SUSTAINablility increase of lightweight, multifunctional and intelligent airframe and engine parts

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 pinpattern 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 <1.1 by advanced HPDC processing of thermal stable nanoeutectics (KET5-KPI). A Structural Health Monitoring system optimizing MRO activity is proven using radically new ZnO nanowires, which will be integrated into polymer as well as metal parts. Finally, SUSTAINair raises the bar with respect to aircraft EoL, introducing Industry 4.0 automated technology for robotic dismantling.