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Testing Advanced Basic Structures with novel Low-Cost Solutions

Periodic Reporting for period 2 - TABASCO (Testing Advanced Basic Structures with novel Low-Cost Solutions)

Reporting period: 2021-04-01 to 2022-07-31

This project has three complementary research objectives. The research program proposed has been applied on a test campaign to validate the integration of a novel Advanced Rear End demonstrator that will be developed by Airbus inside the research program Cleansky.

These three research objectives are:

1) Implement new methodologies to support, validate and correlate Virtual Testing Models
2) Design and manufacture innovative tool and test setups to maximize the instrumented area to better identify the boundary conditions of the test based on Absolute Accurate Methodology.
3) Research advanced instrumentation solutions to improve quality of the results reducing cost and time in future aircraft certification test campaigns.

The integration of this technology in a realistic test setup will improve the quality of the test data and reduce test costs. It will also allow to design and validate lighter and more energy efficient aircraft.

Overall, the research program proposed has been applied on a test campaign agreed with the Topic Manager to validate the integration of a novel Advanced Rear End (ARE) demonstrator that will be developed inside Work Package 1.2 of Clean sky LPA IADP.
During the project's first period (October 2019 - March 2021), resources have been dedicated to the development of research activities related to new instrumentation and test methodologies.
In close collaboration with the Topic Leader, a Test Plan reorientation has also been accomplished in order to better adapt the activities of this project to the developments in WP1.2 of Cleansky.
Intense work has been done to advance in the advanced instrumentation research and methodologies but some adaptations have been proposed to fit better with the new test plan
Once sufficient maturity was achieved in the definition of this Test Plan, the design phase of the tooling for each of the experimental works that make up the Test Plan begun.

During the project's second period (April 2021 - July 2022), an agreement has been reached with the Topic Manager to modify the test plan. This change has been materialised in a signed Grant Agreement amendment.
In addition, the test tools have been designed and manufactured and the advanced instrumentation has been set up. In the last phase of this project, these tools and instrumentation have been implemented to carry out the tests, which have been completed in July 2022 as planned.

The Dissemination Plan of TABASCO project was heavily disrupted by the COVID pandemic.
The planned Expo and congress in 2020 and most of 2021 was cancelled. Nevertheless, TABASCO partners have tried to disseminate the results of the project via channels such as the following:
*Through online meetings with customers and presenting in online conferences.
*ZENODO webpage
*Applus+ website and blog
*Thiot customer dissemination + presentation in Thiot annual Shock Physics Academy.
Progress beyond the state of the art as per TABASCO general objectives:

1. Reduce development time to maintain and extend European industrial leadership:
*Extensive experimental data was provided to Topic Manager to improve the FEM Models. These inputs can reduce the development time.
*Non-contact metrology solutions (wireless sensors, optical metrology that can reduce the test setup time).
*Acoustic camera can provide de-bonding and damage growth real-time detection and reduces the stops in the test for NDT.

2. Reduce recurring cost to meet market needs:
* Extensive information can be provided to the Topic Manager to improve the simulation models.
* Setup cost can be reduced when substituting wired strain gages by wireless sensors and non-contact optical metrology.
* New DIC methodology reduces the pre-calibration time and improve accuracy.

3. Reduce weight (and CO2 emissions) to protect the environment and the energy supply.
* Thanks to a better Test-FEM correlation, an accurate determination of more realistic safety factors will allow a reduction of material usage and total airplane weight.

4. Better and quality employment to meet social needs
* Non-contact metrology increases productivity (cost vs incomes) and quality (more specialized) employment through the validation and certification methodology proposed in this project.
* New DIC methodologies have been implemented and applied. These methodologies reduce time/cost and Increase the employment by improving the competitiveness on the design and manufacturing of aeronautical structures.

Progress beyond the state of the art as per TABASCO industrial objectives:

1. Provide instrumented and real-time monitored test tooling that can apply required loads and boundary conditions to ensure safety and security on aeronautical transportation.
* Sensitive tooling has been considered during the design phase and implemented in the test execution.

2. Provide a practical Virtual Model Validation methodology using Applus IT Tools to develop digitalization in the industry.
*E-Testing IT tools provide 100% real-time follow up of the test that provide key information to validate FEM models and improve accuracy.

3. Optimize advanced instrumentation in an industrial environment to make available appropriate test infrastructures.
*Advanced instrumentation has been successfully implemented in this project.

4. Optimize post treatment cost to increase the competitiveness challenges for European air transport stakeholders.
* E-Testing and acoustic camera have provided advanced innovative in live measurement methodology that allows a reduction in post-treatment time and cost by providing real-time feedback during the test follow-up.
Wireless strain gauge
Example of real-time damage detection with Acoustic camera system