High performance laser micro drilling machine for large Hybrid Laminar Flow Control suction panels

Project Information

HyperDrill

Grant agreement ID: 755620

DOI

10.3030/755620

Project closed

EC signature date 15 May 2017

Start date 1 June 2017

End date 31 December 2020

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 1 968 832,50

EU contribution

€ 1 968 832,50

Coordinated by

FUNDACION TEKNIKER
Spain

Periodic Reporting for period 2 - HyperDrill (High performance laser micro drilling machine for large Hybrid Laminar Flow Control suction panels)

Reporting period: 2018-12-01 to 2020-12-31

Summary of the context and overall objectives of the project

One of the main interests and development lines of the aeronautical sector is the generation of new solutions that allow to create resource-efficient transportation that respects the environment by reducing energy consumption, pollutant agents, noise, etc. In order to fulfil these high demands significant technology breakthroughs in terms of aerodynamics and other disciplines like the design of materials and structures are arisen. A promising approach in this field focuses on a friction drag reduction by Hybrid Laminar Flow Control (HLFC). HLFC allows a drag reduction by extending the laminar flow on an aircraft wing by sucking air through the holes of a perforated skin sheet at the leading edges.

However, a main challenge for the provision of this key technology is its manufacturability. The technical design of HLFC structures requires a complex drilling process to manufacture perforated large metal sheets composed by millions of identical tiny holes. Laser beam drilling is one technique to produce those suction sheets.

Main objective of the HYPERDRILL project was to design, manufacture, assembly and testing of a High Throughput laser Micro-drilling (HTMD) prototype machine with process monitoring and quality control for micro-perforating large titanium sheets with a throughput of over 300 holes per second, to be tested within an industrial environment. The machine is able to generate millions of holes, of less than 100 μm in diameter, on titanium panels up to 5 x 2 m2.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The design, manufacturing, assembly, setting up and testing of a prototype machine for micro-drilling large titanium sheets at drilling rates higher than 300 holes/second has been carried out.

The prototype machine developed is capable of generating millions of tiny holes (~ 0.1 mm diameter) on titanium plates up to 1.5 mm thickness and working area up to 5 x 2 m2.

During the project it has also been developed different monitoring and control systems to maintain a homogeneous treatment, minimizing the number of clogged holes to less than 0.02% and an accuracy in diameter of less than 5 µm.

In addition, the machine is able to measure different geometrical aspects (diameter, circularity, area, separation between micro-holes, clogged micro-holes, etc.) of each micro-hole generated on the titanium panel during the manufacturing process.

Moreover, it allows to perform other complementary processes such as cutting, marking, etc. in order to improve the quality and facilitate the following manufacturing processes of the manufactured component.

Exploitable results identified by the partners of the Hyperdrill project are mainly related to the development of a high performance laser micro-drilling machine for large metallic sheets (up to 2000 x 5000 x 1.5 mm). Actually, a couple of patents related to the machine and the monitoring and control system has been submitted.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The microperforated titanium panels will be part mainly of the leading edge of the wings and stabilizers of the future passenger aircrafts in order to carry out the so-called Hybrid Laminar Flow Control (HLFC). This technique allows, by means of a suction chamber integrated in the wing structure of the aircraft, to suck up through the microperforated skin, the boundary layer of turbulent air generated on the surface of the aircraft aerodynamic surfaces, in flight, and form a more stable flow, called laminar, which ultimately allows to reduce the drag of the aircraft and therefore its fuel consumption.

Hybrid laminar flow control (HLFC) technology can result in a significant reduction of around 10% in the fuel consumption of civil transport aircraft, which in turn represents a significant environmental improvement through the reduction of CO2 emissions and pollutant agents into the atmosphere. The improvement in turn brings with it the possibility of increasing the level of aircraft payload.

Hyperdrill machine prototype