This research project focuses on several key Direct Energy Deposition (DED) Additive Manufacturing (AM) processes that have great potential to be used as cost-effective and efficient repairing and re-manufacturing processes for aerospace components such as turbine blades and landing gears. This project aims to conduct fundamental research to understand the material integrity through chosen DED AM processes, the accuracy and limitations of these deposition processes, effective defect geometry mapping and generation methods, and automated and hybrid DED and post-deposition machining strategies. This project intends to connect repair and re-manufacturing strategies with design through accurate DED process simulation and novel multi-disciplinary design optimisation (MDO) methods to ultimately reduce the weakness of aerospace component at design stage and prolong their the lifecycles. Both powder-based and wire-based DED systems will be investigated to establish an across-the-board comparative study. The data collected through this comprehensive comparative study will be extremely valuable for the OEMs of this project (i.e. GKN, PWC, and HDI) to understand the pros and cons of these DED systems and will help them to select suitable repair and re-manufacturing strategies. The tests conducted in this research are also extremely beneficial for the SMEs in this project (i.e. Liburdi, AV&R, DPS) to validate their existing repairing systems and techniques.

Understanding and quantifying uncertainties (UQ) in aviation structures is vital to assessing risk and safety. UPBEAT will create novel UQ methods and tools to support the production of safer and more innovative aircraft structures and engines while reducing uncertainties in product and engineering lifecycles. The project focuses on metal-composite hybrid aerospace engine parts that are lighter, more durable and cheaper. Innovative design solutions for hybrid interfaces can be achieved using metal additive manufacturing (AM) bonded with carbon fiber reinforced polymers (CFRP). Advanced models of materials and processes will be developed using sophisticated in-situ and ex-situ monitoring and metrology. In aviation engines, the outlet guide vane (OGV) is an essential component that helps de-swirl the flow field from the fan. The OGV's stiffness is crucial as it influences the engine's performance and includes a major load path from its core to the wing. The OGV with two types of CFRP vanes and titanium end fittings will be used as a demonstrator. By combining AM with advanced in-situ melt pool monitoring and characterization (micro-CT & nanoindentation), digital models will be used to optimize design and manufacturing processes and increase awareness on efficiency, safety and risk. This will result in 20-40% weight reduction and 50-70% fewer defects. Streamlined product development reduces qualification time by 30-40% and costs by 25-35%. In-line quality assurance support lowers manufacturing costs by 30-50% and time by 20-30%. UPBEAT will: ✔ Increase understanding of the process, structure, property, & performance with safety focus ✔ Advance process models (AM, CFRP) for planning & optimization ✔ Develop verification and validation using multi-scale models ✔ Integrate UQ in design, materials, manufacturing, qualification, & certification ✔ Demonstration of UPBEAT technologies using a complex aviation use case

Building a sustainable and climate neutral future for aviation is an inevitable requirement for a society with increasing mobility needs. If we are to stabilise the global temperature below the 1.5°C threshold set by the Paris Agreement, rapid action is to be taken. MINIMAL will contribute to a radical transformation in air transport by providing disruptive ultra-efficient and low-emission technologies that will, in combination with the aviation ecosystem, sustainably reduce the climate impact of aviation. The MINIMAL project will, through an unprecedented effort between European engine OEMs, world leading atmospheric physics scientists, and lead researchers in combustion and propulsion, attack the major sources of non-CO2 and CO2 emissions in aeroengines. This will be accomplished with the introduction of climate optimised new propulsion systems based on composite cycle engine technology, that provides unparalleled flexibility with respect to operations, and that has the potential to eliminate the large sources of effective radiative forcing by 2035: 80% reduction from contrails, 52% reduction from net-NOx, and 36% fuel burn reduction resulting in 36% to 100% CO2 reduction, depending on the fuel used. Results will allow assessing the interdependencies between non-CO2 and CO2 effects already during the early stages of aero-thermal-mechanical design and converge into engine options that have minimum climate impact. The findings are supported by numerical (TRL 2) and experimental (TRL 3) proof of concept of Low-NOx opposed-piston constant volume combustion technology with pre-micromixing of hydrogen. In MINIMAL we understand the urgency and aim for maximum impact. Aggressive, but realistic roadmaps will be outlined together with regular exchanges in major industry research centres to develop these technologies into products and bring them to in 2035-2040.

Flightpath 2050 very ambitiously targets 75% CO2 and 90% NOx emissions reductions, relative to year 2000. It is highly unlikely that these targets will be met with carbon containing fuels, despite large research efforts on advanced, and in many cases disruptive, airframe and propulsion technologies, even when coupled with improved asset and life cycle management procedures. Liquid hydrogen (LH2) has long been seen as a technically feasible fuel for a fully sustainable aviation future yet its use is still subject to widespread scepticism. ENABLEH2 will mature critical technologies for LH2 based propulsion to achieve zero mission-level CO2 and ultra-low NOx emissions, with long term safety and sustainability. ENABLEH2 will tackle key challenges i.e. safety, infrastructure development, economic sustainability, community acceptance, and explore key opportunities through improved combustor design and fuel system heat management, to further minimize NOx emissions, improve energy efficiency and reduce the required volumes of LH2. The project will include experimental and analytical work for two key enabling technologies: H2 micromix combustion and fuel system heat management. These technologies will be evaluated and analysed for competing aircraft scenarios; an advanced tube and wing, and a blended wing body / hybrid wing body aircraft, both featuring distributed turbo-electric propulsion systems and boundary layer ingestion. The study will include mission energy efficiency and life cycle CO2 and economic studies of the technologies under various fuel price and emissions taxation scenarios. ENABLEH2 will deliver a comprehensive safety audit characterising and mitigating hazards in order to support integration and acceptance of LH2. Solutions will be proposed for any socioeconomic hurdles to further development of the technologies. A roadmap to develop the key enabling technologies and the integrated aircraft and propulsion systems to TRL 6 by 2030-2035 will be provided.