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advanCEd REar end Structural test program – low level tests

Periodic Reporting for period 1 - CERES (advanCEd REar end Structural test program – low level tests)

Reporting period: 2020-01-02 to 2021-07-01

In order to achieve an optimized rear end structure, new materials (thermoplastic composites, hybrid CFRP materials) and manufacturing processes (stamping, net shape manufacturing, Additive Manufacturing), as well as novel design concepts (laminate configurations to improve impact damage tolerance, highly integrated shell) are being developed under Clean Sky 2 – LPA Platform 1. The implementation of these new concepts into the rear end implies necessarily to fully characterize the behaviour of the material following the building block approach.
CERES will result in very positive impact for European aeronautic competitiveness through the demonstration of new concepts, materials and processes for advanced rear end through the execution of an optimised test program enabled by the development of innovative methods.
CERES aims to design and manufacture the test benches and conduct the test program for the Coupons Level tests of the test pyramid, incorporating innovative testing solutions, which allows to optimize the test program. The outcomes of this project will enable to demonstrate the feasibility of novel design concepts, materials and processes for Advanced Rear End (ARE). Ultimately, the validation of these new concepts will contribute to the development of a rear end offering high level of integration of the most advanced engines at lighter weight and improved mechanical performance pursued by LPA IADP Work Package 1.2.
The work performed from the beginning of the project to the end of the first reporting period incorporate progresses in the eigth advanced rear end's low level test campaigns planned.

For all the campaigns, kick-off meeting has been performed, test plan has been developed and Preliminary Design Review (PDR) has been passed, achieving milestones M1, M2, and M3 of the project.

Critical Design Review (CDR) has been achieved for tests 01, 02, 04, 05, 06 and 08.
Test Readiness Review (TRR) has been achieved for test 01, 02, 04 and test 06.
Test report has been produced for test 01 for which all the activity has been developed.

Advanced monitoring techniques applied in various tests: Innovative test rig, Sound level meter, high speed camera, digital image correlation, laser displacement sensors, real-time remote monitoring system & non-contact metrology.
The task of demonstration of the feasibility of novel aero-structures design concepts, materials & manufacturing processes has traditionally involved large and high resources consuming validation campaigns. Now a days, the most effective approach is combining testing and analysis, where the analytical predictions are verified by testing, and test plans are defined based on the needs of the analytical methodology, the overall effort is reduced while the reliability of the design increases. To this end, CERES proposes to go beyond of the state of the art with an experimental based validation, which incorporates innovative measurement and monitoring methods that enable correlation with numerical analysis.
A test campaign will be designed and executed for the validation of every new structures. Thus, a test program will be conducted dealing with low level tests of the test pyramid, from coupons up to structural detail level. Innovative test rigs will be designed to introduce loads and boundary conditions. Likewise, advanced testing methodologies and innovative techniques will be developed and applied in order to improve the accuracy of test results, reduce the number of specimens to be tested, and reduce testing lead times.
The execution of CERES project will match the expected impacts set out by the topic and detailed in the CS2 Work Plan:
Reducing CO2 emissions: CERES contributes to the reduction of CO2 and NOx emissions by contributing to the development of a new light weight rear end. Saving weight by replacing heavy materials with lighter ones whose mechanical capabilities are the same is a strategy to follow in order to achieve innovation and development in the aeronautic industry, especially in commercial aircraft. Lighter aircraft means less combustible usage, which means less cost for the airlines and the passengers.
Enhancement of the innovation capacity and integration of new knowledge: CERES will bring technical impact through the development of innovative test rigs for the validation of design concepts, materials and processes which will be implemented in the ARE. The application of advanced data acquisition systems, such as Digital Image Correlation (DIC), will contribute to the consolidation of these technologies to provide full-field strain measurements. Likewise, CERES project will imply an improvement of the scientific and technical knowledge which allows to understand the behaviour of the most promising materials which are studied under the proposed test program.
Strengthen the European competitiveness of the sector: CERES will drive a new solution of testing methodologies that is aimed to optimize the costs of a test campaign for the validation of novel design concepts, materials and processes to be implemented in Advanced Rear End. The result of the “Advanced Engine Integration Driven Fuselage” demonstration will deliver a key enabler to acquire 15-20% fuel saving potential in combination with the capabilities to design and produce a competitive industrial solution for a short and medium haul next generation large passenger aircraft. The proposed demonstrator will allow mastering associated industrial challenges and risks and will contribute in a significant way to generate the know-how necessary for maintaining and extending European leadership in this field.
Societal impacts. Initiatives like CERES aim to faster validation capacity of cutting-edge design solutions in Europe by addressing the Aircraft Factory of the Future needs, increasing the technological knowledge and background of the companies involved in the Aircraft Manufacturing Value Chain and encouraging more skilled jobs. Thus, the benefits to be reached from investments in this area of interest will bring the opportunity to the European Aerospace industry to provide better solutions (operational, environmental and technological) than their competitors. Besides, making more efficient laboratories will help to reverse the deindustrialization of Europe and face important societal problems related to high rates of unemployment.
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