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

The ARIAS research and innovation project directly targets “maintaining industrial leadership in aeronautics” of the European aircraft engine manufacturing sector in the important technology sub-area “development and validation of multi-disciplinary design tools that address key isolated or clustered industrial problems with low degree of confidence that need presently extensive experimental verification” by investigating aeromechanical phenomena (flutter and forced response) in three distinct sub-systems (compressor, low-pressure turbine and seals) of the aircraft engine. The interaction of these aeromechanical phenomena is not well characterised. This can lead to inefficient designs or unwanted blade vibration which can increase development time and costs and can ultimately lead to the failure of an engine during operation which can have fatal consequences (Kegworth 1989). Previous EU projects have treated forced response (ADTurB-1&2) and flutter (FUTURE) as isolated phenomena. They have delivered unique experimental data and testing of numerical models enabling industry to progress blade design and analysis. These projects also revealed the need for coupled flutter and forced response methods. ARIAS will provide deeper insight into aeromechanical technologies for more sophisticated and break-through coupled analyses, measurements and vibration mitigations. Beyond state-of-the-art methods that have never been used in blade or seal design, to assess aeromechanical vibrations will be used such as multimodal simulations and superimposition of flutter and forced response. Expected outcomes are a better understanding of flutter and forced response and the development of new higher fidelity analytical tools which will enable the design of more efficient and safer aircraft engines. The project will also contribute to a world-wide unique “MOOC-type” on-line learning material on aeromechanics, involving academic and industrial partners.