Traditional anti-icing/de-icing systems, i.e., thermal and pneumatic, in most cases require a power consumption not always allowable in small aircraft. Therefore, the use of passive systems, able to delay the ice formation, or reduce the ice adhesion strength once formed, with no additional energy consumption, can be considered as the most promising solution to solve the problem of the ice formation, most of all, for small aircraft. In some cases, the combination of a traditional icing protection system (electrical, pneumatic, and thermal) and the passive coatings can be considered as a strategic instrument to reduce the energy consumption. The effort of the present work was to develop a superhydrophobic coating, able to reduce the surface free energy (SFE) and the work of adhesion (W_A) of substrates, by a simplified and non-expensive method. The developed coating, applied as a common paint with an aerograph, is able to reduce the SFE of substrates by 99% and the W_A by 94%. The effects of both chemistry and surface morphology on the wettability of surfaces were also studied. In the reference samples, the higher the roughness, the lower the SFE and the W_A. In coated samples with roughness ranging from 0.4 and 3 µm no relevant variations in water contact angle, nor in SFE and W_A were observed.

One of the crucial issues affecting the structural safety of propeller vehicles is the propeller tonal excitation and related vibrations. Propeller rotation during flight generates vibrating sources depending upon its rotational angular velocity, number of blades, power at shaft generating aircraft thrust, and blade geometry. Generally, the higher energy levels generated are confined to 1st blade passing frequency (BPF) and its harmonics, while additional broadband components, mainly linked with the blade shape, the developed engine power, and the turbulent boundary layer (TBL), also contribute to the excitation levels. The vibrations problem takes on particular relevance in the case of composite structures. The laminates in fact could exert damping levels generally lower than metallic structures, where the greater amount of bolted joints allow for dissipating more vibration energy. The prediction and reduction of aircraft vibration levels are therefore significant considerations for conventional propeller aircrafts now entering the commercial market as well as for models currently being developed. In the Clean Sky 2 framework, the present study focuses on a practical case inherent to the AIRBUS-Racer program aiming to design and develop a multi-tasking fast rotorcraft. This paper defines a finite elements (FE)-based procedure for the characterization of the vibration levels of a main landing gear (MLG) composite door with respect to the expected operating tonal loads. A parametric assessment was carried out to evaluate the principal modal parameters (transfer functions and respective resonance frequencies, mode shapes, and damping coefficients) of the landing gear-door assembly in order to achieve reduced vibration levels. Based on the FE analysis results, the influence of the extra-damping, location, and number of ballast elements, the boundary conditions were investigated with respect to failure scenarios of the kinematic line opening the study towards aeroelastic evaluations. Further experimental ground test results serve as a validation database for the prediction numerical methods representative of the composite door dynamic response.

In this work a mechanical characterization of Ti6Al4V processed by electron beam powder bed fusion additive manufacturing was carried out to investigate the viability of this technology for the manufacturing of flyable parts for general aviation aircraft. Tests were performed on different manufacturing conditions in order to investigate the effect of post processing as machining on the mechanical behavior. The study provides useful information to airframe designers and manufacturing specialists that work with this technology. The investigation confirms the low process variability and provides data to be used in the design loop of general aviation primary structural elements. The test results show a high level of repeatability indicating that the process is well controlled and reliable enough to match the airworthiness requirements. In addition, the so-called “as-built specimens”, i.e., specimens produced by the electron beam melting machine without any major post-processing, have lower mechanical performances than specimens subjected to a machining phase after the electron beam melting process. Specific primary structural elements will be designed and flight cleared, resulting from the findings presented herein.

In the framework of fast rotorcraft, smoothness and flushness of external aerodynamic surfaces present challenges for high-speed conditions, where aerodynamics is the driver of helicopter performance. For AIRBUS-RACER helicopter the main landing gear trap doors are parts of the lower wing skins (in retracted configuration) affecting helicopter performance by minimizing the drag. Flushness requirements must not be in contrast with the functionally of the Landing gear system that must open and close the doors during the landing gear retraction-extension phases at moderately low velocity. To manage these goals, a novel design logic has been identified to support the trap doors development phase. The identified way to proceed needs of relevant numerical method and tool as well. This method is aimed at identifying the main landing gear composite compartment doors in pre-shaped configuration to match the smoothness and door-stopper engagements over each aerodynamic conditions. The authors propose a detailed non-linear Finite Element method, based on MSC Nastran (MSC Software, Newport Beach, US) SOL-400 solver in which the structure is modelled with deformable contact bodies in a multiple load step sequence, open door condition and pre-shaped, deformed under actuator pre-load, under flight load conditions. The method includes the entire pre-stressed field due to the preload and the actual door stiffness, considering the achieved large displacement to verify the most representative strain field during loads application. The paper defines a robust methodology to predict the deformation and ensure the most appropriate door “pre-bow” and pre-load, in order to achieve the desiderated structural shape that matches aerodynamic requirements. The main result is the identification of a pre-shaped doors configuration for the Airbus RACER Fast Rotorcraft.

The evolution of aircraft wing development has seen significant progress since the early days of aviation, with static testing emerging as a crucial aspect for ensuring safety and reliability. This study focused specifically on the engineering phase of static testing for the Clean Sky 2 T-WING project, which is dedicated to testing the innovative composite wing of the Next-Generation Civil Tiltrotor Technology Demonstrator. During the design phase, critical load cases were identified through shear force/bending moment (SFBM) and failure mode analyses. To qualify the wing, an engineering team designed a dedicated test rig equipped with hydraulic jacks to mirror the SFBM diagrams. Adhering to specifications and geometric constraints due to several factors, the jacks aimed to minimize the errors (within 5%) in replicating the diagrams. An effective algorithm, spanning five phases, was employed to pinpoint the optimal configuration. This involved analyzing significant components, conducting least square linear optimizations, selecting solutions that met the directional constraints, analyzing the Pareto front solutions, and evaluating the external jack forces. The outcome was a test rig setup with a viable set of hydraulic jack forces, achieving precise SFBM replication on the wing with minimal jacks and overall applied forces.