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R-NOZZLE Report Summary

Project ID: 325981
Funded under: FP7-JTI
Country: Spain

Final Report Summary - R-NOZZLE (Rotating nozzle)

Executive Summary:
Project Summary
Acronym: R-NOZZLE
Name of proposal: Rotating Nozzle

Technical domain: Aircraft Engines
Involved ITD: SAGE 2

Grant Agreement: 325981
Instrument: Clean Sky JU
Total Cost: 1.999.880,00 €
Clean Sky contribution: 1.499.910,00 €
Call: SP1- JTI-CS-2012-02-SAGE-02-023
Starting date: 15/02/2013
Ending date: 15/11/2016
Duration: 46 Months
Coordinator contact details: Angel Lagraña
Phone: +34935944700 / Mobile: +34648725077

Project Officer: Jean-François Brouckaert
Participating members EURECAT TECHNOLOGY CENTRE – Barcelona - Spain

Project Context and Objectives:
The high concern of Environmental pollution and the need to reduce the CO2 emission, together with always problematic fuel price had made possible to recover the need and the interest of having ultra-efficient engines, especially by the fact of a possible fuel saving of 30% and its equal consequence of CO2 emissions reduction.

The advancements in technology for noise reduction, processes and materials give new push to the development of CROR propellers.

In this sense the FP Funded projects such as: VITAL (FP6), DREAM (FP7) and also the recovered interest by GE Aviation, who since 2009 is performing Wind tunnel Tests with NASA, all go in the direction to give maturity to CROR propeller, taking advantage of new materials and processes, not only to guarantee the efficiency, but also the community and passenger cabin noise reductions, which are also aims of ACARE 2020 roadmap.

The need to replace ageing fleets in the traditional markets such as the US and Europe along with an expansion of aviation in emerging markets such as China, India and Latin America has led to forecasts of demand for 15,000 new aircraft in the next following years. This market is worth US$1 trillion but it is also a huge opportunity to introduce new technologies to cut aviation's impact on the environment. Open rotors are one potential technology that could help achieve this reduction.

In this sense joint ventures such as CFM International joint venture formed to develop new engine technologies, could also serve to emphasize the CROR propellers development, as it will bring experience from several developments projects like: VITAL, DREAM and SAGE2 leadership at CLEANSKY ITD.

There are several dates for TRL9 of CROR on the market, but the important issue it that there are project and programs, tackling the important issues such as; noise reduction, engine positioning on the plane, new materials, new processes; in all these fields research and developments are being addressed to reach this in relatively medium term timeframe.

The objective of R-NOZZLE is to design and manufacture a Rotating Nozzle to answer to the need of SAGE2 Demonstration Project, which aims at designing, manufacturing & testing a Counter-Rotating Open-Rotor Demonstrator, involving most of the best European Engine & Engine Modules & Subsystems Manufacturers.

As described in the CfP text it is understood that the SAGE2 demonstrator will be installed on a pylon located on a test bench for performing ground tests.

Some of the requirements that the project must address are:

• Structural constraints
• Interface achievement
• Functional
• Dimensional
• Weight target
• Operational conditions

The objective requested by the call is to use innovative solutions to the issues of temperature, whilst achieving the weight and strength necessary.

As well the design must then be made so that the exhaust nozzle can rotate at up to 1300 rpm, which will demand strong focus on the balancing of the part taking this into consideration during the design and in the subsequent manufacturing

This rotation in itself will demand a novel approach to the material to ensure the part can survive the fatigue and high dynamic stresses that the assembly will have.

In answering all these challenges is where the innovative approach remains.

To cover the requirements the work carried out in R-NOZZLE covered:

• A conceptual preliminary design.
• Detailed design, through calculation and FE Simulation
• Manufacturing trials for process de risking
• Development of common strategy for interfaces with other partners of the SAGE2 Demo engine
• To manufacture the parts for engine demonstrator.
• To deliver it for the Ground Test Demo Engine

Project Results:
Project Objectives
R-NOZZLE has addressed the challenge of developing all components for exhaust nozzle of the Open Rotor Engine, components that are all rotating, thus critical ones. The aim was to find the right design to sustain the functional and failure loads, while keeping its main function of channel the main air flow from the combustion, as well as the secondary air flow for ventilation to exit the engine boundaries.
The development included the analysis of load cases, dynamic analysis, fatigue analysis, assembly analysis, manufacturing analysis and the analysis of the right quality plan for the parts.
Based in the analysis of thought requirements, the specific objectives of the R-NOZZLE project were:
a. Selection of architecture for the nozzle components, the selection was based in the analysis of pros and cons of several proposed nozzle architecture
b. Material and process detailed selection to allow to manufacture the nozzle to sustain load, temperature and other constraints
c. Risk analysis continuous monitoring to allow early detection of risk an ow to mitigate it considering the high importance of the integrated Demostrator to achieve.
d. Performing all preliminary design phase. The results of the CoR, was a selection of architecture to follow in the preliminary design phase to probe the suitability of this architecture for the function assigned to the nozzle components
e. Carrying out manufacturing trials. With the selected manufacturing processes and materials, it was necessary, according with risk analysis, taking into account the requirements, to carry out manufacturing of dummy components in sizes similar to he expected for the nozzle, as well as with parts details.
f. Passing the Preliminary Design Review (PDR). The preliminary design stage with one architecture, selected, as well as with manufacturing trials performed, allowed to meet on time the next milestone which was the PDR.
g. Carry out Critical Design Phase. With results of PDR the last stage of design started to have a detailed set of nozzle components for manufacturing,
h. Pass CDR. At the end of the CDP, the next milestone was the CDR where all designed details were studied to allow start the manufacturing phase
i. Perform manufacturing, control and delivery of all nozzle parts to SAGE 2 OPEN ROTOR Demo Engine.
Project Results:
o In collaboration with a leader in the aero engine nozzle industry, Eurecat could produce a list of components optimized for requirements and environmental specifications for operation in an integrated engine. Some of the specifications met are:
• Functional
• Dynamical performance vs excitation frequencies.
• Temperature range of operation
• Structural performance vs load cases, both static and fatigue
• Interface achievement
o Research and development of materials and designs for nozzle components, through material selection, manufacturing trials and characterization.
o The nozzle components were subjected to empirical evaluation through a series of manufacturing tests to ensure the quality of the material, process and manufacturing stages.
o The outcome of the initial test was the derisking of the manufacturing of components to deliver to SAGE2 Demo Engine.
o The materials and designs were optimised through modelling and presented in the form of Design reports during PDR and CDR meetings.
o The validated nozzle design was manufactured and delivered to SAGE2.
o Delivered components mostly complied with the built compliance matrix.
o The immediate exploitation of the knowledge developed is to have allowed Eurecat to position in additional private contract projects for other engines.
o The future exploitation of nozzle will follow the path set by the leaders for the Open Rotor

Potential Impact:
Potential Impact:

The Nozzle development seen in an integrated environment into SAGE2 has the potential to contribute in a highly significant way to attain the following impacts:

o CO2 emission reduction by 30%
o Fuel consumption reduction by 30%
o NOx reduction

The R-NOZZLE project has been widely disseminated through the attendance to the following exhibitions:

• ADM Torino 2013
• AIRTEC Frankfurt 2013
• AIRTEC Frankfurt 2014
• AIRTEC Munich 2015
• Europe and Canada meets for Innovation in Aeronautics Montreal 2015
• AIRTEC Munich 2016

In regards to exploitation of results, thanks to the experience acquired during R-NOZZLE project EURECAT, currently the centre is getting private contracts for developments of new components in other engine architectures.

List of Websites:
Coordinator contact details: Angel Lagraña
Phone: +34935944700 / Mobile: +34648725077

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