“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.

NHYTE project aims at developing and demonstrating concepts and methodologies enabling the realization of innovative integrated aero-structures, made of a new hybrid thermoplastic matrix composite material with multifunctional capabilities. The high-performing material proposed, based on a commercial PEEK-Carbon Fiber Prepreg with addition of amorphous (PEI) films, answers to the needs to have reduced weight and consequently reduced fuel consumptions and emissions on an aircraft, as well as reduced manufacturing and operational costs. Demonstration aero-structures will be fabricated by an innovative working cell implementing an advanced continuous automated production process, including: automated hybrid material fabrication; manufacturing of skin panels by automated fiber placement in-situ consolidation process; fabrication of stringers by continuous forming; component assembly by induction welding. The innovative material, conceived and patented by a partner of the Consortium, is an example of multifunctional composite, since it returns both functions of toughness improvement (multilayer material) and process simplification. This concept on one side will provide an advantage from the structural point of view, in terms of better impact damage performance; while on the other side major advantages will result on processing simplification, in particular including improved cycle times and lower energy consumptions, since it does not require the use of an autoclave curing phase. As of today, its usage has been limited to fabricate panels, only at laboratory level; hence, a suitable improvement finalized to process in industrial environment is needed. Proposed process techniques and assembly will be the first step towards the industrial application of the innovative material. Consortium has set a target for weight saving not less than 5% for primary structures. Further reduction of full life cycle cost is expected from scrape material and end of life structures recycling.

The work of this consortium will be the experimental verification by means of a test campaign (Level 2-3) of a novel design, material, structural an industrial process for the Advanced Rear End (ARE) demonstrator included in WP1.2 on Platform 1 of Cleansky project. This project has three research objectives: 1) Implement new methodologies to support, validate and correlate Virtual Testing Models. 2) Design and manufacture innovative tool and test setups to maximize the instrumented area to better identify the boundary conditions of the test based on Absolute Accurate Methodology. 3) Research advanced instrumentation solutions to improve quality of the results reducing cost and time in future aircraft certification test campaigns. To achieve these objectives, the following IT tools, methodologies and novel instrumentation will be researched: a. Applus E-Testing© monitoring service to follow up the metrological data in real-time using a simple internet browser. This technology allows correlating real-time video recording and measured data (load, stress…) with FEM predictions. b. CAETest Bench for accurate representations of material behaviour. c. Thiot CESAR© software to simulate gas gun performance to reduce the initial test trials to adjust the pressure and other launcher parameters. d. Applus Absolute Accurate Methodology e. Faster and more accurate optical Full Field stress measurement based on Match ID Technology that allows improving Digital Image Correlation uncertainty and advanced algorithms to allow measurements in Real- time during the test. f. Innovative methods to improve crack/de-bonding onset and propagation detection by: i. Acoustic Camera contactless metrology from GFAI TECH GmbH to quickly hot-spot de-bonding and first Failure cracks ii. Structural Health Monitoring to control the damages of the structures being tested with the support of Universidad Politécnica de Madrid g. Improved wireless Strain gauges taking advantage of Applus IoT Lab capacities to reduce the test setups time and complexity and allow Structural Monitoring of the tested part. h. Residual Energy “live” sensor based on instrumented projectile catchers developed by Thiot

To enable a technologically and economically feasible H2-powered aviation, new integral LH2 tank solutions are required that could serve as part of the airframe main structure and capable of withstanding its respective loads. The H2ELIOS project will develop an innovative and effective lightweight LH2 storage system for aircraft. It will be implemented as demonstrators in two fuselage-like cylinder section with approximately 1.9 m of external diameter and approximately 2.3 m of external length. These demonstrators would be duly supported by component and subsystem ground tests at appropriate scale at project completion (TRL 5 at storage level). The aim is that the concept is ready to be embedded and integrated in a specified aircraft architecture for flight demonstration in later stages. H2ELIOS will provide a feasible and novel low-pressure double-layer composite tank-based system, enabling the tank shape to be either conformal or non-conformal to the profile of the aircraft. Its general effectiveness will be assessed in terms of high GI performance and easiness of integration within the aircraft structure. This concept will be supported by latest evolutions of innovative methods and technologies in terms of multidisciplinary design development, manufacturing processes and means of compliance and shall be demonstrated in operational conditions: first on ground up to TRL5 and then in flight by the end of Clean Aviation Phase 2 clearing a TRL6 maturation gate. Finally, delivery to the market is expected in the 2030-2035 period. In this way this project shall contribute to accomplish the objectives of the European Green Deal regarding decarbonization of the aviation industry. The activities of H2ELIOS will be supported by explicit agreed support of EASA and an External Advisory Board comprising commercial aircraft OEMs, H2 management and cryogenics experts, MRO services, airlines, aircraft system integrators, materials developers and suppliers and airports operation