“Test Methods for analySis OF Infusion pAnels” (SOFIA) Novel infusion technique could have different implications than classical pre-preg technologies. To increase the robustness in the early design and subsequent Certification Phases of the component is a challenge. The confidence in this technology must be tackle with the analysis and development of new test methods. To comply with this task, the project is focused in three main levels: - A presizing of the component as the initial phase to determine the expected failure modes (FM). This step is the basis to evaluate the behavior of the component under applied loads (combined loading state) and the definition of Level 2 and 3 tests - Level 2 are the characterization of the FM. The first step is to define these expected mechanical FM that will be analyzed. This phase has a significant importance as the classical mechanisms of failure associated with the use of pre-pregs may be altered by the new infusion manufacturing process. The Test plan definition, tooling design and manufacturing, mathematical approaches to be used, test execution and the correlation of the analytical results (developed FEM and / or mathematical laws to predict behavior) with real test results are the main tasks of this stage. This failure mode characterization is the basis for the definition of the behavior of the subcomponent for the next stage. - Level 3 is the validation of the analytical characterization of the FM and the subcomponent global behavior. Non-linear FEM with cohesive elements and Virtual Crack Closure Technique will be developed. The numerical predictions, the test plan definition, tooling design and manufacturing, test execution and the correlation of the expected results vs real test results, are the main tasks of this stage. In addition of this project, if necessary, it is offered to the Topic Manager the possibility for the manufacturing of complementary coupons at any stage of the Project.

The FASTER-H2 project will validate, down select, mature and demonstrate key technologies and provide the architectural integration of an ultra-efficient and hydrogen enabled integrated airframe for targeted ultra-efficient Short/Medium Range aircraft (SMR), i.e. 150-250 PAX and 1000-2000nm range. To enable climate-neutral flight, aircraft for short and medium-range distances have to rely on ultra-efficient thermal energy-based propulsion technologies using sustainable drop-in and non-drop-in fuels. Besides propulsion, the integration aspects of the fuel tanks and distribution system as well as sustainable materials for the fuselage, empennage are essential to meet an overarching climate-neutrality of the aviation sector. Green propulsion and fuel technologies will have a major impact on the full fuselage, including the rear fuselage, the empennage structure as well as cabin and cargo architecture in so far as the integration of storage and the integration of systems for the chosen energy source are concerned (H2, direct burn, fuel cell). Not only do the specific properties of hydrogen necessitate a re-consideration of typical aircraft configurations, requiring new design principles formulation and fundamental validation exercises, but they also raise a large number of important follow-on questions relating to hydrogen distribution under realistic operational constraints and safety aspects. The project will explore and exploit advanced production technologies for the integrated fuselage / empennage to reduce production waste and increase material and energy exploitation with Integrated Fuselage concept selected (maturity TRL3/4) until end of first phase in 2025. An anticipated route to TRL6 until end of the Clean Aviation programme in 2030 will ensure entry-into-service in 2035.

Development of key technologies to address a new wing design for a HER aircraft maturing up to TRL5: manufacturing, assembly, structural concepts and processes, concept studies, configuration and architecture trade offs for a full wing component are part of the activity. As a physical demonstration concept, the detail design and manufacturing of the relevant components of a centre wing section of a HER Aircraft will be addressed. Conceptual wing studies: configuration and architecture (structural arrangement, Systems allocation and disposition, flight control system) trade offs for a full wing. Full wing structural arrangement mock up for innovative wing concepts, Structural and Multidisciplinary Optimization studies for definition of the optimal structural configuration of wing. Demonstration platform: wingbox, high lift devices, control surfaces, load alleviation devices focusing on the centre section as a demonstration platform: - Integrated Centre section wing box structure with the inner Propulsion stage: Full span (pylon to pylon) torsion box concept representative of more ambitious tip 2 tip concept. Multispar concept, Access manholes and panels, Sustainable aviation fuel and Integrated Fuel vent systems. - Inner section Leading Edges, Integrated Inductive ice protection system integration, Multifunctionality: erosion, impact, Lightning, ice protection, Morphing concepts, Functional tests, Bird strike tests (virtual or real) - Inner section Flap and high lift solutions: Integrated flap solutions. Multifunctionality application to flap. Key processing technologies: Low cost-high integrated out of autoclave technologies. Dry fiber placement and liquid resin infusion for integrated multispar torsion box. Thermoplastic composites processing: In situ consolidation for integrated flap skin and Leading edge applications. Thermoplastic welding and co-consolidation for Integration. Bonding technologies exploration towards certifiable solutions.