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Future of Composite Materials in the Austrian Aeronautics/Supply/Industry and Research – December, 1 st 2008 Joint Technology Initiative Clean Sky Composite Materials The Green Regional Aircraft ITD approach Rocco Pinto (Alenia Aeronautica)

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Page 1: Future of Composite Materials in the Austrian …...Cluster, ATR, Cira Plus Cluster, Hellenic Aerospace Industry and ONERA. A sizeable amount of activities are reserved to Call for

Future of Composite Materials in the Austrian Aeronautics/Supply/Industry and Research –

December, 1st 2008

Joint Technology Initiative Clean Sky Composite Materials

The Green Regional Aircraft ITD approach

Rocco Pinto (Alenia Aeronautica)

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Company Confidential

CLEAN SKY JOINT TECHNOLOGY INITIATIVE: OVERVIEW

Clean Sky, a public-private Joint Technology Initiative, launched by the European Council and by a large number of European entities active in aeronautics.

Clean Sky started operations on June 1st 2008

Allocated total budget : 1600M€, with a EU contribution of about 50%.

Clean Sky is led by 12 major European aeronautics entities, two for each of the 6 Integrated Technology Demonstrators, the ITD’s.

ITDs leaders budget sums up to 50% of the total budget.

Other several entities participate in the role of Associates, namely the largest Research Centers and Universities, and some industries, with a budget of about 25% of the Clean Sky total budget.

Partners will be introduced by the ITD Steering Committees by CFP : activities for not less than 25% of the Clean Sky budget.

Clean Sky will assess, design, build and test a number of innovative technology demonstrators, on-ground and in-flight, with the assessment and guidance of an evaluation tool, the Technology Evaluator .

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Vision 2020 Challenges – ACARE Goals

ACAREOctober 2002 : The Strategic Research Agenda (SRA) 5 Challenges

Quality and Affordability Environment Safety

Air Transport System Efficiency Security

Vision 2020 (January 2001)• To meet Society’s needs

• To achieve global leadership for Europe

October 2004 : The SRA 2 High level Target ConceptsVery Low Cost ATS

Ultra Green ATS

Highly Customer

oriented ATS

Highly time-efficient ATS

Ultra Secure ATS

22nd Century

CLEAN SKY

• 80% cut in NOx emissions• Halving perceived aircraft noise• 50% cut in CO2 emissions per pass-Km by drastic fuel consumption

reduction• A green design, manufacturing, maintenance and disposal product

life cycle

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Company Confidential

Clean Sky: An integrated and comprehensive approach

Eco-designFor Airframe and Systems

Vehicle ITDTr

ansv

erse

ITD

for a

ll ve

hicl

es

Smart Fixed-Wing Aircraft

Green Regional Aircraft

GreenRotorcraft

Clean Sky Technology Evaluator

Sustainable and Green Engines

Systems for Green Operations

• All market segments addressed

•TOTAL Budget: 1,6 B€ over 7 years

Leaders: Airbus& SAAB

Leaders: Eurocopter & Agusta Westland

Leaders: Alenia& EADS CASA

Leaders: Dassault Aviation& Fraunhofer Institute

Leaders: Rolls-Royce & Safran

Leaders: Liebherr& Thales

ITD: Integrated Technology Demonstrator

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Company Confidential

Clean Sky main innovative technologies

New concepts & active control, active wing technologies

Smart structures &low-noise configurations

Innovative rotor &engine integration

Low-noise &lightweight low-pressure systems

High efficiency low Nox cores

Novel configurations

All electrical aircraft technologies and systemsThermal managementGreen trajectories management

Green design, manufacture,maintenance, recycling for Airframe & Systems

Monitoring ConsistencySynergy

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Company Confidential

20082008 2009 2010 2011 2013 20142012 2015

• Planning of technology selection/development and demo preparation/modification

• Bring the integration of technologies to a readiness level enabling future aircraft programmes

Clean Sky : Generic Planning Clean Sky : Generic Planning

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Introduction to the Green Regional Aircraft

Integrated Technology DemonstratorGRA-ITD

CLEAN SKY JOINT TECHNOLOGY INITIATIVECLEAN SKY JOINT TECHNOLOGY INITIATIVE

Page 8: Future of Composite Materials in the Austrian …...Cluster, ATR, Cira Plus Cluster, Hellenic Aerospace Industry and ONERA. A sizeable amount of activities are reserved to Call for

Company Confidential

CLEAN SKY GRA – ITD

The Green Regional Aircraft ITD

Regional market is a large part of Air Transport System: today, in the world, 45% of flights are operated with regional aircraft.

In 2020 the share is estimated to rise to around 50%.

Substantial contribution to the “Clean Sky” shall then come from the Regional Air Transport

Improvement of the environmental impact deriving from the operation of regional aircraft are expected mainly from weight and noise reduction technologies, as well as from the integration of advanced technologies belonging to other domains.

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Company Confidential

GRA – ITD : Objectives and expected impacts GRA – ITD : Objectives and expected impacts

The ambition for the GRA - ITD is to achieve a reductionin fuel consumption and noise emitted through:

mature, validate and demonstrate the technologies best fitting the environmental goals set for the regional aircraft entering the market in the years 2015 - 2020

integrate technical solutions from the mainstream technologies ( Low Weight and Low noise Configurations) and from other technical domains of the Clean Sky (Energy Management, Mission & Trajectory Management, Engines, Eco Design) in the Demonstrators of the Green Regional Aircraft, using a multidisciplinary approach.

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The Green Regional Aircraft Platform

GRA – ITD : top Level WBSGRA – ITD : top Level WBS

GRA budget over 7 years: 174,21 M€Co-leaders: Alenia Aeronautica and EADS CASA

GRA 0

Management

GRA 5New Configuration

GRA 1

Low Weight Configuration

GRA 2

Low Noise Configuration

GRA 4Mission & Trajectory

Management

GRA 3

All Electrical Aircraft

GRA 0

Management

GRA 5New Configuration

GRA 1

Low Weight Configuration

GRA 2

Low Noise Configuration

GRA 4Mission & Trajectory

Management

GRA 3

All Electrical Aircraft

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• Low Weight ConfigurationLow weight aircraft configuration, that is the advanced solutions of composite structures with embedded sensors to monitor the eventsoccurring to each aircraft, and with new multi functional architectures. Ground and Flight tests are planned.

• Low Noise ConfigurationLow noise aircraft configuration, consisting of the innovative solutions of the wing high lift devices and of the landing gear installation enabling the generation of less aerodynamic noise while performing their other basic functions at a high level of efficiency.

• All Electrical AircraftMain objective of AEA is to demonstrate the feasibility of on-board systems technologies and architectures: electrical powered air conditioning and pressurization, electrical and electronic technologies for generation, distribution and control, electrical ice protection and flight controls. Flight tests are planned.

GRA – ITD : General approach and contentGRA – ITD : General approach and content

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• Mission & Trajectory ManagementIntegration and validation of new optimised missions and trajectories by using of a flight simulator.

• New ConfigurationNew configuration aims at defining advanced regional aircraft general configurations integrating the innovative powerplants (including Open Rotors), systems and avionics best fitting the regional aircraftrequirements, and the advanced aerodynamics and structures developed in GRA.

GRA – ITD : General approach and contentGRA – ITD : General approach and content

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GRA – ITD : Objectives and expected impactsGRA – ITD : Objectives and expected impacts

Innovative systems (All electrical)Lower Fuel Consumption Lower Maintenance costEcological improvement removing hydraulic fluid (AEA)Reduced environmental impact

Advanced wingLower Fuel Consumption Better climb performanceLower Airframe noise

Advanced engineLower Fuel Consumption Lower Maintenance costReduced CO2 & NOX

Integrated Modular avionicsWeight reduction Upgrade capabilities for MTMLower Maintenance cost

Innovative structures (Low weight) Lower weight Lower Fuel Consumption Lower Maintenance costReduced environmental impact

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The Green Regional Aircraft - LWC : Technical organization

Low Weight configurationsA/C Integration & technologies from other ITD’s

GRA ITD

Requirements

Technologies

Studies and solutions

Ground Demonstration

Flight Demonstration

Low Noise configurations

Requirements

Technologies

Studies and solutions

Wind tunnel testing

Iron bird

Flight Demonstration

New Configurations

All Electric Aircraft

Mission & Trajectory Mng’t

GRA – ITD Low Weight Domain: OrganizationGRA – ITD Low Weight Domain: Organization

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The Green Regional Aircraft – LWC

The others members of the GRA-LWC organization are:Alenia, EADS CASA, Fraunhofer Institute, Air Green Cluster, ATR, Cira Plus Cluster, Hellenic Aerospace Industry and ONERA.

A sizeable amount of activities are reserved to Call for Proposals open to European Institutions and Industries.

GRA – ITD Low Weight Domain: MembersGRA – ITD Low Weight Domain: Members

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The Green Regional Aircraft - LWC

So, the major objectives of JTI-GRA LWC for regional aircraft are to develop :

The research will mainly address to advanced composite and metallic structures in which the enabling technologies will be developed according to the following workflow.

JTI –GRA LWC Development

Research and Technologies acquisition

Requirement & Architectures

Technologies Development

Application Studies

Demonstrators

Yo Y3Y3 Y7

GRA –ITD Low Weight Domain: ObjectivesGRA –ITD Low Weight Domain: Objectives

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The Green Regional Aircraft - LWCIn the current design approach of composite structures their sizing is based on material mechanical properties that are degraded to account for the negative effects of humidity and temperatures and for foreign objects impacts occurring during the aircraft operation. Monitoring of actual events occurring toeach aircraft, which would be made feasible by sensors embedded in the structures, and the maintenance action consequent to damage detection, will allow a different design methodology in which less degradation is to be considered, with a resulting lower weight.The aircraft structures, beyond carrying structural loads, need to perform functions like lightning protection and electrical grounding. In metal conventional structures these functions are carried out by the base material itself. In composite structures these functions require the use of specialised elements, which add weight. This added weight will be minimised by multi-layer/ multi-function architectures.

GRA – ITD Low Weight Domain: ObjectivesGRA – ITD Low Weight Domain: Objectives

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Enabling Technologies

• Sensors to continuously control accidental damage,environment effects, and consequently in service structural degradation.

• Layer, Multilayer/multi-function architectures concept to decrease the negative impact on weight deriving from ancillary functions requested to the structure (lightning protection, grounding,…).

• Nano-material technologies (nanomodified prepreg production,…).

• Advanced metallic structure (fully laser welded integral structure, welded applied to Titanium sheet, …).

Embedding of FOBG sensors into composite materials (carbon)

GRA – ITD Low Weight Domain: Enabling Technologies

GRA – ITD Low Weight Domain: Enabling Technologies

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Main Enabling Technologies to be developed in LWC

GRA-LWC Technologies

GRA-LWC Technologies

Multifunctional Multilayer

WEIGHT REDUCTIONNoise Damping

Flame Smoke and Toxicity resistance Impact resistance

Structural property

Lightning strike Protection

Self-healing

Multifunctional LayerA multifunctional single layer is a structure in which different materials are integrated - in order to assure several functions - in a way that is impossible to identify them as separate layers

Damping

Flame resistant

Conductive Structural property

Self-healing

Environment barrier

A multifunctional multi-layer is a structure in which different materials are integrated, in order to absolve several functions

WEIGHT REDUCTION

Sensors: Fiber Optic Bragg Grating(FOBG)

BRAGGGRATING

FIBER OPTICTERMINATION

Cobonded J-spar with embedded FOBG sensors

Nanomaterials

Nanotubes

Carbon nanotube strengthenedepoxy resin for increasedcompression and interlaminarshear strength in composites (fuselage and wing)

GRA – ITD Low Weight Domain: Enabling Technologies

GRA – ITD Low Weight Domain: Enabling Technologies

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With reference to the generic regional aircraft type, the following demonstrations will be performed:

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. Scope of the Flight Test is to obtain validation in flight for advanced structural technologies that require data acquired in an actual operating environment. Full scale and flight strains will be compared.Scope of the Ground Test is to obtain validation for those advanced structural technologies that require static and fatigue data acquired using a test set-up simulating structural behaviour at full scale section level .

Ground DemonstrationFlight Demonstration

GRA – ITD Low Weight Domain: Demonstrators

GRA – ITD Low Weight Domain: Demonstrators

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Call for Proposals for Year 2009

CLEAN SKY GRA – ITDCLEAN SKY GRA – ITD

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CLEAN SKY GRA – ITD Definitions

• Calls for Proposals: means open calls for specific tasks, resulting in the selection of Partners on a competitive basis.

– Requested by ITD Leaders and Associates– Principles of excellence, transparency and equal treatment– Made during all 7 year time span

• Partner : means a legal entity selected in the course of JTI to perform specific tasks and is not necessarily committed for the full duration of the Joint Undertaking.

– Eligible for funding: Any public or private entity established in a Member State or in a country associated to the FP7

– Industries, SMEs, Research Institutes, Universities– Legal Entity, as recognised by FP7, to be formed in due time for

contract signature. Clusters allowed. One representative, one voice.– Grant agreement with the Clean Sky JU

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Community Contributions to Partners St. Art. 13

An amount of at least Euro 200 million shall be allocated to Partners selected via competitive Calls for Proposals

– 25% of total Community financial contributionParticular attention shall be paid to ensuring adequate participation of SMEs

– The Clean Sky JU shall establish relevant quantitative targets in line with those set in the Seventh Framework Programme

The Community financial contribution shall comply with the upper funding limits of the total eligible costs, laid down by the Rules of Participation of the Seventh Framework Programme

– 75% for Partners which are SMEs, public bodies, secondary and higher education establishments and non-profit research organisations.

Partners will be selected for participation in the activities of the Clean Sky Programme according to open and transparent competitive proceduresThe selection will be done with the assistance of independent experts.

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CfP Proposed steps in the selection process

1. General Selection Criteria (same for all ITDs/CfPs)– CfPs will contain clear details of the assessment criteria

that will be defined to select the best proposals having regard to all relevant factors. General factors common to all CfPs and ITDs include:• Technical excellence • Innovative character• Timetable and Compliancy with the CfP specification • Cost and value for money• Adequacy and quality of respondent’s resources,

management and implementation capabilities and track record

• Contribution to European competitiveness

– A threshold will be fixed for each factor.

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2. Preparation of Call for Proposals from a Member

– One Member of an ITD (the ITD coordinator or another ITD Member) identifies the need or benefit of a CfP for certain Task(s), it prepares an outline proposal, with a first draft of specification and evaluation of associated cost (for internal reference).

– The Member proposes a CfP Manager, who will follow the whole process.

CfP Proposed steps in the selection process

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3. CfP Approval by ITD Steering Committee– The outline CfP proposal is distributed to the ITD

Steering Committee members, for information and comments. The outline will include:• the scope of work. • the timing• the estimated costs (internal)

– The ITD Steering Committee approves the requested CfP

– The JU Executive Director publishes the CfP on the Clean Sky web site and assures a wide communication by the media.

4. All responses are submitted to the JU

CfP Proposed steps in the selection process

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5. Evaluation Panel– It is made up of internal and external experts– The Panel produces a shortlist report ranking the

proposals and explaining the order of merit.– Evaluation is overseen by the JU executive director

6. Selection by the Steering Committee– The SC receives the Evaluation Panel report and decides

the ranking list.

CfP Proposed steps in the selection process

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7. Negotiation Phase– The JU begins the negotiation with the top-ranked

applicant.– The results of the negotiation will be communicated to

the ITD Steering Committee.– ITD SC selects the candidate with the assistance of

independent experts and under the supervision of the JU executive director.

8. Grant Agreement– The selected candidate will sign the Partner Grant

Agreement and the accession to the Consortium Agreement, and then becomes a Partner of the Clean Sky JU

CfP Proposed steps in the selection process

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The Green Regional Aircraft ITD: LWC Technologies

Main technologies are :

WP1.3.2 Layer : C/F fabric Pre-preg interwoven with metallic wires;

WP1.3.3 MultiLayer : C/F pre-preg co-cured with metallic mesh inside or on the outersurface;

WP1.3.5 Nanomaterial: objective is to demonstrate the applicability of nano-filled resin system to produce a composite panel with increased impact (low, medium impact velocity) behaviour. In addition tothe impact resistance enhancement, nano-particles will givea further effect of functionality and/or improved thermo-mechanical properties (electrical conductivity, fire resistance).Nano-modified Pre-preg production, lay-up and curing in autoclave.

GRA- ITD : Main Technologies to be reserved for 2009 CfPs

GRA- ITD : Main Technologies to be reserved for 2009 CfPs

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Thanks for your attention !

Joint Technology Initiative Clean Sky Composite Materials