GENEX

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New end-to-end digital framework for optimized manufacturing and maintenance of next generation aircraft composite structures

Motivation, impact, problems addressed

Global aviation accounts for approximately 2.1% of global CO2 emissions and, by 2050, these are expected to be seven to ten times higher than in 1990 due to the increase in air-traffic. To achieve the EU environmental goals by 2050, drastic improvements over current existing aircraft configurations should be implemented in terms of energy efficiency, reduction of the environmental impact, or increase of passenger comfort and safety[1]. In this context, the implementation of novel holistic and circular approaches, leveraging the potential of Artificial Intelligence (AI), Internet of Things (IIoT), digital twins (DT), and automatised robotics solutions will offer the European aeronautics industry and the whole aviation ecosystem the opportunity to maintain their global competitiveness and leadership while moving forward towards climate neutrality.

Thus, in GENEX, the development of a novel holistic end-to-end DT-driven approach is proposed. The main goal is to provide a framework for managing data from all systems and tools for gaining knowledge from overall composite component lifecycle by the integration of (1) innovative in-line process monitoring systems for measuring the manufacturing quality, (2) optimized on-board and on-site sensors for structural health and usage monitoring and remaining useful life prediction, and (3) advanced digital-based tools and methods for improving maintenance and repairing.

By building the new DT framework, GENEX target to deliver digital and eco-efficient manufacturing technologies to ensure flawless entry into service of composite parts as well as to advance further health assessment and MRO processes to allow continuous airworthiness of European aircrafts.

Work performed and main achievements

During the first 6 months of the project, the consortium worked on the definition of specifications of materials, sensors, and systems to be developed and/or used during the project as well as on the definition of a representative use case to demonstrate the manufacturing and monitoring technologies. An aircraft spar structure was selected with this purpose. Furthermore, the agreement on the Architecture Solution Design or the IIoT framework and its functional and non-functional requirements were achieved.

Once the ground of the project was established, parallel work was launched in the three main technological blocks, namely: manufacturing, health and usage monitoring and repair.  The main achievements of each block are summarised as follows:

1. Several material formulations based on the 3R technology were developed, characterized, and tested for manufacturing by ATL process. A final version of the material is almost ready and undergoing final fine tuning. A hybrid physical- and data-driven simulation of the crystallisation process has been developed to be used as the digital counterpart of the manufacturing process. For the real-time monitoring of the process, a THz spectroscopy monitoring system has been proved as a feasible technology to quantify the evolution of the crystallinity.
2. Both hardware and software have started to be developed. On the hardware side, different MFC sensors have been characterized and a preliminary sensor network designed. Moreover, the architecture for data collection and wireless communication has been prototyped. On the software side, the piezoelectric behaviour has been implemented in an HPC scalable open-source code. Meanwhile, machine learning algorithms have been trained showing a good performance in predicting the size and location of delaminations. Finally, a methodology for validation of delamination progression models has been validated for Mode I.
3. A first version of the hardware and software interface for visual-assisted scarf repair has been done. The feasibility of a laser ablation system to detect and clean contaminants from the composite surface has been demonstrated. A first prototype of a digital tool for heating blanket repair design has been developed. Lastly, the evaluation of smart bonded patch repair has been completed at coupon level showing both the capability of detecting bonding damage and stopping the crack progression.

Transversal to all these activities, the design of the DT framework architecture and its synchronization with the data sources has been performed.

Results beyond the state of the art

The main purpose of GENEX is to develop a disruptive holistic approach covering the whole value chain of composite parts, from design, material, and manufacturing to operation, MRO and EOL to support the next-generation digital aircraft transformation. The integration of all these technologies into a single IIoT platform is expected to impact on the disruptive technologies entering into service by 2035. However, to allow for the implementation of such solution, a supportive regulatory and standardisation framework must be developed and supported by future demonstration.

Policy relevant evidence of the project

At the end of the project, an activity aiming at setting the basis for an extensive and standardised use of the GENEX’s digital-based tools and methods for facilitating repair certification and life-cycle monitoring of repairs, while spreading the range of bonded composite repair applications from secondary structures to primary composite structures of current and future aircrafts is proposed. In this regard, GENEX is working on establishing a collaborative framework with EASA and other relevant stakeholders.

Thanks to the exchange of information with EASA and the corresponding guidance, it is expected that GENEX proposed solutions will be in line with aeronautical certification and continuous airworthiness requirements, facilitating their adoption by the aeronautical industry.