Multiple challenges exist with respect to the development of multifunctional and intelligent airframe and engine parts. These are situated along the entire aircraft component value chain - design, manufacturing, MRO and recycling. SUSTAINair addresses each of these phases.
With respect to design, new joining techniques for metal and composite designs are developed and demonstrated. For metal joining, these include a novel pin-pattern creation with Laser Powder Bed Fusion/Wire Arc Additive Manufacturing/Laser Direct Energy Deposition. For composites, these consist of thermoplastic welding.
With respect to both design and manufacturing, a flexible wing with morphing capabilities is made industrially possible by introducing a novel concept using tailored elastomers, seamless integrated with conventional structural wing parts for lowest integration risk, providing a realistic industrial morphing technology.
The problem of high production waste in the manufacture of composite materials, Ti AM and Al HPDC is addressed, thereby reducing waste streams, e.g.: For thermoset prepreg manufacturing waste and thermoplastic waste, new recycled materials are developed and characterized to allow re-use with recyclability up to 100%, bringing FTB ratio close to 1 (KET3-KPI); Increased BTF ratio of Ti powders by using it 6x (vs. 1x now) (KET4-KPI); Incredible BTF ratio