leader in turboprop aircraft with full capabilities from design, manufacturing, aircraft integration, certification and services. Product portfolio includes: full proven family of transport aircraft: A400M, C295, CN235 & C212; Eurofighter, Unmanned Aerial Systems (UAS), world leader in Air Refuelling Systems & Aircraft; large aero-structures for OEM s such as Airbus and Boeing. More than 90 years in business and more than 6,000 aircraft delivered to more than 140 operators in 70 countries.
The Overall Partnerships Airbus, ALENIA, EUROCOPTER, AGUSTA WESTLAND, SAT Core Team and Fraunhöfer Institute have a central role to AIRFRAME ITD The role of industrial core partners, REs and Academia will be major in three main direction: Development of main technologies and elements of OEM defined demonstrators => direct contributions at models, design, development, manufacture & testing level to demonstrator components Development of other industrial core partner defined major demonstrators, in line with the defined demonstrations objectives and technology routes Development of lower TRL / longer term technologies The AIRFRAME ITD work scope is still under a consolidation process : it is expected to be adjusted and tuned against The final outcomes from the regulation adoption process The recommendations from the expert panel of the Technical Evaluation The suggestions arising from the current Information Process
Transverse Enabling Capability Focused Integrated Demonstrations Investigate advanced engine integration & novel overall architecture Laminar nacelles; NLF smart integrated wing fitting the industrial environment High efficient multi-disciplinary flexible wing; fuselage changes in shapes, & structure Smart multi-function control surfaces & load & flutter alleviation Passenger friendly cabin; ergonomic & flexible, new volume utilisation Low cost composite structures Efficient architectural concept for turbopropeller high wing composite nacelle & adaptative wing New structural paradigm for optimised integration of systems in airframe, electrical wing Novel composite fuselage & cabin; tailless or pressurized fuselage for rotorcraft Overall Technical Overview High Performance & Energy Efficiency High Versatility & Cost Efficiency Innovative Aircraft Architecture Advanced Laminarity High Speed Airframe Novel Control Novel travel experience Next generation optimized wing Optimized high lift configs. Advanced integrated structures Advanced Fuselage Novel Certificat Eco Design Extended Laminarity More Efficient Wing Flow & shape Control Advanced Manufact.
Interfacing & cross interaction management Specifications & Requirements Technology Development & Demonstration Integration Profile Development Integrated Concept demonstrat prototype airframe compon ts IADP RA Concept Analysis Technology Streams Innovative Aircraft Architecture Advanced Laminarity IADP LPA IADP Rcraft High Speed Airframe IADP RA Novel Control IADP LPA Novel Travel Experience IADP Rcraft Next Gen. optimized wing box ITD Systems SAT Transverse act Optimized high lift configurations Advanced Integrated Structures Advanced Fuselage Novel innovation wave TRL <= 5 ITD Engine ITD Systems ECO TE
High Performance & Energy Efficiency- WBS High Performance & Energy Efficiency 65/70 M 40/45 M 35/40M 10/15M 10/15M 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 Leader : Dassault Aviation Co leader : SAAB Management & Interfacing WP A-1.1: Optimal engine integration on rear fuselage WP A-2.1: Laminar nacelle WP A-3.1: Multidisciplinary wing for high & low speed WP A-4.1: Smart mobile control surfaces Innovative Aircraft Architecture WP A-5.1: Ergonomic flexible cabin Advanced Laminarity Novel Control Novel Travel Experience WP A-1.2: CROR configuration WP A-2.2: NLF smart integrated wing WP A-3.2: Tailored front fuselage WP A-4.2: Active load control WP A-5.2: Office Centered Cabin WP A-1.3: Novel high speed configuration WP A-2.3: Laminarity for high lift wing WP A-3.3: Innovative shapes & structure WP A-1.4: Novel certification processes WP A-2.4: Extended laminarity WP A-3.4: Optimized cockpit structure WP A-1.5: Eco Design
TS 1 : Innovative Aircraft Architecture Progress path versus Stateof-the-Art enabled through Clean Sky 2 Partnerships framework Conventional aircraft architectures have been primarily driven by component characteristics, requirements and performances (e.g. pod engine integration for undisturbed air ingestion, etc.); Progress on components and on the understanding of their integration requirements makes new more efficient configurations possible. Identically, radical change in major component such as with the CROR engine leads to a complete re-thinking of the aircraft configuration and the propulsion integration. With progress on certification process and Eco Design capabilities, evolutions in the design & production environment, will create favorable conditions to the coming out of ruptures in aircraft architecture. Engine Supplier, Research Institute, PLM & engineering software provider, Aero-Structure Industry with track record in Eco Design, Material & Coating provider
TS1 High level WP Scope focused demonstrations Level 2 WP Technology Key demonstration vehicle / path WP A-1.1 Opt. Engine Integrat WP A-1.2 Open Rotor Config Conceptual design, overall aircraft design, engine design, architectures, aero-shape optimization, vortex management (possibly done by active means like flow control) on afterbody for drag reduction, efficient air inlet, aero-structural validation, mechanical integration, structural optimization, active noise reduction, performance assessment, accurate noise footprint prediction Advanced pylon architecture Active noise control with pylon trailing edge flow control Validation of improved propeller design acoustic & performance Final down selection of best candidate engine integration aircraft configuration Ground test of engine with simulated distortions Large Wind Tunnel Test Large scaled wind tunnel test with CROR engine mounted to NSR (Next generation Short Range) aircraft. WP A-1.3 Novel High Speed Config Conceptual design, overall aircraft design, engine burst considerations, engine design, architectures, aero-shape optimization, flow management techniques to reduce flow inhomogenities at the intake, flight handling qualities, flexible structures, structural validation, performance assessment WTT of innovative configurations Engine rig tests Possibly (according to preliminary studies results) flight test of aircraft with modified inlet to simulate the buried engine
Level 2 WP Technology Key demonstration vehicle / path WP A-1.4 Novel Certi Process WP A-1.5 Eco-Design TS1 High level WP Scope (2/2) transverse enabling technologies Certification by models, lean and/or virtual means of conformity, innovative methods and data bases for certification, certification by increment; Advanced modelling, Accurate flutter prediction at high speed. Eco efficient technologies & logistics, including : for Carbon Fibre Reinforced Polymers structures: wing stiffened panel by infusion process, integral stiffened structures, low energy curing for thermoplastics : thermoplastic composites for aircraft structures & interior applications for special polymers applications : composites for high temperature applications, conductive composite for metallic structures: light alloys stiffened panel, long life structures, light alloys and surface treatments, corrosion protection and/or self healing, Magnesium Technologies for biomaterials: green polyurethane foams for aircraft seating, secondary structures and interior furnishing for electronics materials: electronic connectors, lead-free solder, and aircraft wiring for tribology : novel coating & corrosion protection for low energetic, waste saving novel processes : welding, forming, bounding, surfacing Wide range of local demonstrations to validate model accuracy & process validity, from ground (Wind Tunnel tests, structural tests, ) up to flight activities (constitution of meteorological database, ) Processes will be demonstrated individually by representative local demonstrator Use of the metallic fuselage section and the composite fuselage demonstrator of the Airframe ITD as reference case a global impact assessment at life cycle level
TS 2 : Advanced Laminarity Progress path versus Stateof-the-Art enabled through Clean Sky 2 Partnerships framework Laminar Flow is the aerodynamics technology with the highest drag reduction potential Within Clean Sky, Natural laminarity of wing for M=0.75 aircrafts is under way to be demonstrated at large scale in major ground rigs and in flight. A subsequent critical additional issue will be to demonstrate the integration of all key elements of a low drag wing into a main wing structural concept that allows for a high rate industrial production at competitive effort. In term of performances, the next step is the increase of Mach number applicability (up to M=0.85 for long range applications) and more extensive applicability on the wing. Laminarity Flow is also to be applied on nacelle as a mean to overcome the drag effect from substantial increase in Fan (respectively nacelle) diameters of innovative turbofan engine solutions. Research Institute, University, Aero-Structure Industry, Nacelle Supplier
Level 2 WP Technology Key demonstration vehicle / path WP A-2.1 Laminar Nacelle WP A-2.2 NLF Smart Integrated Wing WP A-2.3 high lift, turbo-p Laminar wing WP A-2.4 Extended Laminarity TS2 High level WP Scope Aeroshape optimization Nacelle design with smart management of access doors and bleed apertures Manufacturing and assembly technology low geometrical tolerance, high surface quality based on CFRP composites with joints to hybrid components Surface treatment and coatings with high erosion and self cleaning capability Repair technologies for in-field quick fix for small damages and in-hangar for sever damages Flow control for engine pylons Light weight technologies, Multifunctional materials Manufacturing and assembly technologies, e.g. close geometrical tolerance, high surface quality based on CFRP composites Physical features of the design, integration of innovative wing system such as WIPS and control surfaces etc... Advanced CFDs, natural laminar flow, flow control Manufacturing & assembly technologies Advanced CFDs, accurate transition modeling with shockboundary layer interaction, flow control, aero-shaping, Innovative techniques for optimum shape design (krugger device conf, hybrid laminar flow, active shock control) Manufacturing, assembling & joining qualities, MEMs Dedicated structural component tests Full size nacelle structural demonstrator, manufacturing and assembly Demonstration of repair and cleaning technology Demonstration of integration compliance with major system components Flight test of a modified nacelle Potentially large scale flight test validation of some key demonstration article in LPA-IADP Representative full scale test sections of a next generation natural laminar flow wing for a short and medium range LPA To be validated with respect to the efforts in materials, tooling, manufacturing, integration and assembly of components and systems. Wind Tunnels tests The optimal solution => integrated concept of high lift wing for the Regional Aircraft IADP. Simulation & modeling Local demonstrations of flow control device in Wind Tunnel or possibly in Flight
TS 3 : High Speed Airframe Progress path versus Stateof-the-Art enabled through Clean Sky 2 Further to Clean Sky progress on wings, integration of aerodynamic and structure innovations for wing efficiency, demonstration of novel fuselage shapes and structures, rethinking of the forward fuselage/cockpit structure can lead to further progress on drag and weight. Global aero structural optimizations will enable travelling time reduction while improving the global environmental balance of high speed. High speed design shall not come at the cost of the low speed capabilities Partnerships framework Research Institute, University, Aero-Structure Industry, Material Provider, Equipment Supplier
Level 2 WP Technology Key demonstration vehicle / path WP A-3.1 New architectural design => steering (i.e. shape/structure coupled Representative wing box demonstrator optimization) Multidiscip. Improved sizing criteria,, distributed control, sizing & structural wing for H& L Speed optimization for high energy chocs, new coatings (erosion-proof, antiaccretion of ice & bugs...) WP A-3.2 Tailored Front Fuselage WP A-3.3 Cockpit & Fuselage Shapes & Structures TS3 High level WP Scope Overall innovative front fuselage concept design in consistency with the Overall Aircraft Design, aerodynamic shaping, natural & hybrid laminarity (aero, manufacturing & assembly, surface integrity) discontinuities management: innovative antenna integration, novel anemometry, Synthetic Vision Systems based cockpit, thermal cooling New architectural design, new shapes to optimized drag, wing-body fairing optimization at high speed, structure & volume, aerodynamic noise reduction, noise transfer reduction, active noise control, systems & networks physical integration, improved sizing criteria and optimized fatigue sizing, failure tolerance, new low density material, multifunctional materials, composite structure optimization Simulation & Large Wind Tunnel Partial Structure ground demonstration Aero demonstration of realistic structure (large Wind Tunnel Testing and/or Flight Testing, TBC) Local demonstrators of multifunction materials, new structure architecture Fuselage panel demonstrator of assembly for innovative shapes (e.g. link to innovative engine integration at the rear). WP A-3.4 Optimizes Cockpit Structure Manufacturing and assembly technology based on CFRP composites with joints to hybrid components Surface treatment and coatings with high erosion resistance Repair technologies for in-field quick fix for small damages and inhangar for sever damages, demonstration of NDT inspection techniques Dedicated structural component tests Demonstration of repair technology
TS 4 : Novel Control Progress path versus Stateof-the-Art enabled through Clean Sky 2 Linked to innovative wings and afterbodies is the possibility of innovative control strategies both at global level (aircraft control, load, vibration & flutter control) and locally (control of instabilities). Direct gains on efficiency (weight, drag, agility) are expected. Partnerships framework Research Institute, University Aero-Structure Industry, Equipment Suppliers
TS4 High level WP Scope Level 2 WP Technology Key demonstration vehicle / path WP A-4.1 Smart mechanism, aero-elasticity, mechanical structure, smart Full scale ground demonstrator : cinematic, assembly, actuation & control. Control surfaces with flow mechanism functional demonstration : Smart control on demand capability. motion & response time (control loop) Mobile Control Surfaces WP A-4.2 Active Load Control Control algorithm, aero-elasticity, structural dynamics, testing methods & tools, sensing, actuation Flight control system demonstrator : functional test of the control loop (response time from the gust detection to mobile surface motion) on ground and in flight
TS 5 : Novel Travel Experience Progress path versus Stateof-the-Art enabled through Clean Sky 2 Passenger cabins have not been addressed within Clean Sky. => Improved passenger comfort and ergonomy, safety and services, but also significant fuel efficiency through weight reduction & ecological benefit with environmental friendly materials. Partnerships framework Cabin system provider, Research Institute, University, Material Providers, Equipment Suppliers, Design centers, Social behavior analysts
TS5 High level WP Scope Level 2 WP Technology Key demonstration vehicle / path WP A-5.1 New seat arrangement and furniture concepts not only for 1st and Dedicated digital and mock up studies business class Contribution to component and Ergonomic Purpose focused functionalities of cabin areas assemblies manufacturing and assembly Flexible Cabin Local environment tailoring including demonstration WP A-5.2 Office Centered Cabin Optimal volume usage, innovation by design, light weight multifunctional/convertible seat & couch, multifunctional furniture, smart galley, novel catering equipments, flexible interior lightning, waste & wastewater management, new eco compatible material Full size functional mock-up of a functional zone (catering for business jet) Local/partial cabin items demonstrators
High Versatility & Cost Efficiency- WBS High Versatility & Cost Efficiency 30/35M 25/30M 50/55M 65/70M TS B-1 : Next Generation optimized wing box WP B-1.1: Wing for incremental lift & transmission shaft integration WP B-1.2: More affordable composite structures WP B-1.3: More efficient wings technologies WP B-1.4: Flow & shape control TS B-2: Optimized high lift configurations WP B-2.1: High wing / large Tprop nacelle configuration WP B-2.2: Optimized integration of Tprop nacelles WP B-2.3: High lift wing TS B-3: Advanced Integrated Structures WP B-3.1: Advanced integration of system in nacelle WP B-3.2: All electrical wing WP B-3.3: Highly integrated cockpit WP B-3.4: Advanced integration of systems in small a/c WP B-3.5: More affordable small a/c manufacturing WP B-3.5: New materials & manufacturing TS B-4: Advanced Fuselage WP B-4.1: Rotor-less tail for Fast Rotorcraft Innovative Aircraft Architecture WP B-4.2: Pressurized fuselage for Fast Rotorcraft WP B-4.3: More affordable composite fuselage WP B-4.4: Affordable low weight, human centered Cabin Advanced Laminarity Leader : EADS CASA Management & Interfacing Novel Control Novel Tra Experien
Progress Path & Expected Impact Progress path enabled through Clean Sky 2 Lead Actors / Key Contributors Next Generation Optimized Wing Box Optimized High Lift Configurations Structural improvements for wing, better use of composite materials and optimization of the wing efficiency will lead to further progress on drag, weight, for new, affordable and performing wing. Advanced aircraft configurations, more global aero structural optimizations and enhanced nacelle/engine integration will lead to further progress on drag and integration for high wing with large turbo propulsors. Dassault, EADS-CASA, EC, SAT Research Institute, University, Aero-Structure Industry, Material Provider EADS-CASA Research Institute, University, Aero-Structure Industry, Nacelle suppliers, Engine suppliers.
Progress Path & Expected Impact (Cont d) Progress path enabled through Clean Sky 2 Lead Actors / Key Contributors Advanced Integrated Structures Low Speed A/C Advanced Fuselage Improvements in the design and production processes will lead to more affordable, weight optimized structural components. A native, optimized integration of equipment & systems in the structural design will improve the final quality of airframe equipped with numerous novel equipments & systems, more and more power addicts. Innovations within Clean Sky have been limited to some major components or section with significant progress in particular on structural weight saving for the cockpit & forward fuselage barrel in GRA. More global aero structural optimizations, and more efficient system integration, including propulsion integration, can lead to further progress on drag, weight and manufacturing processes. Airbus, Alenia, EADS-CASA, SAT, SAAB Research Institute, University, Aero-Structure Industry, Material Provider, Equipment Supplier Alenia, EADS-CASA, EC, AW, SAT, GhG Research Institute, University, Aero-Structure Industry, Material Provider, Equipment Supplier
HVCE Airframe ITD June 2013 TS 1 : Next Generation optimized wing box WP 1.1: Wing for incremental lift & transmission shaft integration WP 1.2: Optimized composite structures WP 1.3: More efficient wing technologies WP 1.4: Flow & shape control
TS B1 : Next Generation optimized wing box Level 2 WP Technology Key demonstrator vehicle WP B1.1 Wing For Incremental Lift And Transmission Shaft Integration CFD optimization of aerodynamic design (airfoils, flaps, 3D) for full aircraft L/D. Wingfuselage and wing-propeller integrated design. TE flaps ensuring incremental lift control with minimal drag impact and allowing to reduce wing blockage of rotor downwash in hover; Design-to-stiffness, aero-elastic tailoring Advanced structural design i.e. topologic optimization and smart combination of composite and metallic materials; Study to consider interest of WIPS; if confirmed, provision for integration (no development); Transmission shaft and harness integration for high integrity; full tank integration (optional); Green materials, low energy & low scrap production processes (fiber placement, out-ofautoclave curing), reparability & recyclability Design to Cost (NC, DMC) Full scale wing and flap, one article to be delivered for the Iron Bird (mechanical test bench), another article to be delivered for flight demonstrator assembly (shake test and flight campaign); Full range of calculation and simulation tools (CFD, FEM, dynamics); sample, subcomponents and full component ground tests; substantiation documents for Permit-to-Fly. TRL 5 with Airframe ITD; TRL6 after flight demonstration in IADP R/C LifeRCraft project.
TS B1 : Next Generation optimized wing box (cont d) Level 2 WP Technology Key demonstrator vehicle WP B1.2 More Affordable Composite Structures Investigation of the possibilities of application of modern out of autoclave technologies like low pressure and low temperature pre-preg and liquid infusion methods in the area of production, also enabling easy in-field repair possibilities. Investigation of the possibilities of application of higher temperature resistant resin. Improvement of automation during production process of composite structures. Investigation of the possibilities of application of hybrid materials. Application of modern thermoplastics for secondary aircraft structures using the better impact and damage tolerant capabilities compared to composite material. Design and manufacturing of a substantial part of a composite wing Secondary aircraft structures nacelle designed and manufactured with the aim of low cost and weight, static test, fire resistance test, leading to TRL level 5-6 validation Static testing of Floats aircraft structure manufactured in hybrid materials leading to TRL level 5-6 validation
TS B1 : Next Generation optimized wing box (cont d 2) Level 2 WP Technology Key demonstrator vehicle WP B1.3 More Efficient Wing WP B1.4 Flow & Load control CFD and multidisciplinary approach Aero-shape optimization Morphing technologies Flow control Flow control for winglet Winglets and wing plant optimization Enhanced EMI EMC protection, lightning protection Anti-icing coatings Multifunction coatings Repair technologies Health monitoring, health assessment Advanced CFD & flow control technologies applied to delay or mitigate the flow detachments Morphing concepts for the loads control Aerodynamics and aero-elastic concepts for the passive loads control Active loads control using classical primary and innovative controls in combination with functionalities in the FCS Partial demonstrator for wing testing, in particular Wind Tunnel Possibly, according to preliminary studies, in flight demonstration of local/basic technology Demonstration in Wind tunnel test with scaled models The combined structural concepts and aerodynamics concepts with full scale models will be demonstrated in flight test in the R- IADP
HVCE Airframe ITD June 2013 TS 2: Optimized high lift configurations WP 2.1: High wing / large Tprop nacelle configuration WP 2.2: High lift wing WP 2.3: Optimized integration of Tprop nacelles
TS B2: Optimized high lift configurations Level 2 WP Technology Key demonstrator vehicle WP B2.1 High Wing / Large TProp Nacelle Configuration WP B2.2 Optimized Integration Of Nacelles For Turbo Propelled Aircraft Novel architecture design of propulsion integration on high wing New ventilation concepts and nacelle shapes Advanced architecture conceptual development High Integration of hybrid components : metallic and composites Use of multifunctional materials within new conceptual laminates with improved mechanical, acoustic, thermal, electrical, impact protection and anti-erosion behaviour Multidisciplinary design harmonization Methodology development for simulation, virtual & real testing Systems-structure integration Assessment of systems functionalities. Statement of updated requirements Analyses CFD Wind tunnel tests Simulation & virtual testing Manufacturing trials of panels & structural details Coupons & panels test Components manufacturing (one hand mounting and cowlings) for non destructive testing research. Integration & assembly of systems. Verification of accomplishment of structural and systems requirements & interfaces Substantiation of systems performances & functionalities through ground testing
TS B2: Optimized high lift configurations (contd) Level 2 WP Technology Key demonstrator vehicle WP B2.3 High lift wing Advanced Structure concepts, manufacturing and testing Technologies of active or passive means of lift increasing devices Wing Leading edge Morphing including actuation by EMAs providing the basis for the integration of anti-ice systems Winglets morphing - structural devices that might be optimally adapted to different flight conditions through relatively minor shape alteration induced by relative displacement of trailing edge. Adaptive High Performance high lift devices Drag reduction including Improved laminar flow Active Load protection Improved high wing nacelle and power plant integration new cowling concept significantly lighter in terms of weigh/unit of area New fire resistant materials Improved ventilation architecture Enhanced sealing for.fire extinguishing Wind tunnel tests of future SAT RA wing full scale ground demonstrator: Flight physics assessment and analysis CFD and wind tunnel Structural & weight (includes bird strike) Manufacturing (includes spring back) Development of SHM application Assessment of anti-ice system integration Manufacturing trials of scaled component Tooling design and manufacturing Inspections & repairs Development of the structural concept & manufacturing of structural elements Assembly and rigging of 1st Article Ground Test Program
HVCE Airframe ITD June 2013 TS 3: Advanced Integrated Structures WP 3.1: advanced integrated cockpit WP 3.2: Advanced integration of system in nacelle WP 3.3: All electrical wing WP 3.4: New materials & manufacturing WP 3.5: MAME2 metallic fuselage
TS B3: Advanced Integrated Structures Level 2 WP Technology Key demonstrator vehicle WP B3.1 Advanced Integrated Cockpit WP 3.2 All Electrical Wing Advanced structural architecture and systems integration taking into account the system installation and manufacturability aspects. Improvements in wiring leading to reduction of complexity (configuration control, safety) and weight High Integration of hybrid components : metallic and composites system installation optimization from modularity and use of advanced concepts (Optical fiber, wireless, etc) Assessment of systems functionalities. Statement of additional requirements New architectures for Power supply and actuator control Actuator technologies Duty Cycle Life endurance anti jamming capabilities Fiber optic optics and wireless technologies Installation characteristics force fighting Full scale hybrid integrated cockpit demonstrator with cockpit system integration. Manufacturing trials of scaled component Extended ground testing Avionics systems functionality verification Substantiation of structural and systems requirements & interfaces Bird strike strength substantiated by analysis. Validation in bench facilities, integrated & tested into the high lift wing demonstrators part of the more efficient wing activities in the Airframe ITD Flight tested in the RA -IADP
TS B3: Advanced Integrated Structures (cont d) Level 2 WP Technology Key demonstrator vehicle WP B3.3 Integration Of Systems In Nacelle High temperature / impact resistance composites Highly coupled engine airframe integration De-risking highly integrated airframe structures at competitive cost Power management and electric anti-ices synergies with engine & systems ITDs Safety assurance in all normal/failure operating conditions Advanced sensing system / power control Operational validation of active (flow control) and passive (high DoF) liners for noise reduction Structural integrated ducts and manufacturing challenges for impedance matching Heating systems Power reduction techniques and energy/heat management (SHS, wettability control, heat pipes, ) For Electric Anti-Icing System A 3D IWT Test Item For Large Scale Icing Wind Tunnel Campaign Is Foreseen Acoustic Technologies And Models Will Be Demonstrated Via The Realization And Testing Of Full Scale Wide Frequency Absorbing Acoustic Panels For Anechoic Chamber Measures Integration Of Heating Systems Into The Acoustic Treatments Will Be Demonstrated With 2D Icing Wind Tunnel Test Campaign.
TS B3: Advanced Integrated Structures (cont d 2) Level 2 WP Technology Key demonstrator vehicle WP B3.4 New materials & manufacturing WP B3.5 More Affordable Small Aircraft Manufacturing Automation, high speed machining, novel alloys machining, novel forming, bounding, welding techniques, novel part joining techniques, advanced jig technologies, composite parts production techniques. Hybrid metal/composite joining techniques Production control, testing in production, maintenance in production Automated metal structures assembling Friction Stir Welding technologies for specific structural parts Advanced technologies in jigs/fixtures production Alternative joining methods Effective combination of metallic and composite structures Advanced production technologies Material testing & validation Local demonstrations on representative part to validate a production/assembly technique Ground demonstrators consisting of central fuselage airframe subassemblies of metal fuselage and wing sections. Technological demonstrators represented by airframe subassemblies. Type of test: technology verification strength test fatigue tests
TS B3: Advanced Integrated Structures (cont d 3) Level 2 WP Technology Key demonstrator vehicle WP B3.6 Advanced integration of systems in small a/c Advanced system technologies developed in ITD System and focused on reduction of the Operational Costs, improved cabin (noise, thermal, entertainment) & flight comfort and safety and security Efficient operation of small aircraft with affordable health monitoring systems More electric/electronic technologies for small aircraft Fly-by-wire architecture for small aircraft Affordable SESAR operation, modern cockpit and avionic solutions for small a/c Comfortable and safe cabin for small aircraft
HVCE Airframe ITD June 2013 TS 4: Advanced Fuselage WP 4.1: Rotor-less tail for Fast Rotorcraft WP 4.2: Pressurized fuselage for Fast Rotorcraft WP 4.3: MAME2 composite fuselage WP 4.4: Low weight, Low cost Cabin
TS B4: Advanced Fuselage Level 2 WP Technology Key demonstrator vehicle WP B4.1 Rotorless tail for fast rotorcraft CFD optimization of aerodynamic configuration & design (fuselage tail junction, tail boom, empennage and fins including control surfaces) taking into account constraints for rear access doors and rescue hoist operation, airframe angle of attack and attitude control, dynamic pitch and yaw stability (with and w/o active stability augmentation), interaction with propeller slipstream and tail shake prevention in the full flight envelope including mass and CG variations; Flow control devices either passive or active to be studied if needed to prevent flow separation; Aeroelastic tailoring Advanced structural design i.e. topologic optimization using smart combination of composite and metallic materials for minimal weight; Green materials, low energy & low scrap production processes, reparability & recyclability Design to Cost (NC, DMC). Full scale, flightworthy tail assembly to be delivered for flight demonstrator (shake test and flight campaign); Full range of calculation and simulation tools (CFD, FEM, dynamics); sample, subcomponents and full component ground tests; substantiation documents for Permit-to-Fly. The tail assembly includes: tail boom, empennage and fins with pitch and yaw control surfaces. Flight demonstration in IADP R/C LifeRCraft project.
TS B4: Advanced Fuselage (cont d) Level 2 WP Technology Key demonstrator vehicle WP B4.2 Pressurized fuselage for fast rotorcraft Optimal design, through extensive use of design and simulation tools such as CFD, structural and vibrational analysis, aeroelastic modelling and systems integration. The detailed design will leverage a dedicated selection of materials and manufacturing technologies (including but not limited to hybrid composite-metallic structures, automated tape laying for single piece outer skin, lightweight hybrid transparencies for deicing and bird strike resistance, use of thermoplastic matrix composites from initial conception). Manufacturing of physical components for testing and for assembly of the technology demonstrator with flight clearance related to each of the 3 components: front, central & rear fuselage parts. The fuselage will be structurally tested on dedicated benches to support flight clearance. Individual sub-assembly tests will be performed as required
TS B4: Advanced Fuselage (cont d 2) Level 2 WP Technology Key demonstrator vehicle WP B4.3 More Affordable composite fuselage Methodologies for modelling & simulation for high efficient, high performance computing non linear structural analysis and damage models applied to composite & laminates. Affordable technologies to reduce the environmental impact with use of a recycling process based on simple chemical-physical procedures involving no chemical reactions and low energy consumption. hybrid & composite materials with a high impact resistance or multifunctional composite for acoustic improvements, thermal protection, EME or lightning features or integrated SHM/NDI systems. technologies for low cost manufacturing with large one piece manufacturing, high automation, advanced infusion, curing & bonding techniques, and low cost assembling with high automation, lean, low infrastructure processes, efficient fastening. Impact damage survey on full scale items. NDI/SHM techniques for materials, assembling and design, including self-sensing. Technologies for complex shapes and high-loaded parts. Technologies for maintenance and repair In the framework of the AIRFRAME ITD, demonstrations are carried out up to component level by following the building block approach. Such will include a full scale barrel ground demonstrator. The generated technology base will be integrated in the full scale fuselage demonstrator inserted in the R-IADP demonstration
TS B4: Advanced Fuselage (cont d 3) Level 2 WP Technology Key demonstrator vehicle WP B4.4 Affordable low weight, human centred cabin Innovative multifunctional materials for interiors components including secondary structure integration concepts; development of chemical-free processes (thermoplastic welding, thermoforming, etc.); development of VOC (Volatile Organic Compounds) free materials in order to reduce passive toxicity related to the cabin furnitures. human perception and psychoacoustics with respect to A/C interior noise and vibration; new simulation technologies and methodologies for comfort (ergonomics, noise, thermal verification) A small-scale validation activity will be used, specifically targeted at a local change, to define the new concept(s) and validate in a local context according to type of application. Performance, operability and the acceptability of operational aspects will be the primary concerns. Virtual Reality setups will also be used to support the design conditions, allowing an optimisation of the environment for these tasks and is already used for multiple design processes. Small scale test will be performed for preliminary validation to assess the comfort index and noise/acoustic and FST performances.
European Small Aircraft OEM partnership* Piaggio Aero - P180 Mielec PZL M28 Aircraft Industries L-410 Grob -G120 TP Evektor EV-55 Diamond DA42 The European Small aircraft industry has a market position on the global general aviation and utility aircraft market both pistons and turboprops (excluding business jets and new category of Light Sport Aircraft) of around 33% in value (around 5 Billions Euro last ten Years). *OEM showed interest in SAT during consultation sessions 44
Major Research Areas to be addressed with JTI CS2 ITD Airframe Small Air Transport Overall A/C Design and Configuration Management Interface & Cross-interaction Management Reference aircraft Coordination and execution (aircraft level) of demonstration activity Optimized Composite Structures (wing box, engine nacelle) Advanced out of autoclave (OOA) technologies More automation for low-volume composite production More affordable metallic manufacturing (linear joints, local joints) Optimization of Friction Stir Welding technologies Automated metal structures assembling in low volume production High Lift Wing (SAT) High/Low Speed Innovative Aerodynamic Concept
Further Information Clean-SKy2-Airframe@dassault-aviation.com Goran Bengtsson - SAAB Alain Bouillon Dassault Aviation Miguel Llorca Sanz EADS CASA
Thank you for your attention! Innovation Takes Off