The PALACE project aims to develop a new generation of pump architecture for electrical machines cooling for aircrafts. It meets Clean Sky 2 (CFP03) objectives by significantly reducing weight, by increasing durability, and availability as required by aircraft manufacturers. The PALACE approach goes a step further, with a challenging objective of a 30% mass reduction, using non-conventional solutions, such as additive manufacturing processes, enabling hollow structures for some components of the pump. New coatings and new functional surfaces texturing will complete the design, with regards to friction, lubrication and thermal performances at the required very high speed conditions. Innovation in PALACE is not limited to new manufacturing processes but will rise up also from the combination of several design methodologies (Design For Manufacture and Assembly, tribology, topology and CETINNOV - a CETIM specific proven innovation methodology) along with a multi physics expertise. The multiphase Computational Fluid Dynamics - CFD models including oil cavitation, CFD tool shapes optimisation will address the high efficiency performances. PALACE will address the optimisation issue not only at the pump level but broaden the view at the whole cooling system level and make recommendations for more system optimisation. The consortium’s ambition is to develop a European, clean, robust and efficient pump architecture that will be implemented into most of systems of the More Electric Aircraft. SERV (SME), as one of the few European aeronautic pump manufacturers, associated to CETIM, a mechanical research centre, have the competences and ambition to bring the PALACE pump to the European market. The project will lead to an ITAR free (International Traffic in Arms Regulations) export. Partners are willing to transfer the PALACE innovations in other sectors searching for high performances such as the space, nuclear power, energy transfer or the auto racing industries.

SHERLOC QSP aims at designing and manufacturing a batch of composite panels incorporating thermoplastic composite window frames (for regional airplane) made following an innovative manufacturing process, called QSP that allows lighter mass with cheaper cost and shorter manufacturing cycle time of parts than existing processes. The project will contribute to the reduction of the environmental impact: - Weight saving of parts manufactured by the use of net shape and multi-thickness preforms with the right material at the right place, will contribute to the reduction of CO2 emissions, - Significant reduction of waste material by exploiting the composite at the maximum of its possibilities. It will help the industrials to be more efficient and performant: the above points automatically result in cheaper cost of the parts (less expensive material used by a better exploitation of materials, less composite waste implies therefore a better valorization of costly noble materials). QSP, developed for high rate production of automotive parts (one composite part/minute), will finally contribute effectively to reach the necessary productivity in the near future to meet the ramp up production of planes and aircraft components. The very short deadline imposed by the call (18 months) has guided the decision to build a small consortium with only 2 partners, Cetim (a French technological research center involved in composites since the 80’s) and Compose Tooling (one of the major French tool makers). These 2 partners are used to work together and are very agile to solve problems in a short time. Together, they have the complete skill to answer all the technical needs expressed in the call (design, manufacturing of parts and assemblies, material testing, NDT control, cost assessment, repairing). Cetim and Compose were involved in the implementation of QSP for automotive parts and have a clear strategy with other industrial partners to transfer this technology to aeronautic sector.

Designed to achieve reduction in fuel consumption, the Ultra-High Bypass and High Propulsive Efficiency Geared Turbofan engine incorporates evolutions likely to produce high frequency (HF) vibration excitations which propagate through the structure. Numerical simulation is an efficient tool to control vibrations hence supporting the mechanical design. Where Finite Element (FE) based approaches show limitations due to computational hardware performances and HF dispersion management, Statistical Energy Analysis (SEA) stand as proven and effective method for this frequency range to predict the vibrational energy transfers across partitions – subsystems – of a structure. Challenges of SEA modelling consist of the structure partitioning which usually requires expertise and the accuracy loss at lower frequencies where the high stiffness of parts or complexity of junctions counter the method initial assumptions. Those statements depend strongly on the studied structure, therefore the objective of the proposed project is to develop and demonstrate a SEA modelling process to predict the vibration propagated in a typical complex engine frame. In this scope, best modelling practices from detailed numerical analysis are engaged to both support an extensive test campaign preparation including test vehicle design and manufacture, and produce models covering the target frequency range: from 400Hz to 10kHz. A crucial phase consists in the validation and update of these models from tests post-processing techniques and known methods such as Experimental SEA, Decay Rate damping estimation or input conductance as well as innovative inverse approaches relying on optimization loops. From the comprehensive comparison of these different methods with tests results, a best methods and associated modelling practices are delivered to the topic leader. CETIM and ESI join their complementary competences to develop the modelling and experimental know how applied to the HF vibrations assessment.