Our activities

To achieve the objectives identified in the project, and to realize the Engine Demonstration, a set of dedicated technical activities have been settled-up

Key sub-systems and Engine Demo Platform

In an Agile approach will investigate all subsystems and components not already present in ENLIGHTEN, ENLIGHTEN-ED and FLLP ESA PROM-H programmes, and developed during the period in order to perform a screening of potential other technologies that could be integrated in the Engine Demo Platform. The main outcome of this task will be the possibility to integrate other technology in the engine demo platform.

In this framework, several areas have been identified as key subsystems for the future engines, among them we can cite Low-cost Laser Ignition Systems, Low-cost Regulation Valves, Low-cost single element nozzle extension, Thrust Chamber assembly and testing on engine platform.

All the identified technologies will make use of AM and AI, and then integrated in a single engine demonstrator to be tested at DLR-Lampoldshausen.

Maturation of extended Additive Manufacturing technologies

Objective is to set-up and mature the identified AM technologies that could be applied at subsystem level.

Specifically, maturation of Large-Scale Printers PBF-LB based up to TRL6 and production of a demonstrator will be implemented, having as a target application a turbomachinery product that will be integrated in the engine demo platform.

Another AM technology will be the maturation of Laser Metal Deposition powder (LMD-p) for nozzles. This process could be beneficial for some components, in particular a full-scale exhaust line demonstrator will be ready for the engine demo platform.

Finally, the consortium proposes manufacturing a demonstrator part from two different metallic materials using Laser Powder Bed Fusion of Multi-Materials (PBF-LB/MM) process. What has been developed during the ENLIGHTEN project will be here matured, characterized and tested, targeting an application in engine demonstration platform to get TRL7 to the ED.

Artificial Intelligence and Machine Learning

The consortium will define and ensure feasibility of the overall logic for the EHMS (Engine Health Monitoring System) deployment. An engine simulator will be also designed for data generation for the upgraded Vulcain 2.1 specific engine, in order to provide a dataset that allows for training algorithms on both the start-up and the flight phases of the engine. The EHMS requirements shall ensure to fulfil the needs of the ENLIGHTEN-ED system and tests.

To realize this AI application, there will be both hardware and software implementations, including AI-card and associated firmware, Startup transient, Steady flight, Electrical system with Hardware-in-the-loop, all covered by tests and validation phases.

Engine Demo Platform

Engine Demo Platform will include detailed definition, production & test campaign preparation.

DLR, as center of excellence for hydrogen test bench, will realize the engine fire test campaign for the engine demo platform that aims to maturate technologies from ENLIGHTEN, ENLIGHTEN-ED & ESA FLPP. All partners will contribute to the fire test objectives and exploitation of the results in their technical perimeters.

All the activities identified in the previous domains, such as key subsystems, AM and AI&ML, will converge into elements to be Assembled, Integrated and Tested at DLR test facility. This will include management of Green H2 and propellants, H2 production and carbon footprint analysis.

Exploitation of the test results will be also part of the activity, having as a target the expertise of the hardware that has been matured and tested.