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Periodic Reporting for period 2 - GAM-2020-ENG (H2020-IBA-CS2-GAMS-2020-2021)

Reporting period: 2021-01-01 to 2021-12-31

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.
Ultra-High Propulsive Efficiency (UHPE) Demonstrator for Short / Medium Range aircraft (WP2), the technology maturation plan has progressed through the completion of several rig test campaigns on the key enabling technologies preparing the Engine Ground Test Demonstrator.
Business Aviation / Short Range Regional Turboprop Demonstrator (WP3), the Tech TP demonstrator was modified to integrate the PAGB with an electrical machine to start to test hybridized functions. In parallel, PAGB rig dynamic commissioning was completed and mixed flow compressor successfully tested at rig level.
Advanced Geared Engine Configuration (WP4), the engine demonstrator detailed design has been completed and conceptual design of the two-spool rig compression system finalized with the Preliminary Design Review and Test Concept Review passed.
Very High Bypass Ratio (VHBR) Middle of Market Turbofan technology (WP5) most of the IPT aerodynamic and aero-acoustic rigs have completed testing with results analysed. The High Pressure Turbine rig has been assembled and is being commissioned in readiness for the test campaign.
Very High Bypass Ratio (VHBR) Large Turbofan Demonstrator (WP6) engine programme has successfully completed the overall engine Test Readiness Review and the first ground test engine is currently being built with testing planned for early in 2022.
Reliable and more efficient operation of small turbine engines (WP8), the hybrid electric architecture for SAT application was selected after evaluation with the airframer. Technology development on additive combustor have progressed and compressor studies have been finalized.
WP2: multiple maturation studies were performed to assess the path for the engine demonstrator and the Open Fan engine architecture was pre-selected.
For nacelle maturation, the acoustic inlet demonstrator validated the MRL6. Several rig tests campaigns of supporting technologies for the transmission system were completed, preparing the TRL4. For the High Speed Low Pressure Turbine, the maturation activities delivered results contributing to de-risk the full design, contributing to prepare the TRL4.
- Disassembly and inspection of the PAGB after test campaign.
- Assembly of a new PAGB to test hybrid functions with TechTP.
- Start of the TechTP test campaign with embedded electrical machine.
- Partial ground demo tests of gas turbine components and modules have been launched (Mixed flow compressor rig test, Drained bearings partial test, Tri-sector combustor partial test).
- PAGB partial test bench commissioning.
- Manufacturing and instrumentation of optimized compressors for robustness and performance tests are completed.
- Manufacturing of turbine blade out partial test rig nearly completed.
WP4: in the compression system, the Preliminary Design review of the two spool compressor rig was passed. Correspondingly, the test setup, intrumentation requirements, measurement systems concept were defined and reviewed in the Test Concept Review.
The expansion system engine demonstrator passed the critical design review DR5 mid-year and has released the finished parts for machining. The technology development has been continued and acceptance tests for the casted blade and the CMC segments have been defined and prepared. Based on the Corona situation schedule impacts have been evaluated and communicated to the JU. The project plan has been adjusted with the test campaign now starting early in 2022.
WP5: the final report on the alternative Aluminium alloy for ICC (Intermediate Compressor Casing) has been completed supporting the achievement of TRL4. The VT-2 data analysis and comparison Outlet Guide Vane measurements were completed.
WP6: a Flight Test Bed is planned to test the next generation of cutting-edge technologies regarding UltraFan® demonstrator. The pylon design Preliminary Design Review (PDR) component maturity gate was successfully completed and the Pylon integration PDR was also completed. The nacelle component PDRs are launched and will complete through to the end of 2021/start of 2022. The Test Readiness Review (TRR) of the IP Turbine has been completed and key components manufactured and are being built into the first IPT module supporting the first ground test engine. The UltraFan® programme successfully passed the overall engine Test Readiness Review (TRR) and will complete the first assembly in time for testing early in 2022.
WP8: 2021 has been focused to the hybrid electric activities and the completion of some loop 2 tasks. The team completed the activities on architecture, with a close collaboration with Piaggio. An evaluation of compressor sensitivity to blockage and distortion has been completed. Based on the test results achieved within previous test on all additive combustor, improvement opportunities were investigated. A test campaign on the cooling technique has been carried out.
WP9: In WP9.1 (CFP AMANECO) different kind of samples have been manufactured and tested to define the boundary limits in additive manufacturing for new heat exchangers. This allows defining the design of a whole heat exchanger that will be optimized in term of weight and heat transfer. WP9.2 (CFP MANIFICA) has produced first recycled semi-products from carbon fibre wastes.