Periodic Reporting for period 1 - MORPHO (Embedded Life-Cycle Management for Smart Multimaterials Structures: Application to Engine Components)
Período documentado: 2021-04-01 hasta 2022-09-30
The supply chain for European aircraft aims to achieve competitive and sustainable products with high quality standards. Aircraft and engine manufacturers are also demanding for a radical change in the efficiency, profitability and flexibility of industrial processes in order to adapt to high production rates and ever-increasing product complexity and variability. In the framework of the transition to an industry 4.0 the deployment of connected objects is transforming the manufacturing and maintenance processes enabling tighter integration of the value chain. Therefore, adding native connectivity to the various parts of an aircraft, will be a key technology to speed up this transformation. This goes through embedding sensor technology into airframes, providing them with cognitive capabilities to improve manufacturing process and operational availability without compromising safety. MORPHO is the joint effort of European experts in smart manufacturing, sensor integration, structural health monitoring and recycling of aerospace structural parts and SAFRAN, a major OEM to face this tremendous challenge
Modern and future fan blades are designed and manufactured using a hybrid metal and advanced composite configuration. Indeed, for the LEAP engine, the core body of the fan blades is built up of 3D-woven composite manufactured using RTM (Resin Transfer Molding) process, while the leading edge is made up of titanium. This new design allows for a mass gain and exhibit high strength and fracture toughness, yet they remain vulnerable to foreign object impact and delamination damages.
MORPHO’s goal is to promote industrially the deployment of smart engine fan blades by adopting a cognitive paradigm for their manufacturing, health monitoring during service-life, and recycling. MORPHO’s key objective is to advance the design, production, and field operation of multifunctional fan blades, with an emphasis on efficient, profitable, and environmental-friendly manufacturing, maintenance, and recycling. Indeed, during the life cycle of equipment (LCM), particular importance is given to: (i) the control of its manufacturing process, (ii) its operational availability, (iii) its maintenance (iv) the recycling of the components that constitute it.
In order to master the LCM of the fan module, which is the primary interface of the engine and the environment, we propose to embed sensors (printed piezoelectric and temperature and fiber optic) inside/on each blade and develop dedicated digital/hybrid twins to provide aircraft engines blades with cognitive capabilities. These will allow to manage and assess their entire life cycle. Last but not least, MORPHO’s ambition is to set the cornerstones of future standards for a reliable, sustainable, agile and cost-effective industrialization of this new generation of intelligent and multifunctional parts and of their associated manufacturing processes.
Modern and future fan blades are designed and manufactured using a hybrid metal and advanced composite configuration. Indeed, for the LEAP engine, the core body of the fan blades is built up of 3D-woven composite manufactured using RTM (Resin Transfer Molding) process, while the leading edge is made up of titanium. This new design allows for a mass gain and exhibit high strength and fracture toughness, yet they remain vulnerable to foreign object impact and delamination damages.
MORPHO’s goal is to promote industrially the deployment of smart engine fan blades by adopting a cognitive paradigm for their manufacturing, health monitoring during service-life, and recycling. MORPHO’s key objective is to advance the design, production, and field operation of multifunctional fan blades, with an emphasis on efficient, profitable, and environmental-friendly manufacturing, maintenance, and recycling. Indeed, during the life cycle of equipment (LCM), particular importance is given to: (i) the control of its manufacturing process, (ii) its operational availability, (iii) its maintenance (iv) the recycling of the components that constitute it.
In order to master the LCM of the fan module, which is the primary interface of the engine and the environment, we propose to embed sensors (printed piezoelectric and temperature and fiber optic) inside/on each blade and develop dedicated digital/hybrid twins to provide aircraft engines blades with cognitive capabilities. These will allow to manage and assess their entire life cycle. Last but not least, MORPHO’s ambition is to set the cornerstones of future standards for a reliable, sustainable, agile and cost-effective industrialization of this new generation of intelligent and multifunctional parts and of their associated manufacturing processes.
The main results achieved so far are listed below:
- Providing the first specifications and requirements related to the life cycle monitoring and assessment of 3-D woven composite/titanium demonstrator named FOD (Foreign Object Damage) panel. These requirements concern process monitoring, sensing integration, structural health monitoring and prognostic, dissembling/recycling, digital/hybrid models and material characterization
- Elaborating a hybrid twin merging physics-based and data-driven models for the RTM manufacturing process of the smart structure. This hybrid twin allows real-time prediction of flow front position and global material parameters identification using only resin time arrival at sensors location. It will need to be updated with data from the upcoming experimental campaign.
- Developing a detailed Finite Element (FE) model allowing simulating the mechanical response of the realistic geometry of the FOD panel. The FE model encompasses failure criteria and considers the effect of the induced centrifugal forces and the bird strike case. Moreover, a draft regarding Piezoelectric (PZT) sensors positioning has been provided.
- Performing static and dynamic characterization of the 3D woven composite using Universal Testing Machines as well as the split Hopkinson pressure bar apparatus.
- Proposing an integration concept of fiber optic (FBG) sensors inside the mold. Solutions for connectorization, sealing and FBG embedding on preform have been provided.
- Developing an ultra-fast resin arrival sensing system alone with sensors plugs installations and check at the FOD mould
- integrating printed sensors (PZT and temperature) on samples having the same structure and surface finish than the targeted FOD panel.
- Conducting preliminary FE simulations and experiments of the shock laser-based disassembly process. The first results show the capability of this process to separate the Titanium layer from the composite (PCM)
- Performing Lab-scale pyrolysis and post-pyrolysis on composite samples (rCF). The recycled Carbon Fibers have been mechanically characterized and compared to virgin ones to evaluate their properties. The findings are very encouraging.
- Creating a collaborative space to manage the project, share document and host MORPHO data.
- Providing with a Data Management Specifications (DMS) and a common data storage format based on the open source HDF5 format.
- Creating the MORPHO website alone with the communication and dissemination plan including Book of Style.
- Setting up and animating social media channels of the project Participation in different events with project presentations and papers: EU Green Week partner event “Circular aviation for green growth”; 11th EASN International Conference “Innovation in Aviation & Space to the Satisfaction of the European Citizens”; Final Public Workshop of SuCoHS project; 12th EASN International Conference on Innovation in Aviation and Space for opening New Horizons. Participation in events with communication materials (videos, brochures): Ecomondo 2021, JEC World 2022; Delft Summer School 2022 and ILA Berlin 2022.
- Proposing an exploitation strategy and managing the IPR (Intellectual Property Rights)
- Identifying the appropriates health and safety procedures conforming to the relevant local, national and European legislation followed in the framework of the Morpho project.
- Providing the first specifications and requirements related to the life cycle monitoring and assessment of 3-D woven composite/titanium demonstrator named FOD (Foreign Object Damage) panel. These requirements concern process monitoring, sensing integration, structural health monitoring and prognostic, dissembling/recycling, digital/hybrid models and material characterization
- Elaborating a hybrid twin merging physics-based and data-driven models for the RTM manufacturing process of the smart structure. This hybrid twin allows real-time prediction of flow front position and global material parameters identification using only resin time arrival at sensors location. It will need to be updated with data from the upcoming experimental campaign.
- Developing a detailed Finite Element (FE) model allowing simulating the mechanical response of the realistic geometry of the FOD panel. The FE model encompasses failure criteria and considers the effect of the induced centrifugal forces and the bird strike case. Moreover, a draft regarding Piezoelectric (PZT) sensors positioning has been provided.
- Performing static and dynamic characterization of the 3D woven composite using Universal Testing Machines as well as the split Hopkinson pressure bar apparatus.
- Proposing an integration concept of fiber optic (FBG) sensors inside the mold. Solutions for connectorization, sealing and FBG embedding on preform have been provided.
- Developing an ultra-fast resin arrival sensing system alone with sensors plugs installations and check at the FOD mould
- integrating printed sensors (PZT and temperature) on samples having the same structure and surface finish than the targeted FOD panel.
- Conducting preliminary FE simulations and experiments of the shock laser-based disassembly process. The first results show the capability of this process to separate the Titanium layer from the composite (PCM)
- Performing Lab-scale pyrolysis and post-pyrolysis on composite samples (rCF). The recycled Carbon Fibers have been mechanically characterized and compared to virgin ones to evaluate their properties. The findings are very encouraging.
- Creating a collaborative space to manage the project, share document and host MORPHO data.
- Providing with a Data Management Specifications (DMS) and a common data storage format based on the open source HDF5 format.
- Creating the MORPHO website alone with the communication and dissemination plan including Book of Style.
- Setting up and animating social media channels of the project Participation in different events with project presentations and papers: EU Green Week partner event “Circular aviation for green growth”; 11th EASN International Conference “Innovation in Aviation & Space to the Satisfaction of the European Citizens”; Final Public Workshop of SuCoHS project; 12th EASN International Conference on Innovation in Aviation and Space for opening New Horizons. Participation in events with communication materials (videos, brochures): Ecomondo 2021, JEC World 2022; Delft Summer School 2022 and ILA Berlin 2022.
- Proposing an exploitation strategy and managing the IPR (Intellectual Property Rights)
- Identifying the appropriates health and safety procedures conforming to the relevant local, national and European legislation followed in the framework of the Morpho project.
The proof of concept addressed in MORPHO is related to an aeronautical engine fan blade composed of hybrid material with an emphasis on smart manufacturing and health assessment. The project is mainly positioned on the aeronautical market and, by extension, the space, automotive and naval sectors may also be targeted. Moreover, connection to wind power industry is straightforward. It’s expected impacts as well as the actual project contributions are the following one:
- Manufacturing next generation multifunctional and intelligent airframe and engine parts: RTM process of the fan blades is about to be monitored and a hybrid twin of this process has been developed. In that sense, MORPHO is on the way to reach this impact.
- New manufacturing paradigm shift with enhanced ecological maintenance and recycling characteristics. Dismantling tests using LASER shock and pyrolysis tests on SAFRAN materials have been successfully carried out. In that sense, MORPHO is on the way to reach this impact.
- New/updated technologies that will offer a competitive advantage of European MROs.
- Maintaining and extending European industrial leadership.
- Manufacturing next generation multifunctional and intelligent airframe and engine parts: RTM process of the fan blades is about to be monitored and a hybrid twin of this process has been developed. In that sense, MORPHO is on the way to reach this impact.
- New manufacturing paradigm shift with enhanced ecological maintenance and recycling characteristics. Dismantling tests using LASER shock and pyrolysis tests on SAFRAN materials have been successfully carried out. In that sense, MORPHO is on the way to reach this impact.
- New/updated technologies that will offer a competitive advantage of European MROs.
- Maintaining and extending European industrial leadership.