Periodic Reporting for period 2 - ADDAPTTA SEALS (ADDitive mAnufacturing oPTimized TAilored SEALS)
Período documentado: 2020-04-01 hasta 2021-02-28
The main objective of the ADDAPTTA SEALS project will be to develop new concept seals for wing aerodynamic surface, with better performance than currently used and further advantages in terms of cost, time to market and maintainability of the aircraft. This will be achieved due to the benefits of additive manufacturing technologies and the usage of specific materials developed for this particular purpose.
In addition to improving the aerodynamic performance of the aircraft, the use of this technology for the manufacture of the seals provides another series of advantages, including an optimization in resources needed for manufacturing, in terms of personnel, energy needed, less need for tooling, etc. All this results in a minimization in carbon footprint.
Conclusion:
Additive manufacturing technologies and specific materials has been developed for this particular purpose. For achieving these ambitious targets, a number of particularly complex knowledge and expertise are needed, related to aeronautic design, additive manufacturing processes, elastomeric materials specifically formulated for additive manufacturing, and qualification of products under aeronautical standards. Hence, ADATICA Engineering, CSIC-ICTP and APPLUS Laboratories consortium was created.
The main activities carried out by CSIC-ICTP has been related to analyze the elastomeric materials compatible with 3D printing prone to be employed in the elaboration of aircraft seals and formulate printable materials that fulfils the mechanical, environmental and functional requirements defined by the Topic Manager of AIRBUS.
On the other hand, Adatica has developed seal design optimization for each seal to improve friction and aerodynamical performances.
Simultaneously, coupons have been manufactured for technology and material testing ensuring that the selected material and manufacturing technology fulfills with the mechanical requirements. Once tested by Applus+, seal coupons where manufactured to develop functional and qualification tests at Applus+ infrastructures.
Lastly, manufactured seals for the wing of FTB#2 Regional Aircraft Flight Demonstrator of AIRBUS have been tested and an optimization loop to improve manufactured seals have been carried out. It is important to note that, the results of all functional tests on the optimized designs have been satisfactory, confirming that seals manufactured using additive manufacturing technology are an interesting solution when fast design changes are required.
In addition to improving the aerodynamic performance of the aircraft, the use of this technology for the manufacture of the seals provides another series of advantages, including an optimization in resources needed for manufacturing, in terms of personnel, energy needed, less need for tooling, etc. All this results in a minimization in carbon footprint.
Conclusion:
Additive manufacturing technologies and specific materials has been developed for this particular purpose. For achieving these ambitious targets, a number of particularly complex knowledge and expertise are needed, related to aeronautic design, additive manufacturing processes, elastomeric materials specifically formulated for additive manufacturing, and qualification of products under aeronautical standards. Hence, ADATICA Engineering, CSIC-ICTP and APPLUS Laboratories consortium was created.
The main activities carried out by CSIC-ICTP has been related to analyze the elastomeric materials compatible with 3D printing prone to be employed in the elaboration of aircraft seals and formulate printable materials that fulfils the mechanical, environmental and functional requirements defined by the Topic Manager of AIRBUS.
On the other hand, Adatica has developed seal design optimization for each seal to improve friction and aerodynamical performances.
Simultaneously, coupons have been manufactured for technology and material testing ensuring that the selected material and manufacturing technology fulfills with the mechanical requirements. Once tested by Applus+, seal coupons where manufactured to develop functional and qualification tests at Applus+ infrastructures.
Lastly, manufactured seals for the wing of FTB#2 Regional Aircraft Flight Demonstrator of AIRBUS have been tested and an optimization loop to improve manufactured seals have been carried out. It is important to note that, the results of all functional tests on the optimized designs have been satisfactory, confirming that seals manufactured using additive manufacturing technology are an interesting solution when fast design changes are required.
The total scope of this project will cover the detailed design, manufacturing, optimization and qualification of a full set of seals adapted to the wing of FTB#2 Regional Aircraft Flight Demonstrator by Additive Manufacturing technologies.
From the beginning of the project until today, the following phases have been completed:
1. Materials Development and Trade-Offs at the CSIC facilities
2. Design seals Trade-offs, Preliminary and Critical Design Review in ADATICA facilities
3. Coupons and Seals manufactured for tests in ADATICA facilities
4. Seals manufactured for Step-1 Functional Tests
5. Material Qualification tests in CSIC and APPLUS facilities
6. Endurance test definition and realization in APPLUS facilities
7. Optimized design. Improvement and optimisation of the designs, with the information of the results obtained during the functional tests carried out on the aircraft
8. To manufacture by additive process technology the seals designed and optimized in Functional Test. These seals will be used for flight tests on the aircraft.
9. Qualification test results and Seals Qualification Report
10. Report on Communication, Dissemination and Exploitation actions
The end result has been very satisfactory. The seals have been designed, manufactured and installed on the aircraft as planned. In addition, the advantages of this technology have been demonstrated, being the most important, the ability to apply modifications to the part, quickly and flexibly. These advantages are easily extrapolated to other sectors where rapid modifications of this type of parts are required.
These results will be disseminated and exploited as much as possible, although for now it has not been possible to do so normally, due to the impact produced by Covid-19. As soon as normality is restored, all the results will be presented in different forums and events.
From the beginning of the project until today, the following phases have been completed:
1. Materials Development and Trade-Offs at the CSIC facilities
2. Design seals Trade-offs, Preliminary and Critical Design Review in ADATICA facilities
3. Coupons and Seals manufactured for tests in ADATICA facilities
4. Seals manufactured for Step-1 Functional Tests
5. Material Qualification tests in CSIC and APPLUS facilities
6. Endurance test definition and realization in APPLUS facilities
7. Optimized design. Improvement and optimisation of the designs, with the information of the results obtained during the functional tests carried out on the aircraft
8. To manufacture by additive process technology the seals designed and optimized in Functional Test. These seals will be used for flight tests on the aircraft.
9. Qualification test results and Seals Qualification Report
10. Report on Communication, Dissemination and Exploitation actions
The end result has been very satisfactory. The seals have been designed, manufactured and installed on the aircraft as planned. In addition, the advantages of this technology have been demonstrated, being the most important, the ability to apply modifications to the part, quickly and flexibly. These advantages are easily extrapolated to other sectors where rapid modifications of this type of parts are required.
These results will be disseminated and exploited as much as possible, although for now it has not been possible to do so normally, due to the impact produced by Covid-19. As soon as normality is restored, all the results will be presented in different forums and events.
After the completion of 100% of the project, we can make some conclusions regarding the results expected when the project was started.
After the laboratory tests, both environmental and endurance tests and the functional tests carried out on the aircraft, the results obtained have been very positive. All the seals have performed as expected and have not been affected in any way during the tests.
As a last phase, with the seals optimised, manufactured and delivered, the flight tests will be carried out. For these tests, which will be carried out when Airbus has everything ready, the last set of seals delivered will be installed.
If the market expectations are met according to the forecast made by Airbus for the aeronautical sector, the impact of the ADDAPTTA project can be fulfilled as indicated in section 2.1 of the DoA after having developed all the project. This second and final period would confirm that the forecasts made at the beginning are achievable.
Due to the current situation of the COVID-19 outbreak, the future of the aeronautical sector could be affected, causing the growth forecasts of the sector to be corrected downwards. In any case, the benefit of the project would continue to exist, even if in a lower proportion, due to a lower growth of the sector.
After the laboratory tests, both environmental and endurance tests and the functional tests carried out on the aircraft, the results obtained have been very positive. All the seals have performed as expected and have not been affected in any way during the tests.
As a last phase, with the seals optimised, manufactured and delivered, the flight tests will be carried out. For these tests, which will be carried out when Airbus has everything ready, the last set of seals delivered will be installed.
If the market expectations are met according to the forecast made by Airbus for the aeronautical sector, the impact of the ADDAPTTA project can be fulfilled as indicated in section 2.1 of the DoA after having developed all the project. This second and final period would confirm that the forecasts made at the beginning are achievable.
Due to the current situation of the COVID-19 outbreak, the future of the aeronautical sector could be affected, causing the growth forecasts of the sector to be corrected downwards. In any case, the benefit of the project would continue to exist, even if in a lower proportion, due to a lower growth of the sector.