Periodic Reporting for period 3 - DOMMINIO (Digital method for imprOved Manufacturing of next-generation MultIfuNctIOnal airframe parts)
Okres sprawozdawczy: 2024-01-01 do 2024-09-30
In the last few decades the aeronautical industry has experienced a drastic transformation in the manufacturing philosophy in response to the growth of aircraft production and transition towards net zero technologies (materials, electrification, H2, etc). The transition to the use of more advanced and sustainable composites together with the increase in aircraft performance and productivity rate have increased the challenges faced by designers and manufacturers to produce cost-effective structures and components using greener materials and technologies, allowing cost, weight and fuel consumption reduction with shorter manufacturing cycles and increasing energy efficiency in aircraft fabrication.
DOMMINIO has 4 high level objectives:
• O1: Enable flexible multistage robotic-based production processes for manufacturing of multifunctional composite airframe parts
• O2: Develop novel data-driven pipeline supporting the design, simulation and production planning of multifunctional and intelligent composite airframe components
• O3: Develop a Quality-by-Design (QbD) manufacturing strategy, based on the development of process control and advanced quality monitoring systems
• O4: Develop a new digital-combined-physical driven methodology for Monitoring and Management of the Health of multifunctional airframe parts.
DOMMINIO has 4 high level objectives:
• O1: Enable flexible multistage robotic-based production processes for manufacturing of multifunctional composite airframe parts
• O2: Develop novel data-driven pipeline supporting the design, simulation and production planning of multifunctional and intelligent composite airframe components
• O3: Develop a Quality-by-Design (QbD) manufacturing strategy, based on the development of process control and advanced quality monitoring systems
• O4: Develop a new digital-combined-physical driven methodology for Monitoring and Management of the Health of multifunctional airframe parts.
During RP3, the consortium successfully advanced towards the project finalization. This period started with WP1-WP5 finalized, meaning that all the technologies (materials, manufacturing hardware and digital development) were accomplished in the previous RP2, thus the technical work throughout these months consisted of demonstrating all the developments by manufacturing 3 types of demonstrators (WP6). Also, WP7-Multidisciplinary optimization and virtual certification developed most of its developments within this period, as it was delayed as compared to the initial Gantt, and benefiting greatly from the project extension (3 months). Within this WP7, the consortium interacted with EASA, which provided key insight towards virtual certification roadmaps of thermoplastic materials and structures with embedded sensors for SHM. Regarding Dissemination, Communication and Exploitation, the consortium accelerated the intensity and a great part of the KPIs were achieved within this period, including the final event at EASN Conference. From a management perspective, RP3 was a very intense period with 2 General Assembly, delivery and acceptance of periodic report Nº2, project extension amendment, TORTECH withdrawal finalization and mitigation plan acceptance, altogether keeping the regular monthly touchpoint for WP6 and WP7. Regarding the demos, two repetitions of two mechanical use cases (300 x 500mm) consisting of stiffened laminates combining laser-assisted insitu consolidation of LMPAEK tapes by Automated Tape Laying and overprinting of PEKK gyroids by FFF were successfully manufactured, demonstrating the feasibility of the combination of laser-assisted insitu consolidation ATL and FFF of high-performance thermoplastics (LMPAEK and PEKK), leading to intermediate-to-high mechanical properties up to 889MPa on four point bending test. Despite the good adhesion between overprinted PEKK gyroids and LMPAEK laminates assisted by laser, based on tomography analysis and mechanical results by flatwise, it is shown that there is still room for process optimization from the temperature point of view to minimize internal porosity and enhanced interlaminar adhesion. SHM prototype was successfully manufactured and tested. This demo consisted on a quasi-isotropic ATL laminated with embedded CNT yarns sensor developed in DOMMINIO, as a piezoresistive sensor able to detect strain, and its evolution based on potential damage. An impact damage test (low velocity impact with an energy of 7J) was carried out on the laminates. After the impact, the panel was tested in four-point bending, and no effect in registered load or strain was observed, meaning damage was not sufficient to degrade stiffness enough to be measured by standard sensors. Results are promising, however an increased stability and robustness of CNTs yarns sensors are needed to rely on the data and to have a proper diagnosis of damage. A similar panel as the SHM was manufacture with embedded CNT yarns, to test their functionality as heaters based on joule-effect. The laminates were manufactured with CF/LM PAEK tape, with 16 layers. Two types of test were planned i) De-icing test (removal of ice already in place), ii) Anti-icing tests (maintain the temperature above freezing to avoid ice formation). The tests have demonstrated that the embedded cCNT filaments provide a viable means of heating local regions of the thermoplastic composite laminate and raising surface temperatures to a sufficient level to prevent icing. Specimens for disassembly of the 3D-printed structure reinforcing the laminate by means of induction technology have been made and correctly tested, validating the functional materials developed within DOMMINIO to enable high-performance composite disassembly. Regarding Dissemination, communication and exploitation, the Key Performance Indicators (KPIs) reflect the exceptional outreach and dissemination achievements of the project, highlighting both the breadth and depth of its impact. With 23 participations in conferences and workshops, 13 scientific publications, and the successful organization of 3 workshops and 3 clustering events, the project has significantly advanced scientific dialogue and collaboration. The dissemination efforts extended beyond academia, with 11 participations in exhibitions, which brought the project's innovations to diverse audiences. Additionally, the creation of 18 videos, garnering approximately 2600 views, and the publication of 6 DOMMINIO newsletters and 1 press release, ensured consistent engagement with the public and stakeholders. Importantly, the project went beyond the expected KPIs by producing 20 non-scientific publications, maintaining a strong presence through 85 posts on social media, and securing 2 high-profile interviews in CompositeWorld, a renowned industry platform. These accomplishments not only demonstrate the project's ability to meet its initial goals but also highlight its commitment to maximizing impact and ensuring the dissemination of results reaches a wide and varied audience. In summary, during the last RP3, DOMMINIO consortium successfully accomplished the objectives established for this period taking benefit from the extension. In this report, a detailed explanation of the work is presented.
DOMMINIO includes the following progress beyond the state of the art in the field of advanced manufacturing of composite structures:
- Multi-stage ATL combined FFF manufacturing of multifunctional composites
- Numerical simulation of plies consolidation
- Novel controllable laser-scanning system for customized heating in ATL process
- Novel sensorized FFF nozzle for high-performance TPs
- Advanced non-contact UT methods for quality monitoring in ATL process
- Innovative piezoresistive-based CCNT fibre strain sensors
- Data-driven pipeline for MDO of airframe parts
- Multi-stage ATL combined FFF manufacturing of multifunctional composites
- Numerical simulation of plies consolidation
- Novel controllable laser-scanning system for customized heating in ATL process
- Novel sensorized FFF nozzle for high-performance TPs
- Advanced non-contact UT methods for quality monitoring in ATL process
- Innovative piezoresistive-based CCNT fibre strain sensors
- Data-driven pipeline for MDO of airframe parts