Future aero engines will need to be more efficient and contribute to the reduction on environmental impact of air transportation. They must reach some standards of performance by reducing emissions and creating some savings on operation costs. EIMG consortium has launched since several years some initiatives to develop future engines in the frame of the European Committee research programmes. Within different project such as DREAM, VITAL, NEWAC or LEMCOTEC, EIMG is ensuring the development of innovative technologies in order to further reduce the fuel burn, emissions and noise. In order to ensure the technological breakthrough, future aero-engines will have higher overall pressure ratios (OPR) to increase thermal efficiency and will have higher bypass ratios (BPR) to increase propulsive efficiency. These lead to smaller and hotter high pressure cores. As core engine technologies have been addressed in the previous project, E-BREAK project will ensure the mandatory evolution of sub-systems. It is indeed required for enabling integration of engine with new core technologies to develop adequate technologies for sub-systems. E-BREAK will aim to adapt sub-systems to new constraints of temperature and pressure.
The overall picture of these initiatives bring all technology bricks to a TRL level ensuring the possibility to integrate them in a new aero engines generation before 2020.
In its 2020 vision, ACARE aims to reduce by 50% per passenger kilometer CO2 emissions with an engine contribution targeting a decrease by 15 to 20% of the SFC. NOX emissions would have to be reduced by 80 % and efforts need to be made on other emissions.
The main E-BREAK expectation is to develop and validate adapted generic technologies (up to TRL 4-5) and robust sub-systems by minimising the losses that naturally occur as engine cores get smaller so that the fundamental gains from higher turbine entry temperature, overall pressure ratio and bypass ratio are realised in an engine environment.
E-BREAK will complete the map of technologies required for UHOPR engine and high BPR engines competitiveness in term of reliability and maintainability of the engine. Development of these new technologies will enable to an additional reduction of CO2 emission compared to the 2000 engines generation.
To achieve its objectives, E-BREAK work is divided in 6 subprojects:
- SP1 : Overall Engine specification and assessments to define and explore technical frame and to provide detailed requirements, operational environment constraints and precise objectives to the following steps. This subproject is also in charge of consolidating project technology benefits and provide assessment at overall platform level.
- SP2 : Advanced sealingsystemsto reduce oil and air leakages. Breather concepts will be investigated and tested to improve air-oil separation. Modelling of complex multiphase air/oil mixture behaviour, oil particle size measurements and oil degradation modelling will also be addressed Innovative sealing technologies will be evaluated and their performance simulated. Piston seals, labyrinth seals and brush seals will be developed to higher performance boundaries with new materials and engine architecture. Air-riding seals will be developed from concept to demonstration.
- SP3 : Engine variability and thermomechanical behaviour to ensure stability of thermo-dynamical cycle. New engine architectures and certification requirements lead to a need of a more robust and accurate variable systems to withstand higher temperatures and pressures as well as bird debris impact during a bird ingestion event. The target is to establish new design rules validated by component testing and simulation, and to investigate their effect on the engine efficiency and architecture. Tip clearance control issues will also be tackled.
- SP4 : Higher temperature materials to prevent from fast degradation at high temperature. The objective is to validate both the use of new materials and methodologies for high temperature abradables and the development of high temperature components such as thermal barrier applications to allow a higher operating temperature with a better efficiency and reliability.
- SP5 : Lightweight material to preserve from a significant mass increase. The work will focus on the development of the TiAl intermetallic alloys for low pressure component application. The use of TiAl in the engine is a major breakthrough in engine weight reduction. Technical gaps hindering the use of TiAl need to be assessed.
- SP6 : Heath monitoring to anticipate sub-systems degradation. The objective will be to investigate relevant new technologies mandatory for maintaining safe engine operation with higher OPR and assess and enhance existing health monitoring techniques for both in service and MRO applications.
The consortium mobilized to reach E-BREAK project goals is composed of 42 partners with complementary resources. Ten countries are in addition represented (France, Italy, Germany, Belgium, United Kingdom, Poland, Netherland, Sweden, Switzerland and Spain). E-BREAK project thus requires a specific organisation to maintain administrative and technical coordination.
The administrative coordination will be supported by a small Administrative Management Committee, lead by a Senior Management Project, the E-BREAK coordinator TURBOMECA, supported for operational tasks by a Project office composed of ALCIMED. This level will deal with the day-to-day running of the project. The management and coordination of scientific and technical integration will be supported by the Executive Management Board led by the Coordinator with the support of the 6 Sub-Project leaders. Furthermore, each Sub Project also has its Sub-Project Management Team, led by each Sub-Project leader, with the support of the Work Package leaders and shall consist of leading the tasks which are part of the Sub-Project.
Download the E-BREAK leaflet for more information.