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  • Research
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  • Clusters of Excellence at TU Braunschweig
  • SE²A - Sustainable and Energy-Efficient Aviation
  • Research
  • ICA B "Flight Physics and Vehicle Systems"
Logo Sustainable and Energy Efficient Aviation of TU Braunschweig
B3.2 - Advancing the additive xHLFC suction panel concept towards wind-tunnel readiness
  • ICA B "Flight Physics and Vehicle Systems"
    • B5.2 - Application of physics-based finite-element tools in stiffness tailored structures for cryogenic hydrogen storage for improved mechanical and thermo-mechanical response
    • B4.2 - Consistent Multilevel Model Coupling and Knowledge Representation in Multidisciplinary Analysis and Design
    • B4.1- Collaborative Multidisciplinary Structural Design and Thermal Management for Electric Aircraft
    • B3.5 - Production technologies for hybrid suction designs - Bonding of micro-perforated sheets for hybrid laminar flow control suction panels
    • B3.2 - Advancing the additive xHLFC suction panel concept towards wind-tunnel readiness
    • B3.1 - Protective, multifunctional suction shells for hybrid laminar flow control: Design, integration, simulation and testing
    • B2.5 - EverScale - Enhancement and verification of load alleviation technologies by subscale flight testing
    • B2.4- Hybrid load alleviation by fluidic/reversed control and nonlinear structures
    • B2.3 - ARGO2 - Integrated design of control methods for stability of elastic aircraft
    • B1.9 - Validation of turbulent boundary layer-induced sound transmission through a fuselage section
    • B1.8 - Wind-tunnel experiments of advanced design of swept-wing with suction surfaces
    • B1.7 - Extension of Correlation-based Transition Transport Models for Laminar Aircraft Design
    • B1.6 - Effective Design Methods and Design Exploration for Laminar Wing and Fuselage
    • B1.5 - Sensitivities of Laminar Suction Boundary Layers for Large Reynolds Numbers
    • B1.3- Physics of broadband noise of sound sources from installed propulsors
    • JRG-B1 - Physics of Laminar Wing and Fuselage
    • JRG-B2 - Flow Physics of Load Reduction
    • B1.1 - Propeller and wing aerodynamics of distributed propulsion
    • B1.2 - Aerodynamic analysis of partly embedded boundary layer ingesting propulsors
    • B1.3 - Fast non empiric prediction of propulsion installation related noise
    • B1.4 - Transition Prediction and Design of Hybrid Laminar Flow Control on Blended Wing Bodies Based on 3D Parabolized Stability Equations
    • B2.1 - Load reduction potential of nonlinear stiffness and damping technologies
    • B2.2 - Structural technologies enabling load alleviation
    • B2.3 - Active load Reduction for enabling a 1-G wing using fOrward-looking and distributed sensors (ARGO)
    • B2.4 - Morphing structures for the 1g-wing
    • B3.1 - Global and Local Design Methodology for Laminar Flow Control
    • B3.2 - Process simulation and multiscale manufacturing of suction panels for laminar flow control
    • B3.3 - Thin Plies in Application for Next Generation Aircraft (TANGA)
    • B3.4 - New methods for failure and fatigue analysis of suction panels for laminar flow control
    • B5.1 - ADEMAO: Aircraft Design Engine based on Multidisciplinary Analysis and Optimization
    • JRG-B5 - Long-Range Aircraft Configurations and Technology Analyses
    • JRP - Permeation assessment for cryogenic applications by means of Fiber Bragg Grating sensors
    • ⯇ back to research

B3.2 - Advancing the additive xHLFC suction panel concept towards wind-tunnel readiness

Laminarisation of aircraft wings reduces their friction drag and thereby increases the aircraft’s energy-efficiency. To achieve laminarity, extended hybrid laminar flow control (xHLFC) concepts are investigated that integrate active boundary layer suction at the rear section of the wing. If applied properly, the active suction of air from the boundary layer delays laminar-turbulent transitioning. This leads to a higher percentage of laminar flow on the surface of the wing and therefore to reduced friction drag.

Project B3.2 investigates an additive xHLFC suction panel concept that unites multiple functions in one integral part. By means of additive manufacturing a panel is designed that consists of a micro-perforated skin as aerodynamic surface, a core structure that provides structural support and transport of the suction air and connector solutions for transporting loads and suction air. Triply periodic minimal surface (TPMS) sheet networks are used to create the core structure as they allow lightweight construction, transport of air in every direction and adaptability of pressure distributions inside the core. Based on works from the prior project phase, first complete and working test panels will be designed and tested in wind tunnel campaigns.

Integral concept by means of additive manufacturing

Additive manufacturing promises to create complex integral structures with minimal effort. That is why this approach is chosen in this project for manufacturing of xHLFC suction panels with their dense but porous support structure. Especially stereolithography (SLA) and selective laser sintering (SLS) are investigated in this project due to their precision which is important in creating aerodynamic effective surfaces. Challenges are the perforations of the suction skin and connection solutions for panel sections, which are addressed in this project.

Curved suction panel, maunfactured integrally with TPMS core, micro-perforations and connector solutions
Integral suction panel with gyroid core

TPMS as core structure

In the first project phase, TPMS structures have shown promising properties for use as a suction panel core structure. They allow mass transport in every direction through their channel-like design, which enables the transport of the air that is sucked in. In addition, they create a stiff but also lightweight support for the suction skin that can deal with the mechanical loads applied to the panel. First results show that they have equal mechanical properties as Honeycombs in terms of area moment of inertia when used as core in sandwich like structures.

Another important reason for the use of TPMS structures is their adaptability. As shown in the first project phase, the parameters of the TPMS structure can be variable in different directions to selectively adjust pressure losses inside the core structure. This is known under the expression functional grading and allows to fit a specific pressure distribution to the suction surface. Thereby it is possible to passively control the suction rate continuously over the perforated surface without pressure steps resulting from a chamber design as used in different approaches.

Printed micro-perforations

Micro-perorated, printed skin on a TPMS core panel, integral part
Printed perforations on a suction panel

A main challenge in additive manufacturing of suction panels is printing the perforations in the suction skins. Generally, one aims at as many holes as possible which are as small as possible to come close to a continuously porous skin. However, the printing process limits the minimal hole size by printing parameters like the layer height and laser spot size.

This challenge is addressed by specific hole geometries that allow to print as small perforations as possible by avoiding significant overhangs while allowing removal of residual material. In addition, special post-processing steps are developed to remove such residual printing material. These approaches shall extend the limit of printable minimal hole sizes for effective suction skin design.

Testing and experimental validation of the suction panel concept

To evaluate partial solutions and the overall panel design, extensive test and measurement campaigns are planned. To model pressure losses and flow behaviour correctly, aerodynamic characterization of printed suction skin specimens and TPMS structures has to be conducted, for example measurements of pressure losses or impedance. In addition, the mechanical properties of the suction panels are important. Especially bending of the structure is investigated as wing bending will be a major effect in future applications. This can lead to a change in hole geometry and even hole blockage, which has to be prevented by means of an adequate hole design.

Special attention shall be given to wind tunnel campaigns. With the results from the first project phase in mind, all aspects shall be brought together into complete and functional suction panels that can show the suction behaviour under realistic flow conditions. With this, the benefits of additive xHLFC suction panels can be evaluated and valuable data for design of future panel designs can be collected.

Details of the project

Research Assistant

Jan Kube M.Sc.

Institute of Mechanics and Adaptronics
Langer Kamp 6, 38106 Braunschweig
Phone: +49 531/ 391-8050

Contact

Project lead

Prof. Dr.-Ing. Christian Hühne

Institute of Mechanics and Adaptronics

Organisation

Institute of Mechanics and Adaptronics

TU Braunschweig

Langer Kamp 6
38106 Braunschweig
Germany

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Cluster of Excellence SE²A –
Sustainable and Energy-Efficient Aviation
Technische Universität Braunschweig
Hermann-Blenk-Str. 42
38108 Braunschweig

se2a(at)tu-braunschweig.de
+49 531 391 66661

 

 

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