The RECYCOMP project is focused in the reutilization of uncured scrap material, aiming at preparing it for a subsequent reuse for the manufacturing of functional components. The main activity focuses on the development of an equipment able to recover the uncured scraps coming from lamination process, avoiding the degradation (associated to undesired curing) and preparing the material in a suitable form for the generation of new pre-impregnated material useful for the lamination process of new components. The main objective of the RECYCOMP project is to develop a machine for the recovery and recycling of CFRP uncured scraps, taking the surplus material coming from lamination and generating new useful pre-impregnated material in a roll. The machine includes 3 main modules able to: identify the scraps area and fibre orientation; cut the scrap in rectangular chips; and to pick and place the chips in a new backing material for the subsequent use.

Surface characteristics such as smoothness and other geometrical surface are conditions that wing panels have to accomplish in order to have an aerodynamic profile for efficient wing with natural laminarity. Besides these surface and geometrical requirements there are other functionalities that are critical to the overall performance of the wing and the platform. The increasing need to reduce weight in aircrafts in order to improve fuel efficiency has promoted the adoption of lightweight materials like CFRPs which are intensively used in aeronautics applications due to their strength/weight ratio, but they suffer from rain and particle erosion from which they have to be protected. Other problem to be addressed is the ice resulting from the solidification of atmospheric moisture that becomes a problem especially on the wing leading edges. By tuning the electrical properties of the skin it is possible to obtain resistive heat de-icing systems and/or to provide the coatings with sensing features. Additionally, surface electrical properties are important in aeronautics skins for several reasons, such as lighting strike protection and EMI shielding. Thus, it is necessary for aeronautics industry to have erosion-resistant surfaces which also show anti-icing/de-icing features. Physical Vapur Deposition (PVD) based coatings are excellent candidates to be used as multifunctional coatings as they have already proven their suitability for erosion protection and the possibility to tailor the electrical properties in other applications. In this context WINNER aims to obtain multifunctional coatings having erosion resistant and tailor made electrical properties on CFRP by means of PVD processing technologies.

The overall goal of the project is focused on incrementing the efficiency of Electro-Mechanical and Electro-Hydrostatic systems in terms of extending the life and improving the reliability and enhancing the performance of the maintenance activities of wing actuation systems. With this objective in mind, the activities within the project have been oriented to the following goals: To investigate innovative and alternative sealing solutions that able to reduce the friction, wear and leakage at high level of deformation monitored in accelerated seal tests and can increase lifetime to thermal cycles. To investigate innovative and alternative lubricant solutions that are able to reduce friction and wear and to increase extreme pressure properties, increasing the temperature limit and time to a fixed temperature in Differential Scanning Calorimetry and Thermogravimetry measurements, in relation to reference lubricants. To provide new oil sensing systems to monitor the status of the lubricant with a twofold aim: identify faulty conditions and extend the life of the lubricant. To control the lifetime of the gears materials and lubricants by means of accelerated simulated tests reproducing the micropitting/pitting lifetime and confirming for best materials/lubricants combination, using real gear testing benches, reproducing the generation of main failure mechanisms monitoring in parallel both vibrations and wear using oil sensors, in order to create the right knowledge for conditions monitoring. To develop, implement and integrate Health Monitoring algorithms to predict failures before affecting the actuator output in a critical way, addressing some mechanical parts of the actuation systems such as seals, gearbox, screwballs, etc.. The project has clear objectives to mature technologies to extend the life of EMAs and EHA: In this scenario, ISSELUB aims to address the challenge of extending the life of EMAs and EHA.

FluidER project aims to deliver fully integrated and autonomous sensor for in-line sensing and diagnosis of aviation hydraulic fluids (HF) used in electro Hydraulic Actuators (EHA). The proposed diagnosis approach is based on the combination of hydraulic fluid physic-chemic parameter sensors and fluid contamination sensors and, with the aim of achieving an early warning of degradation signs, especially in terms of particulate count and water contamination, before the hydraulic fluids exceeds the service limits. The combination of a set of heterogeneous sensor technologies is motivated by the lack of accuracy achieved by single devices, especially when dealing with multi-source contaminations and when an early identification of degradation evidences is targeted. FluidER proposal merges two types of approaches: (i) Sensors delivering measurements of physical and chemical parameters of the Hydraulic Fluid as the Viscosity, Density, Moisture, Dielectric Constant, Colour or Temperature, and (ii) sensors specifically designed to monitorize different contamination sources as the particulate matter concentration, presence of air or water. Specifically, FluidER will address the analysis of physical contaminants (metallic and non-metallic particulate count, air bubbles, etc.) through in-line microscopic imaging and machine vision proprietary techniques. Additionally, chemical contaminants (water content, acidity) will be estimated through VIS-IR spectroscopic inspection and chemometric algorithms. The information obtained from the different sensors will be used to generate a Diagnosis of the status of both, the fluid itself and the EHA equipment, through new health monitoring algorithms. The different hardware and software components included in the FluidER solution will be gradually tested in different test beds, ranging from controlled laboratory hydraulic test beds to a complete EHA test bed and different standardized aircraft tests.

The main goal of the Hyper-Drill project is the development of a laser micro-drilling machine prototype for the manufacture of Hybrid Laminar Flow Control (HLFC) titanium suction panels with dimensions up to 5 m x 2 m and able to fulfil the requirement of a production rate ≥ 300 holes/s. This includes the creation of knowhow in producing such kind of structures as a basis for the industrial manufacturing of HLFC leading edges. For this purpose, firstly an optimization of the most suitable laser based technologies and processing parameters for the micro-drilling process will be carried out. The single pulse micro-drilling (SPMD) and the percussion micro-drilling (PMD) techniques are the covered technologies in this proposal for the micro-drilling of titanium sheets. In contrast to other approaches, both techniques have been widely investigated and are able to provide the requested results described in the Call by demonstrating at the same time feasibility on large Ti panels. Obtained production rates with these methods are above 400 holes per second. Several technical as well as economical aspects will be analysed in order to determine the most suitable technique for different specifications and conditions. A machine prototype equipped with both micro-drilling techniques will be designed, assembled and tested for production of 5 x 2 m Ti panels. A tentative design of the prototype based on the Consortium previous experiences and expertise is provided. The proposed design allows future upgrades for further increasing production rates beyond those requested in the Call for proposals. Several features for quality inspection of the micro-holes such as machine vision systems as well as quality control by in-situ monitoring the laser working distance have been included. Finally, the prototype will be optimized and commissioned at the Topic Manager facilities.