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Periodic Reporting for period 1 - GAM-2020-ENG (H2020-IBA-CS2-GAMS-2020-2021)

Reporting period: 2020-01-01 to 2020-12-31

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, ground and flight 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.
For WP2, the techno maturation plan contributed to decrease the technical risks for the Engine Ground Test Demo. In particular, the gearbox module achieved significant progress through various rig tests. The maturation plan on the Low Pressure Turbine resulted in enhanced integration and performance. The manufacturing readiness level increased in parallel for several components.
For WP3, 2020 focused on completing the test campaign on Tech TP demonstrator. Regarding techno, testing activities of mix flow compressor started, turbine blade off rig test manufacturing was anticipated and pressure probes calibration was delayed. The Power & Accessory Gear Box (PAGB) test rig was almost completed. Design and manufacturing activities were performed to upgrade TechTP demonstrator for hybridization. Optimized compressor parts were manufactured for robustness demonstration.
For WP4, The compression system activities focused on completion of the conceptual design of the two-spool rig. The preliminary design review and the Test Concept Review were passed. The engine demonstrator detail design activities were completed, the critical design review was passed.
For WP5, The LP Turbine rig testing was completed. Hardware timescale is in line with rig Pass To Test. The PGB (Power Gear Box) Bill of Materials for the first ground test engine was defined. The TRL4 for the alternative structural casting material was achieved.
For WP6, The engine programme progressed to detailed component design release and manufacture of engine hardware for the engine development plan. Engine build was launched, with parts now being received into finished parts stores.
For WP8, The activities related to the power gearbox and to the Axial Centrifugal Compressor Vehicle test results were completed. The hybrid electric architecture was down selected, while the combustor investigation on additive continued.
For WP9, the activities on demo parts continued enriching the Life Cycle Inventory database.
For WP2, maturation studies consolidated the architecture for the Engine GTD. Functional analysis were initiated at component level as well as maturation studies on modularity & maintainability. An acoustic inlet demonstrator was built to validate the MRL6 (Manufacturing). A test module for the gearbox completed the design phase. For Low Pressure Turbine, the maturation activities progressed to plan. All parts for a Turbine Rear Frame demo were received. Sectors of Turbine Vane Frame were rig-tested. The COVID-19 crisis however induced an estimated delay of 5 to 12 months, depending on the topic.
For WP3, main activities performed in 2020 are, despite of COVID crisis:
- Test phase completion of the Tech TP demonstrator target configuration.
- Launch of several rig tests for gas turbine components.
- Preparation of Tech TP engine hybridization demo with embedded electrical motor
- PAGB partial test bench preparation for endurance test
- Manufacturing of optimized compressors for robustness test
- Start of Manufacturing of turbine blade out partial test rig components.
For WP4, the compression system made significant progress for the two spool compressor rig. The conceptual design then the Preliminary Design review were passed. The test setup was also validated in the Test Concept Review. The expansion system engine demo passed the critical design review and released the finished parts. Finished parts drawings were aligned with suppliers and completed. Trial parts were evaluated in first article inspections and machining of engine parts was released. Based on the Corona situation schedule impacts were evaluated. The project plan was adjusted and the test campaign delayed to 2022.
For WP5, GKN matured alternative Aluminium alloy for ICC, resulting to TRL4. For ITP, IPT casing was successfully ballistic tested, and the first casing for UltraFan engine 1 was completed. For ITP in WP5.2.3 rig tests were successfully completed. In WP5.3.1 the AORBIT construction was completed and the rig fully operational. Rolls-Royce’s work with UNOTT and ANSYS on AERIS made significant progress, reaching TRL4. DLR and RRD used NG-Turb test facility circuit virtualisation to predict operational parameters and constraints for campaign planning.
For WP6, the nacelle integration PDR was completed and pylon detailed design launched. In WP6.4.7 the flight test instrumentation sketch documents were provided to partners. In WP6.1.1 the IPT subsystem detail design review was achieved, enabling the manufacture of components for UltraFan® engine 1 to progress. In WP6.1.2 GKN in collaboration with RR progressed to ICC#1 manufacture. The UltraFan® programme released component designs for manufacture with now over 1000 parts already in stores for engine 1 build.
For WP8, 2020 focused to the hybrid electric activities kick off and some loop 2 tasks. In WP8.1 the activity on the eMAESTRO architecture started, with a close collaboration with Piaggio that leads to the down selection of an architecture. Progresses were done on the virtual engine transient model design. WP8.2 tasks related to the reduction gear box were completed, validating the Direct Gas Quenching heat threatment with a dedicated test campaign. The activities on the propeller blade manufacturing were not performed due to the COVID-19. In WP8.3 the extended analysis of ACCV and blowdown tests were concluded, as well as the impact of potential bleed requirement and its influence on compressor stability was carried out. In WP8.4 the all additive combustor test data post process was completed, assessing the new NOx emissions with this technology. Based on test results, a series of additional activities were been planned for 2020-2021, to better investigate the cooling technique.
For WP9, test specimens were manufactured and characterized in WP9.1. In WP9.2 activities were launched with a new Partner. In WP9.4 above 20 LCI data sheets were gathered on the Blisk Design Model. A Manufacturing analysis was performed on an Inlet Guide Vane geometry.