RFPs: Ground Test Demonstration and Preparation of Flight Test of an Ultra High Bypass Ratio Ducted Geared Turbofan Engine for SMR Aircraft

Scope

• This topic is intended to deliver a full ultra-efficient engine ground demonstrator to meet, by project completion, a propulsion system at TRL5, supported by critical technology bricks, to be flight tested in real operating conditions at a later stage in the programme. Applicants should propose and build a demonstration plan aiming to validate a propulsion architecture on ground by end of 2029 and subsequently in flight by end of 2030.
• Applicants should demonstrate TRL4 already completed and achieved for key technology bricks at project start, based on synergies with activities from CA Phase 1, or funded by national/regional or other European programmes, and identify the remaining key challenges in the path towards TRL6 by end 2030.
• The primary objective of the topic, therefore, is to design, develop, manufacture, and test an UltraHigh Bypass Ratio ducted engine for SMR aircraft for ground testing up to TRL5, including advanced core engine and combustion technologies, advanced thermodynamic (variable) cycle and hybridisation. The following features are part of the scope:
  • overall propulsion system architecture, capable of demonstrating all the requested performance targets.
  • All major modules in the powerplant system, including:
    • Low speed fan system, next generation composite architecture and installation concept including nacelles where required for lowest weight, drag and noise.
    • New generation power gearbox for SMR scale featuring a low weight and volume design and reduced loss turbomachinery transmission with optimised oil system, delivering new standards of transfer efficiency, and facilitating highest propulsive efficiency.
    • High efficiency core with advanced light-weight materials, cooling system and aerodynamics that enables higher level of power offtake than current operations and reliable operations of the product in all environments and throughout the whole flight envelope with adequate margins.
    • Advanced low NOX combustion system designed to deliver beyond state-of-the-art reductions in NOx and nvPM across the flight cycle (e.g., LTO, cruise). The system being designed to eliminate architecture and scaling challenges such as coking and thermoacoustic instabilities.
    • Next generation High-Speed Low-Pressure Turbine, achieved by new standards of blade aero-loading that enable high efficiency and low-weight, integrating novel technologies to minimise the design constraints of aerofoil aeroelastic phenomena.
  • Variable cycle technology that allows the engine to adapt and provide power more efficiently depending on operation.
  • Engine integrated electrical motor generators enabling more-electric operations (e-start, eactuation etc.)
  • Smart Offtakes that integrate with aircraft systems to enable optimised power management throughout the flight cycle unlocking design synergies to deliver optimal physical and functional sizing
  • High efficiency Fuel and thermal systems that enable the use and benefits of drop-in 100% SAF usage, and further developed for non-drop in SAF system benefits e.g. due to higher calorific value, thus improving thermal efficiency.
  • Optimized engine-aircraft integration considering aerodynamic, structural and systems improvements to reduce weight and increase efficiency
• The second objective of the topic is to prepare the fully instrumented and modified Flight Demonstration Platform to enable the flight test of the Ultra-High Bypass Ratio ducted turbofan architecture for SMR aircraft, at a later stage in the programme, to validate the technologies at TRL5 including:
  • Development and acquisition of the relevant flight instrumentation, fulfilling the performance targets for flight test instrumentation systems detailed in the section on performance targets, to carry out in-flight measurement of thrust, emissions, and other characteristics such as noise and soot, as applicable. The technologies developed should reach the maturity of TRL6 during the Clean Aviation programme duration and fulfil the need for in situ measurements and access hard-to-reach areas
  • Engine integration activities on the flight test demonstrator should be performed up to Critical Design Review phase and include a full aircraft performance analysis to support flight clearance and flight test campaign, aircraft systems and airframe adaptation including hardware and software.
  • The need for Wind Tunnel Testing activities supporting flight clearance shall be assessed.

Funding Information

• The maximum EU contribution for the topic is EUR 70 million.
• The maximum EU contribution per project funded under this topic is EUR 70 million.
• Indicative project duration: Maximum 48 months.

Expected Outcomes

• Project results are expected to demonstrate a ducted propulsion system on-ground at TRL5 for a Short Medium Range aircraft concept considered by Clean Aviation SRIA for EIS in 2035:
  • Deliver a new Ultra-High Bypass Ratio ducted geared turbofan whole-engine SMR-scale ground demonstrator with a sea-level static thrust of 25000 to 30000 lbf at TRL5, going through design freeze, manufacturing, instrumentation integration & calibration, and assembly of all engine parts.
  • Demonstrate and validate up to TRL5 the targeted performance of the key technology bricks and full engine via ground test campaigns over the period of 2026-2029.
    • The reduction potential of CO2 emissions should be quantified based on demonstrated ground test performance targeting at least 20% CO2 emissions reduction at SMR aircraft concept level.
    • The key parameters and exhaust emissions linked to non-CO2 effects (including but not limited to NOx, water vapour, and non-volatile Particulate Matter) should be assessed monitored and reported against regulations on non-CO2 aviation effects (Directive (EU) 2023/958) for assessments of compliance.
  • Achieve the Preliminary Design Review and Critical Design Review phases of the Flight Test Demonstration aircraft preparation activity, specifically for the UHBR ducted turbofan demonstration, including design of hardware to support modification of the aircraft and integration of the engine to the FTD, later in the programme. The need for Wind Tunnel Testing activities supporting flight clearance shall be assessed. Key flight clearance activities in support of full flight clearance and flight test will be executed at a later stage in the programme.
  • Identify route to certification, with high complexity means of compliance (MoC) areas demonstrated. The propulsion system shall be compliant to the DO 160, DO 175, CS-25 and CS-E certification requirements, achieving a Certification Readiness Level 5 (CRL 5) within the project, enabling the route to CRL 6 within the Clean Aviation programme.
  • Deliver and demonstrate Flight Test Instrumentation for emissions and thrust, soot and noise measurement, enabling to reach TRL6 within the Clean Aviation programme duration, enabling the highest accuracy and in situ measurement, in the short term and suited to areas with limited access.
  • Provide a roadmap to TRL6 for all engine parts with identification of their current level of maturity and propose a maturation plan for implementation, along with the flight test readiness plan.
• Project results are expected to directly contribute to the performance targets of the SMR aircraft concept with EIS by 2035:
  • The propulsion system shall enable and contribute to a 30% CO2 emissions reduction at aircraft level (including weight and aerodynamic integration effects of the propulsive system), compared to the 2020 SoA aircraft (enabling 86% net CO2 reduction with 100% SAF)
  • Evaluation, monitoring and reporting of key parameters needed to assess non-CO2 effects and noise emissions, shall ensure compliance with foreseen regulations and standards for a 2035 EIS.
  • Adequate KPIs at integrated system and key technology levels shall be defined, to support the effective achievement of the expected outcomes, and shall be aligned with the performance targets
  • A clear route towards certification, exploitation, and industrialization shall be identified, including the identification of operational requirements to subsequently support successful entry into service.

Eligibility Criteria

• Entities eligible to participate:
  • Entities eligible to participate Any legal entity, regardless of its place of establishment, including legal entities from nonassociated third countries or international organisations (including international European research organisations) is eligible to participate (whether it is eligible for funding or not), provided that the conditions laid down in the Horizon Europe Regulation have been met, along with any other conditions laid down in the specific call/topic.
  • A ‘legal entity’ means any natural or legal person created and recognised as such under national law, EU law or international law, which has legal personality and which may, acting in its own name, exercise rights and be subject to obligations, or an entity without legal personality .
• Entities eligible for funding :
  • To become a beneficiary, legal entities must be eligible for funding. To be eligible for funding, applicants must be established in one of the following countries:
    • the Member States of the European Union, including their outermost regions:
      • Austria, Belgium, Bulgaria, Croatia, Cyprus, Czechia, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden.
    • the Overseas Countries and Territories (OCTs) linked to the Member States:
      • Aruba (NL), Bonaire (NL), Curação (NL), French Polynesia (FR), French Southern and Antarctic Territories (FR), Greenland (DK), New Caledonia (FR), Saba (NL), Saint Barthélemy (FR), Sint Eustatius (NL), Sint Maarten (NL), St. Pierre and Miquelon (FR), Wallis and Futuna Islands (FR).
    • countries associated to Horizon Europe;
      • Albania, Armenia, Bosnia and Herzegovina, Faroe Islands, Georgia, Iceland, Israel, Kosovo, Moldova, Montenegro, New Zealand, North Macedonia, Norway, Serbia, Tunisia, Türkiye, Ukraine, United Kingdom.

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