Uncertainty Prediction & Bias Elimination in Aviation for Safety

Understanding and quantifying uncertainties (UQ) in aviation structures is vital to assessing risk and safety. UPBEAT will create novel UQ methods and tools to support the production of safer and more innovative aircraft structures and engines while reducing uncertainties in product and engineering lifecycles. The project focuses on metal-composite hybrid aerospace engine parts that are lighter, more durable and cheaper. Innovative design solutions for hybrid interfaces can be achieved using metal additive manufacturing (AM) bonded with carbon fiber reinforced polymers (CFRP). Advanced models of materials and processes will be developed using sophisticated in-situ and ex-situ monitoring and metrology.

In aviation engines, the outlet guide vane (OGV) is an essential component that helps de-swirl the flow field from the fan. The OGV's stiffness is crucial as it influences the engine's performance and includes a major load path from its core to the wing. The OGV with two types of CFRP vanes and titanium end fittings will be used as a demonstrator. By combining AM with advanced in-situ melt pool monitoring and characterization (micro-CT & nanoindentation), digital models will be used to optimize design and manufacturing processes and increase awareness on efficiency, safety and risk. This will result in 20-40% weight reduction and 50-70% fewer defects. Streamlined product development reduces qualification time by 30-40% and costs by 25-35%. In-line quality assurance support lowers manufacturing costs by 30-50% and time by 20-30%. 

UPBEAT will:

✔ Increase understanding of the process, structure, property, & performance with safety focus

✔ Advance process models (AM, CFRP) for planning & optimization

✔ Develop verification and validation using multi-scale models

✔ Integrate UQ in design, materials, manufacturing, qualification, & certification

✔ Demonstration of UPBEAT technologies using a complex aviation use case

RISE role in the project

In addition to supporting partners across various work packages (WPs), RISE is leading the Requirement Analysis and KPI Elaboration WP. This WP focuses on the definition of requirements and key metrics for the overall project, the evaluation of current UQ modeling methods needed for extensions and identification of new paradigms, and the increased robustness and characterization of modeling methods regarding manufacturing process simulations.