CORDIS - EU research results


Periodic Reporting for period 3 - GAM-2020-ENG (H2020-IBA-CS2-GAMS-2020-2021)

Reporting period: 2022-01-01 to 2022-12-31

The platforms or demonstrators of these architectures are summarized as:
- Ultra-High Propulsive Efficiency demonstrator addressing Short/Medium Range aircraft market 2014-2023: design, development and ground test of a propulsion system demonstrator to validate low pressure modules and nacelle technology.
- Business aviation/Short range regional Turboprop Demonstrator 2015-2022: design, development and ground testing of a new turboprop engine demonstrator.
- Advanced Geared Engine Configuration (HPC and LPT technology demonstration) 2015-2023: Design, development and ground testing of a new demonstrator to reduce CO2 emissions and noise as well as engine weight;
- Very High Bypass Ratio Middle of Market Turbofan technology 2014-2023: development and demonstration of technologies in each area to deliver validated powerplant systems matured for implementation in full engine systems;
- VHBR Large Turbofan demonstrator UltraFan™ 2014-2023: design, development, build and ground test of an engine to demonstrate key technologies at a scale suitable for large engines;
- The Small Aero-Engine Demonstration projects related to Small Air Transport focuses on small fixed-wing aircraft in the general aviation domain and their power-plant solutions, spanning from piston/diesel engines to small turboprop engines.
- Conclusions will be established when demonstration activities will be finalised.
Ultra-High Propulsive Efficiency (UHPE) Demonstrator for Short / Medium Range aircraft (WP2), the technology maturation programme has successfully demonstrated TRL4 achievements on low-pressure modules and nacelle technologies. The Engine Ground Test Demonstrator (GTD) achieved the Architecture Review milestone.
Business Aviation / Short Range Regional Turboprop Demonstrator (WP3), the Tech TP demonstrator was modified to integrate an electrical machine into the Power & Accessory Gear Box (PAGB) for hybridization purpose. The related test campaign was finally completed within the last quarter of 2022. In parallel, rig testing activities validated TRL5 achievement on several key technologies such as enhanced operability on compressor or injector relight altitude tests with several types of SAF (Sustainable Aviation fuels).
Advanced Geared Engine Configuration (WP4), the engine demonstrator detailed design is completed and current phase focuses on major parts assembly as well as test facility adaptations. The detailed design of the two-spool rig compression system is also completed, assembly of the rig has started on the third quarter of 2022.
Very High Bypass Ratio (VHBR) Middle of Market Turbofan technology (WP5), the Intermediate Pressure Turbine (IPT) rig results post-processing and analysis have been completed. The High Pressure Turbine (HPT) rig facility Phase 1 measurement campaign was completed.
Very High Bypass Ratio (VHBR) Large Turbofan Demonstrator (WP6), First ‘ Ground Test ‘ engine ‘ UF001 ‘ build is complete, engine successfully docked onto the pylon in testbed end of 2022 and is getting ready to test.
Reliable and more efficient operation of small turbine engines (WP8), integration studies for hybrid configurations are completed, and supported the update of the requirements for the Hybrid Electric aircraft. Combustor investigation related to the test campaign have been finalized.
ECO design in engines (WP9), Life Cycle Inventory data was collected from the manufacturing of different parts (ex: blisk) and has been used to perform impact analysis according to eco-design standards.
WP2 will deliver a complete and dual set of Low Pressure modules and nacelle technology bricks matured up to TRL4/5 supporting both ducted and unducted engine architectures. These technology maturation activities have complemented substantial engine architecture and aircraft installation studies that led to the confirmation of the low wing Open Fan architecture selection for the Ground Test demonstration. The engine programme will achieve TRL4 by the end of 2024 through detailed design finalization, hardware manufacturing and preparation of the testing phase that will pursue within the Phase 1 of Clean Aviation.
WP3 activities are completed and culminated with the successful ground demonstration of a hybridized Tech TP engine. The run of this machine architecture demonstrated the full capability for taxiing (propeller drive), motoring (electrical and thermic powers combination), generating power (electrical) from thermic engine.
The test operations provided lessons learned on hybrid test management and control integration, which is a key driver for this electrical technology incorporation in thermal engine to reduce fuel consumption and CO2 emissions. In parallel, the preliminary tests results of enhance operability compressor demonstrated TRL5 and final analysis activities will enable to reach TRL6 for this key technology. Additionally, partial ground tests of tri-sector combustor injectors relight were performed with different types of SAF for the comparison and performance assessment. At last, limitation on the operability of the power gear box endurance test bench was confirmed after investigation (torque) and jeopardized the Power and Accessory Gera Box (PAGB) endurance test campaign start.
While detailed design is completed for both WP4 demonstrators (compression system and expansion system), remaining activities towards the end of the project will consist in assembling the rigs, preparing the test facility and performing the tests. The completion of the test campaigns will thus support the technology maturation:
- up to TRL6 for the 2-spool compression system (improvement on fuel consumption resulting from overall weight reduction thanks to a more compact system)
- up to TRL5 for the expansion system (enabling variable flow characteristics as a results of improvements on aerodynamics and structures)
The purpose of WP5 is to mature a set of technologies required for the future development of a very high bypass ratio engine, from fan inlet through the complete compression, combustion and turbine to exhaust. These technologies will be matured up to TRL5 within the timeframe of Clean Sky 2. The testing performed under turbine rig activities have for instance confirmed of the improvements on aerodynamics of the Intermediate Pressure Turbine (IPT) and supported the validation of the noise reduction technologies.
WP6 aims at designing, developing, building and ground testing an UltraFan® engine to demonstrate key technologies at a scale suitable for large engines. The UltraFan® programme successfully completed the first assembly and was docked onto the pylon in testbed end of 2022. The programme will culminate in 2023 with the start of the ground test campaign.
WP8 matured technologies related to compressor, combustor and turbine for small turbine engines building on demonstrations using the Catalyst as engine model. Preliminary studies related to an hybrid-electric exploitation of the MAESTRO engine were also performed under this work package. The WP will be closed early 2023 once the airframer Piaggio has finalized the update of the requirements for the hybrid electric propulsion.
WP9 activities up to the end of the project will cover the manufacturing of remaining parts (heat exchangers, complex engine bracket, floor panel), the finalization of Life Cycle Inventory data delivery as well as the completion of the Notional Engine Approach methodology.