Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - ECOFUNEL (Eco Design: Composite functionalization: thermal and electricalconductivity)

Teaser

Environmental Control Systems (ECS) are challenged by a demand to significantly reduce weight and manufacturing cost of all electrical actuator component parts which ensure the control and the tuning of the global system performance and to be compliant with REACH directives...

Summary

Environmental Control Systems (ECS) are challenged by a demand to significantly reduce weight and manufacturing cost of all electrical actuator component parts which ensure the control and the tuning of the global system performance and to be compliant with REACH directives. Actuator bodies are currently manufactured with aluminium alloys in order to ensure a high electrical conductivity level. Some actuator bodies also require a high EMI protection level and some specific bonding when higher electrical conductivity levels are required. The current solution is an additional hazardous surface treatment containing CMR-like Cr6+ compounds. Therefore the Topic Manager (TM) is exploring various manufacturing process with thermoplastic composites reinforced with short or long fibres. Nevertheless these solutions cannot be simply achieved by a direct paradigm change from aluminium alloy towards thermoplastic composite (black metal approach). They actually require some innovative concepts in terms of material formulation and functionalization strategy in order to meet both electrical conductivity and EMI protection requirements. Some results obtained from recent research programmes have provided much evidence that an industry-driven material formulation and functionalization strategy does significantly lead to benefits onto an aeronautical structural composite part in terms of mechanical resistance, electrical conductivity, product manufacturing time, environmental efficiency (recyclability) and safety conditions. ECOFUNEL (Eco design:COmposite FUNctionalization: thermal and ELectrical conductivity) is a 3 years research program for developing, optimizing and down-selecting an innovative actuator body solution obtained by molding (injection and/or compression) a functionalized thermoplastic composite material in compliance with aeronautical ECS requirements and standards, namely regarding weight efficiency, electrical conductivity and EMI protection.

Work performed

From the technical point of view the project advances include the creation of adhoc formulations of injection moulding grade composites with enhanced electrical feature. These new materials are under investigation for obtaining a property matrix so that it is possible to select the proper candidate with the appropriate conditions to be used for the final prototype manufacturing. During development of materials they were found several difficulties in regard sample manufacturing which lead to invalid laboratory results. The activities were re-scheduled and the characterization campaign was started with a new batch of specimens. New materials present enhanced electrical feature which is been evaluated, but also show a slight decrease in mechanical properties. In the other hand, a novel approach of manufacturing with injection grades of compounds is being developed in parallel.
In regard of dissemination of results it was cleared by all members that a presentation will be brought to MATCOMP 19 Congress with agreement of all parties so that the information to be shown will not interfere a potential protection of the advances.

Final results

ECOFUNEL aims to contribute to the successful development of the Systems ITD that aims at developing, on one hand, an equipped airframe with minimum inputs, outputs and nuisance and, on the other hand, design architectures of aircraft systems towards an all electrical aircraft, in order to reduce the use of non-renewable and/or noxious substance during operation and maintenance while keeping the aircraft at the appropriate level of quality and performance. In addition, the project will contribute to the principal objectives identified in the ACARE’s report European Aeronautics: A Vision for 20201, the most relevant being the last goal: ”To make substantial progress in reducing the environmental impact of the manufacture, maintenance and disposal of aircraft and related products”, and its Strategic Research Innovation Agenda – SRIA, which highlights in the Challenge 3 “Protecting the environment and the energy supply” the expected target by 2050: “air vehicles are designed and manufactured to be recyclable”. A successful ECOFUNEL project will have a strong technological impact (with significant improvements in weight reduction, process efficiency, environmental impact) that will contribute to the environmental H2020 strategy in relation to the Smart, Green and Integrated Transport challenge and facilitate the accomplishment of Clean Sky 2 JU key outcomes, specifically the first one related to “creating resource-efficient transport that respects the environment. […] Beyond 2020, new efforts are needed to get within reach of the Flightpath 2050 targets of a 75% cut in CO2, 90% in NOx and a 65% noise reduction.” Moreover, ECOFUNEL will as well provide socio-economic benefits within the next five to ten years by means of: Enhancing the technological leadership of the Topic Manager (TM) and Systems ITD members; Enhancing the competitiveness and leadership of European aeronautic industry: Supporting employment of highly skilled professionals; Meeting society needs for environmentally friendly, safe and efficient air transport.

Website & more info

More info: http://www.ecofunel-project.eu.