ecodesign itd, clean sky closing event · • the improvement of environmental aspects (e.g....

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Lessons learnt, the way forward and

key partner contribution

ecoDESIGN ITD,

Clean Sky Closing Event Brussels, 22nd March 2017

John Simpson

Fraunhofer Gesellschaft

General Director Aviation


Eco DESIGN a success story in green aviation

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CSJU footnote: “ecoDESIGN is in the essence of the Clean Sky DNA and design

philosophy, underpinning every project and initiative we undertake across all programme

areas, ITDs and IADPs


ecoDESIGN/ Best value research through partner collaboration

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Key Material Innovation Integration

Key Specialist Eco Technology Integration

Key Technology Portfolio

Excellence in Detail

First Clean Sky Project: CORA

Clean Sky Awards Winner 2016: SENTRY

Accolade of CfPs, key words appended


Example, Eco-Statements – Trade off lesson (s)

∆ = Partial

replacement

of petrol

based polyol

Global Warming Potential [kgCO2e/kg PUR foam]

∆ =

∆ =

No flame

retardant

1.4 – 2.4

↓ 7 % - 12%

Green PU seating cushion

A/c -seat 10-14kg, on the cushions ->

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Lessons, Implementation and more

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• The reduction of the manufacturing costs & time combined with decreased energy consumption, due to

higher integration of automated manufacturing processes

• The improvement of environmental aspects (e.g. substitution of noxious substances, less waste, reduction

of primary resource consumption, increased recycling ratios)

• The creation of customized LCA models for current and future aircraft, covering production maintenance

and end of life – CS Materials DataBase, BOM, BOP,

advanced Aeronautics Materials, Clean Technologies(Cr6 free etc.)

• Less fuel consumption through (clean approach) lightweight architecture (multifunctional materials, new

processes & more efficient use of resources) and efficient energy management which consequently results in

CO2 and NOx emission reduction

• New ecolonomic Machine Architecture potentials, keeping an emissions benefit margin, beckoning design

investigation sensitivity at high TRL for tomorrow

in key areas e.g. High Voltage and High Temperature (ElectricB and ThB)

with low SNR Disturbance and optimal Energy Management Sink


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• increased aircraft availability through more efficient maintenance

(repair, longer lifetime etc.)

• reduction of ground and flight tests during the design phase as well

as reduced buy to fly ratios through innovative concepts and

technologies

• benefits in recycling and corrosion resistance (innovative surface

treatment, reduced use of sealants by improved welded joint designs)

• clean manufacturing conditions: no dust, no chemicals..

process efficiency opportunities… advanced skills (socio-economic

impacts)

• less energy consumption due to “Out of Autoclave” processes

Lessons, Implementation and more


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AChSo Novel preforming of textiles (chemical stitching) ACID Advanced Composite Integrated Skin Panel structural testing

ADVANCED Advanced heating system and control for homogeneous high temperature curing of large composite repairs

AEROBEAM SLM and EBW for direct manufacturing of titanium stator vanes AiMeRe Recycling routes screening ALT

Aluminum alloys for high temperature applications AMICOAT Cromium free primers (fungus growth inhibition) APRIL

Advanced preform manufacturing for industrial LCM-processes BFCLeaner Borate free Cleaners for Aluminum Alloys

BIO_LCA_TOOL Simplified LCA Tool development BIFTTEC bamboo fibers BiMed Repair solutions (paint removal by

bicarbonate blasting) BME CS 27 Development of an innovative bio-based resin for aeronautical applications BRIGHT

Applications of bio materials to cabin interiors CF-THREAD Accelerated testing methodology (composites structures)

COMAG Conductive coatings for Mg sheets CONDUCTOR Repair solutions (flexible inductive heating device) Co-Proclam

Corrosion protective coatings on light alloys by micro-arc oxidation CoSPI Reduction and reuse of wet/dry composite materials

(infusion induction) CR FREE EPAINT Cr free coatings (anaphoretic paint) CHROMFREE Multi acid anodyzing (TSAA

cromate free sealing) DEFCODOOR Development of an eco-friendly final consolidation step using thermoplastic fibre

placement for a helicopter door DISACOP Disassembly of eco-designed helicopter demonstrators DIMAG Development and

implementation of magnesium sheets in A/C ECEFA Aluminum alloys for B2 demo ECO-FAIRS ecoDESIGN and

manufacturing of thermoplastic structural fairings for helicopters ENDAMI Industry LCA tool simplified and advanced

applications Extra-laser Extrapolation and Technical and economical study of a LBW technology FATIMA Accelerated testing

methodology (fiber reinforced laminates)

Accolade of partner projects I


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FIBIOSEAT Cushion polyurethane foams GELAIR Application of sol gel technologies on low weight green metallic fuselage

section HI-STA-PART High Strength Aluminium Alloy parts (Aluminium Scandium Alloy-Scalmalloy) by Selective Laser Melting

(SLM). Comparison with existing manufacturing methods. HiTemComFil Manufacturing of high temperature composite parts for

air cooling unit by filament winding HVRCFM Recycling into new fabric ILMAS Extrapolation to industrial condition of the

liquid infusion manufacturing process IMAGINE Processing for glass fibers reuse IRECE Extrapolation to industrial condition of

a cured composite and thermoplastic recycling process IRIDA Industrialisation out of autoclave polymerization for LR

ISINTHER Thermoplastic processes (in-situ consolidation) LAWENDEL Laser Beam Welding (LBW) approach LIBSAC

Identification and mapping for recycling (laser induced spectro) LCA-DATIM Life cycle assessment database improvement LEAF

Tool for ecoDESIGN Airframe simplified LCA LIGHTWELD Characterization of metallurgical joining technologies (through

Laser Beam Welding LBW) for Mg – Al and Mg – Al-Li joints LRI-HiT LRI and out of autoclave curing MAGNOLYA Advanced

environmentally friendly chemical surface treatments for cast magnesium helicopter transmission alloys preservation MIFACRIT

Methodology toolbox for Aacelerated fatigue testing of FRP materials: micro-structural failure criterion for multi-axial fatigue of

FRP structures NEMESIS Sustainability assessment for EcoDesign-Guideline OPTOCLAVE Design, implementation and

validation of an automatic learning cure cycle optimisation process for the eco-efficient autoclave processing of composite materials

PlasmaClean Surface mapping and control during atmospheric plasma treatments PLENOPTIMUM Manufacturing

optimization of a plenum with GFRP cyanate ester-based prepreg REMART Recycling of metallic materials from rotorcraft

transmissions SAA-Seal Multi acid anodizing (Sealing on SAA layer) SELFRAG CFRP electro dynamic fragmentation SENTRY

LCA of low weight green metallic fuselage panel(s) including physical dismantling and recycling

Accolade of partner projects II


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SPECIMEN Cyanate ester based composites SUPERBLEND Thermoplastic matrix (similar to PEEK) RASAC Identification

and mapping for recycling (raman spectro) SUSRAC Sustainable recycling of aircrafts composites SPECIMEN Cyanate ester

based composites SUSRAC CFRP recycling (waste filled compound process) TARTASEAL Chromate free and energy efficient

sealing of TSA anodic films for corrosion protection Thermoplastic scroll Manufacturing and optimisation of a PEEK scroll by

fusible core injection molding for E-ECS MTC TIFANManufacturing by Selective Laser Melting (SLM and bar machining) of

Titanium Fan wheels VALIDATE Validation of TSAA coating technology WISMOS Wireless integrated strain monitoring and

simulation

(EDS systems level)

AEGART Generator design and Construction AEROTHERMOPROP Thermophysical Properties Library for Relevant Fluids

AeroL-HP Heat pipes BESTT Development, Construction and Integration of Bench Systems for Ground Thermal Tests CORA

Sensor for Convective and/ or Radiative Heat Loss ELTESTSYS Electrical test bench drive systems: mechanical interfaces

EPOCAL Electrical Power center for aeronautical loads HEMAS Helicopter swash plate EMA High PMAAC Electrical

Test Bench Control System I PRIMES Intelligent Power regulation using innovative modules for Energy supervision MAS DE

NADA Modeling and advanced software development for electrical Networks in aeronautical domain analysis SEPDC Electrical

Test Bench Power Center SMART Saber model automatic translation tool SPLS Advanced programmable loads SUPREMAE

Software for saber models conversion to multi-systems simulation platforms

Accolade of partner projects III


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Dissemination & Communication Analyses, CFP/ GAP

[ JU 17. Dec. 2015,

I. Bitsios with 65 from 69 (Spring- 2016 wrapped- up)

GAPs]

GAM 2011*-15 Total 225 Final Report 2016

GAM 2008-15 Total 348 Fraunhofer Monitored

Weighted Mutiannual, JU,

2009-2016, Dissemination & C.

GAM: 216

GAP: 317

ecoDESIGN-GAM, Reference

technical delivery closure: Dec. 2015 317

* 2011 means 2008 - 2011 CSJU weakly accounted,

Advocacy up to 2008 and into 2009 NOT AT ALL

Numbers for

Deliverables Outputs/ Inputs are taken as duty

to the core GA purpose and are NOT INCLUDED


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CFP/ GAP, Leading, exploitable foreground cases

[ JU 17. Dec. 2015, I. Bitsios]

GAM : 53 Final Report dB/ 2011-15

GAP:

Total = 192

Environmental Benefit Technologies

infused to connected EDA components

Pathway-

Total = 176

139

Total 176


Dissemination & Communication

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Events 2016

• JEC Europe, 8th to 10th March 2016, Paris, France

• 3rdEuropean Aircraft Recycling Symposium, 16th and 17th March 2016, Stuttgart, Germany

• Clean Sky Forum, 4th March 2016, Brussels, Belgium

• ILA Berlin Air Show, 1st to 4th June 2016,

Berlin, Germany (Fraunhofer booth)

• Farnborough Air Show, 11th to 17th July 2016,

Farnborough, United Kingdom

recent

procedings in analysis


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JEC Paris

The demonstrator EDA A3 at the JEC in Paris.

The demonstrator EDA I2 at the

JEC in Paris.


Dissemination examples


Highlights ongoing

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Award

eco DESIGN ENDAMI Tool for Sustainia

Eco DESIGN ENDAMI Tool

made it into the Top Ten in

the category IT.

Statement of the Jury:

ENDAMI addresses the

environmental impacts of

building new aircraft.

Implementation will add no

costs to traditional design

processes. The modular

and flexible structure is

readily adaptable to other

products and sectors.


Highlights ongoing

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Symposium

Aircraft Recycling Symposium, Stuttgart

Implementation of the Symposium as yearly event since 2013


News and Themes learnt for the Future?

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Global trends still valid

Globalisation and

Urban sprawl

Demographic

change

Informational

society and

new technologies

Increasing mobility

and transportation

Energy consumption

and resource depletion Climate change

2008 View - Generality


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Boundary conditions 2016?

-> more circular and inclusive thinking is necessary

“Clean Sky is not only an Initiative in the Air”

& “ecoDESIGN is not only a land fill topic for Aircraft Retirement”


Eco-Innovation (secured creativity) Concerns?

• Emerging standards, awareness on

REACh, primary energy cost risks etc.

are firmly with us, resource scarcity and economic/

material flow competition &

skill flow competition

• If European services/ techn. Labour is not assisted by new

business approaches/ technologies

it will be outsourced from Europe

Staying in Charge of Connectivity

• Europe has to consider which products

it wants to commercialise in the future,

Creativity for that, the outset design domain

[Competitiveness! difficulty for the average-BAU]

2025


Eco-Design Charta - to date

Eco-Design has key Materials, Processes and Resources impact and a strong relevance from the

Flight Path 2050, European eco-Innovation Agenda and the HORIZON programme.

This goes well beyond full green recyclability and pristine life cycle guidance: Eco-Design serves as synergy

and motivator for partnership in new business strengths, in

the aeronautics manufacturing base of excellence, in new supply chain services (even more

than MRO + Financial Systems) -interactions, advanced material cycles and opening synergies in

innovative technology streams [with ITD/IADPs]

CS2 Regulation[incl. CS delivery] Art. 2

Part III societal-challenge roof top priority and Horizon Regulation annex 1

eco-Innovation chap 4, 5 – & circular connection to part I and II

2(a) supply chain excellence

2(b) contribution to NOx and CO2 reduction

(advanced MPR manufacturing

….. e-learning, future factory, LCA,

connected (circular) productivity,

societal inclusive, „Industry 4.0“

…(real) Free Material Optimisation

additive/ intrinsic quality deployment

… Human-, Information

business connectivity

…. Digital Economy,

(Smart) Mega Trends


ecoDESIGN future building on Clean Sky foundations


Where are we in conceptual DESIGN Methodologies ?

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Range

BFL

Ma

FL

PAX

„Life Cycle Derivative“

Basic Conceptual Parameters

New Processes„ Derivatives

Services

Economic end to end drivers

Flight Physics

Innovative Configurations/ Vehicles

Innovative Productivity Models Life Cycle Engineering Value

Integrated Product Policies

-> added supply-chain value

EDS Systematic capability to upscale focus inside -out problems: e.g. 7000GWP - factor Halon Replacement Yes/ NO? Introduction of legacy or new Components, ecolonomic/reliability risk controlled, to free AEA concept Investigations, definition capacity for exploitable hybrid electric, fluidic concepts;

Life Claims (IPR, Marketability/Redundancy/ Re-Use)

Socio-Economic Deriv.

(SED)

EDA

Data Bases connected high TRL – cluster Demonstration (s) Production Phase Impact- Eco Statement; LCA monitored, Environmental Stewardship, Relevant CS Collaboration Scale

Objectives

Academic DOC

or

User Benefit, LCC…

Requirements, Certification Ease

Life Cycle Inventories(LCI) ->


AP

POCP

EP

Coupling and snow-ball, collective

effects

are a challenge, yet closer, magnitudes higher

ISO 14040..ILCD collaborative application and

communication discourse

value compared to 2008 Status

(just three of the CS1 widely implemented

Potentials, considered impact routes)

[Lindner/ Hauser]

Around 12 SOA solid Environmental Impact Potentials

are now in widespread aeronautics „understanding“ , in high TRL applications


The inclusive effect of ecoDESIGN

Inputs

Endpoints

Ground Pollution Action Frame,

Sustainability &

Productivity

Empowerment

User Satisfaction/

friendliness – security-

Health/

Working Environm., skills and

process change opportunities

Ecolonomic

differentiators, Connectivity

IPR, Societal-;

Information

Inclusiveness

Energy

Matter (Resources)

Water

Impacts Potential


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[A]: LIFT,

Identification

strategy, Life

scoping

[B]: Materials,

Processes &

Resources

(MPR)

[C]:

Manufacture/

Production

[D]: Services to

component and system

(MRO, financing,

accounting, storage, inside-

outside gate processes, alt.

Parts/ COTS…. Material

Flow Logistics)

[REUP]:

Re-Use

[EoL]:

End of life

[ADS]:

Integration/ Field

Assembly-

Disassembly-

Separation

[ASA]: alt.

sectorial

applications

[UP]: Use

Phase (

partial, socio-

economic

evaluations

derivative)

vertical/ horizontal activity,

ecoDESIGN Themes


Global Clean Sky eco DESIGN Key Performance Indicators @ 2016

• The RE-cycle, RE-use quota (RRQ),

• The equivalent ground pollution

potential (GPP)

• An “advanced” Eco Statement (ES)

with the socio-economic statement

(SES), owning an Eco Design socio-

economic derivatives set.

Summed,

Bottom-up

micro-economic contributions

State of the art

Life Cycle portfolio

of environmental factors-equivalent

not „just“ GWP

Avoiding waste, reducing GWP


Eco-Design Guidance


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Reaping ecoDESIGN added values for 2024 and beyond

will probably mean the challenge

of completely new tools and capabilities,

joint and several open mindset to Dissemination and Exploitation,

new partnership experiments to that cause,

building beyond

legacy aeronautical, industrial programmes„ experience

and past decades„ changing R&D networks,

some steps of the ITD-ecoDESIGN-phase 2008-2016;

But luckily we have the community tenure,

pool of innovative connections and resources

through the Clean Sky JTI

to tempt and evolve transversal change

ecoDESIGN Clean Sky Framework Prospectus


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Aknowledgement to the

CSJU ecoDESIGN Core Team Partnership

ecodesign itd, clean sky closing event · • the improvement of environmental aspects (e.g....

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