Optimization of APU Exhaust Muffler Thermal Barrier and Air Intakes construction Technologies

Project Information

CHRZASZCZ

Grant agreement ID: 101007816

DOI

10.3030/101007816

Project closed

EC signature date 18 December 2020

Start date 1 January 2021

End date 30 June 2023

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 1 044 462,50

EU contribution

€ 899 881,25

Coordinated by

SIEC BADAWCZA LUKASIEWICZ-INSTYTUT LOTNICTWA
Poland

Periodic Reporting for period 2 - CHRZASZCZ (Optimization of APU Exhaust Muffler Thermal Barrier and Air Intakes construction Technologies)

Reporting period: 2022-04-01 to 2023-06-30

Summary of the context and overall objectives of the project

The main issue of CHRZASZCZ project is to replace classical approach of designing APU equipment with new materials and production technology. The main goal is to lower mass and improve acoustic attenuation properties with optimization of costs and maintenance procedures securing thermal and fire protection of each component.
Reduction of environmental impact of aviation industry is necessary to contribute global warming stopping. Weight decreasing reduces fuel usage and noise reduction will influence surrounding of airports making living near them more comfortable. New materials allows to optimize costs and maintenance of new designs.
The main objective of CHRZASZCZ Project is design, development and manufacturing of technology demonstrators of Air Intake and Muffler for APU of Large Passenger Aircraft. Part of demonstrators delivery is detailed works description with achievements summary and possibilities of future improvements.Final summary of project results:
• All dimensional requirements fulfilled
• Surface quality for air intake improved
• Weight reduction achieved – for air intake 46% (60% for 3D model assumption) and for produced
muffler 22% (40% for 3D model assumption)
• Fireproof – materials selection and test done, fire did not penetrate outside surface, approach for
aviation certification investigated
• Noise level reduction achieved
• Environmental condition – fulfilled, material selection
• Drainage capabilities – tested
• Maintenance capabilities improved for both designs
• Production strategies optimized

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

First reporting period has been covered by initial design and FEM activities. Inputs, like basic geometries and requirements, delivered by the Topic Manager were implemented in 3D design to start discussion about possible strategies of improvement of current design. Install design was used for material selection process, that was strictly connected with requirements from Topic Manager. Initial FEM, acoustic performance and thermal analysis were done to secure proper approach with proposed design. Detailed 3D models were delivered for partners for review and final design changes implementation.

Several test samples were produced to obtain information about production process. Information from production and tests were implemented in to detailed design to secure fulfillment of all requirements. Parallel to those activities, detailed acoustic optimization process was started, to improve acoustic attenuation of proposed design. Results of those analysis was used to re-design initial design but with restriction to requirements provided at the project beginning. Acoustic data correction was done after delivery of test results for muffler and showed good match with analytical approach.

Second period was devoted to finalize all test activities and implement results in to numerical calculation, where necessary. In parallel final 3D models and production documentation was created and delivered. Critical Design Review, penultimate milestones, was carried out on the 27th of October 2022. All documentation was delivered alongside future concepts, improvements and reaching higher TLR level data. Final milestone, delivery of demonstrators was done in mid of June 2023 and closing meeting of the project took place on 26th of June 2023.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Current status of the project is showing huge mass reduction in comparison to previous solutions. Chosen materials implemented in to current 3D design resulted mass reduction estimation by 40-50%. Final delivered demonstrators are securing also quite big mass reduction around 33% in total. Rise of mass of delivered demonstrators was done due to production constrains, thus delivered result is also very good.
Calculations of acoustic performances of both demonstrators also show rise of acoustic attenuation compared to current solution. Acoustic samples and testing activities provided real data for calculations, that slightly reduced expected attenuation levels, but overall calculations showed good match with experiment.
Thermal and fire proof performance calculation are showing possibility to remove any additional heat protection, as proposed solutions secure fulfillment of those requirements. Final tests showed, that in fact there is still possibility of improvement in terms of mass reduction, as flame did not penetrate both samples.
Improvement was done also on maintenance field, as proposed design can be partially replace, if needed, contradictory to previous solution. Delivered demonstrators fully showed, that proposed design solution was possible to be implemented and delivered.

Planned research on new technologies carried out in parallel with design activities focused on searching for solutions providing the best performance developed innovations meeting the needs of the European and global markets due to huge improvement in acoustic attenuation and big mass reduction in highly demand environment for such components. Project results should be widely used by aviation industry, as possibility of application developed technologies is very wide, not only auxiliary power unit equipment. Delivered solutions shows clearly, that it can be for sure used for commercial purpose, with additional statement of future works needed for final product phase achievement.

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