ELUBSYS Objectives

1. Oil Systems for Next Generation Engines-ELUBSYS Project Mid Term AchievementsAerodays Conference 2011 31st of March 2011

2. ELUBSYS Objectives • FOCUSSED Project • FP7 Workplan • ACARE Goals • Relation with CleanSky • Green + Cost Efficient + Time Efficient • Achieve REAL results • Technology bricks for future projects • Design practices for direct implementation • Continuous evaluation tool to assess overall impact • Dissemination • OUR strengths • High quality & experience of partners • Motivated T.E.A.M.

3. ELUBSYS Objectives Advanced seals and associated oil system architecture = enabling technologies for future engine needs

4. 2003 2004 2008 2011 2013 2009 2010 2012 2014 2015 Elubsys project • Advanced seals  TRL 5 • Advanced oil system architecture • Associated components design rules Advanced seals  TRL3 Components improvement ATOS & INTRANS Elubsys – TRL 5 JTI – TRL6 Engine integration Development Prototype and industrialisation

5. ELUBSYS Objectives Continuous evaluation of the project results through 0D model

6. ELUBSYS WP & Partners WP0: Global project management (TA) WP1 Advanced Sealing • WP1: Advanced Brush Seals for Bearing Chambers (MTU) • Partners : MTU, RRUK, ITP, ULB, FIT, UNOTT, SN, • Activities: • Performance and endurance validation for different types of seals (MTU,SN) • Impacts on bearing chamber • WP2: Bearing Chamber Flow and Heat Transfer (RRD) • Partners : RRD, TA, RRUK, SN, TM,ULB,INSA, UoB, UNIKARL, UNOTT • Activities: • Models and experiments of bearing chamber • Oil flow interruption (TM,INSA) • WP3: Externals (TA) • Partners : TA, MTU,SN, WSK, ULB, Cenaero • Activities: • Supply system (TA,ULB,Cenaero) • Scavenge system (MTU,WKS) • WP4: Oil Quality and Coking (SN) • Partners : SN, TA, RRUK, ULB, USFD, TK,UMons) • Activities: • Modelling of oil behaviour (USFD+RRUK,SN) • Detection of coking(SN,UMons,TK) • Anti-coking coating development (UMons) WP2 Housing Heat management WP4 Oil quality and coking WP3 Externals + WP5: Scientific coordination and benefit evaluation (ULB) Partners: ULB, TA,ULG

7. WP1 Advanced brush seals for bearing chambers • Partners: MTU, RRUK, SN, ITP, ULB, FIT, UNOTT • Objectives • To investigate performances of advanced brush seals for bearing chamber including: • Kevlar brush seal: measure of frictional heat (using pyrometer) under different overlap conditions and rotational speeds (up to 22000 rpm) , impact of oil coking on the stiffness and efficiency of the seals (MTU) • Carbon brush seal: endurance tests ( 8000 h) with different overlaps (SN) • Carbon brush seals on ULB/TA test rig under extreme conditions ( hot T°, reverse P, High/low speed) • To study the two-phase flow behaviour, heat transfer and pressure loss in the scavenge pipe when brush seals are used and the vent pipes removed (FIT) • To investigate the effect on bearing chamber thermal behaviour of the reduced air flow anticipated through brush seals and optimise the bearing chamber thermal design: • Design optimisation with a CFD model and also a thermo-mechanical model of a real engine Tail Bearing Housing (TBH). Through a sensitivity analysis the benefits of advance sealing technologies when applied to a real component will be evaluated (RRUK, ITP) • CFD model of the bearing chamber investigated under the first objective (MTU rig) will be created and the data compared to experimental data (RRUK, UNOTT) code validation • Bearing Chamber Design Optimisation and Sensitivity analysis

8. Testing of Brush Seals (Kevlar and Steel materials) Bearing Chamber Rig High Speed Cam WP1:MTU brush seal rig

9. Pyrometer Ports Brush Seal Kevlar WP1: MTU and ULB/TA brush seal rig ULB/TA test rig MTU test rig

10. high low WP1: two phase scavenge flow simulation (FIT) woil « wair woil » wair Bubble flow finely dispersed with a high air concentration in the core and a very low concentration near the wall Bubble flow with a high air concentration at the wall and a very low concentration in the core

11. WP1 CFD Model: TBH model and MTU test rig Real Engine TBH Simulation (RRUK,ITP) 2 phase CFD Methodology for Real Engine Bearing Chamber Application of film model developed by UNott in WP2 to an industrial case; Inform but also use CFD modelling Methodology developed in WP2 Supply of thermal data to ITP for thermo-mechanical model CFD model of MTU bearing chamber (RRUK, UNott) +comparison with test results

12. WP2: Bearing Chamber Flow and Heat Transfer • CHALLENGES • Relation to ACARE goals (Advisory Council Aeronautics Res. EU) • enabler of higher operating temperatures for better SFC=> supports general design trend • weight reduction by reduced heat and cooler size for SFC=> includes reduction of unit cost • less development cost by advanced and faster methods • higher reliability (avoidance of oil leakage)=> reduce operation costs and maintenance effort • State of the Art • Bearing chamber design based on experience or try&error • Intended Progress • Make bearing chamber design variants predictable

13. WP2: Objectives • Improve scavenge and vent port performance as well as heat transfer (RRD,KIT) • Optimize CFD modelling for 2-phase flows in bearing chambers (RRUK,UoB, UNott) • Predict heat transfer in bearings during oil flow interruption (TM) Grooved offtake Baseline rounded Ramp offtake

14. WP2.1 and 2.2: First Test Campaign (RRD,KIT)

15. Stationary casing Oil injection Core airflow, uair Oil droplets Inner shaft gravity Oil film, uoil y s Scavenge (Oil exit) WP2.1 and 2.2: Bearing Chamber CFD Strategy - Develop wall film model (alternative: apply Volume of Fluids method) • Test in simplified 2-D geometry • Integrate into 3-D CFD Program • Validate for rig geometries • Extend to engine representative geometries Illustration of simplified 2-d model

16. Heat source WP2.3: Oil Flow Interuption (TM) • Context: in case of oil pump defusing  unsteady thermo mechanical behavior • Consequences on the bearing ? • Analytical study ( INSA): • Power losses: drag and hydrodynamic rolling traction force • Thermal network analysis • Aerodynamic approach ( CFD model and wind tunnel test) • TM will perform tests on a partial rig to validate the hypothesis performed during modelling • Steady state tests • Oil shut off tests • Measurements: • Cfriction, Axial load,Q, V shaft • T°in, T° out, T°outer race

17. WP3.2: Supply System Components Optimization • Partners: TA and ULB • Supply system influence on the pump performance: • Hydraulic circuit (inlet length, roughness) • Accessories connected (strainers, valves,...) local head loss • Air content in the oil and his influence (cavitations & air content in the pump): • Macro bubbles, dissolved gas, micro-bubbles • Dissolved gases in Mobil Jet 2 oil measured by chromatography ->up to 12% in volume, N2 and 02 • Visual oil analysis: • Tubular sight glass & camera • Particle Tracking Velocimetry New practical rules for Supply system design

18. WP3.2:1st test campaign • First test campaign finishes- analyses in progress • Results: big influence of air content on pump performances (reduced Pout, pulsation,…) • Problem detected  air accumulation in the visualisation cell • Probable cause: divergent before visualisation cell • Identified solution: divergent before elbow • visible improvement: reduction of air volume and turbulence • New test campaign foreseen in June with test rig improvements

19. Common outlet BRG cavity X BRG cavity Y WP 3.3 : Scavenge system and vent component optimisation Multiple inlet scavenge pump ( WSK) • Scavenge pump design – completed • Test rig modifications – completed • Hardware & Instrum purchasing – completed • Assembly of pump in progress • Beginning of testing – March 2011

20. Ejector Mapping (operating area) WP3.3 :Scavenge system MTU ejector • 1D analytical tool for designing 2 phases flow ejectors has been created • CFD simulation is ongoing • Ejector hardware in quarz glass for high speed camera visualization • Different sprayers (i.e. flat cone, hollow cone, solid cone etc) will be used • Delivery of H/W and start of testing in March 2011 • different primary oil flows • different seal upstream pressures • deteriorated seals • variable back pressure (deaerator pressure) Deaerator Tank SpeedCam Scavenge Scavenge X Pump Pump Ejector Bearing chamber

21. ELubSys – WP4 Input for AerodaysWP 4: Oil quality and coking • Objectives • Predict oil behaviour in a complex environment (oil condition, temperatures…) • Develop sensors able to analyse oil condition under severe engine environment (Temperature, vibrations) • Develop anti-coking coatings • Participant roles in the WP4 • RRUK + SHEFFIELD INIVERSITY : to develop and validate numerical methods of characterising and predicting oil ageing and degradation in complex aero transmission systems. • SHEFFIELD INIVERSITY : Experimental validation of developed coatings for the reduction of oil deposition on heated tubes. • Snecma + UMons : to develop a sensor to monitor the oil condition in the engine • Snecma + UMons : to develop a coating able to prevent oil coking (sump walls, vent tubes, supply tubes) • ULB : test the different sensors in real oil conditions and test the anti-cocking coating • TA and Tekniker : assess integration of sensors in oil system • Tekniker will contribute in the sensor design and development, micro manufacturing, assembly and test, as well as in chemical fluid characterisation.

22. Development of a specific oil ageing code by USFD Selection of reduced step reaction mechanism for lubricant ageing Translation of a reacting system into a system of Ordinary Differential Equations Decomposition of the reaction rate optimisation method for parallel computation Validation on a typical reaction and ODE system Next steps Code development completed  next step focused on experimental aspects Running the LSIS to generate samples of appropriately aged gas turbine oil, TK to analyse the samples so that mass fraction concentration can be used as inputs for the optimisation of the reaction rate parameters for the suggested lubricant degradation reacting scheme WP4:Development of a lubricant degradation reduced step reaction mechanism LSIS test facility and key components

23. WP4. Task 4.1- MODELLING OIL BEHAVIOUR (TK) TK Progress Overview: oil characterisation ARTIFICIAL AGEING OF MOBIL JET II -Most representative techniques usable to check oil degradation are: *RULER: electrochemical analysis (Antioxidant additives control) *FTIR Infrared spectroscopy (OH band for acid compound generation) *AN determination of titration (for Acid compound generation) AMINES additive monitorized by RULER FTIR (3500cm-1-OH bond)-oxidation band decrease with oxidation time -Under this working condition, warning limits are between 400-800 hours for 1st stage of oil degradation (additive depletion)

24. WP4. Task 4.2- Device development, testing and integration Near Infrared sensor (NIR sensor) Magnetostrictive sensor VISCOSITY Optical Particle Detector (OPD) • Sensor able to detect • particles size and shape • air bubbles in oil • Generates a report with the count and classification following ISO standard • Minimum size detected : 1µm Sensor to measure the oil degradation. The sensor has been tested in industrial applications for water and insoluble content monitoring in oil . Oil degradation prediction Sensor to measure the Oil Viscosity. The sensor has been tested at laboratory scale. Oil degradation prediction TEKNIKER Sensors will be tested on Tekniker test rig,CTA Hydraulic test rig and ULB test rig

25. NIR Spectrometer miniaturization New detector array (higher pixel n°, smaller size) No diffractive optics: optical wave selection by narrow band pass filters array ( 400-1000 nm Autonomous electronic OPD sensor improvement Software changes( back ground homogenization, bubbles and particles distinction, shape classification following lab system analyses) Housing adaptation to aeronautical requirements Electronics for autonomous functionality and communication protocol Choice of CMOS camera modules New illumination device WP4 task 4.2: NIR and OPD sensors – Future Work Schematic of a filter based spectrometer. Microfluidic cell Light holder

26. WP4. Task 4.2- Development & testing of QCM oil sensor UMons sensor: PROGRESS overview • QCM sensor characteristics: • - Measure the change in frequency of a quartz crystal resonator • - Highly effective at determining the affinity of molecules to functionalized surfaces • Surface functionalization: MIP - sol-gel technique • Principle validated on a lab sensor version • Next step:Oil sensor integration: from Lab to Aircraft • Testing: on ULB test rig installed on a derivation Bare Crystal « TiO2 » Crystal

27. ELubSys - WP5WP 5: Scientific coordination and Benefit evaluation • Objectives • To coordinate all scientific and technical aspects of the project • To develop an overall global 0D model for the whole lubrication system, as an evaluation tool of developed technology from ELubSys • To optimise the gains achieved by ELubSys through a systematic evaluation of the results achieved in the WPs 1-4. • Participant roles in the WP5 • University of Liège and University of Brussels (ULB) : to develop and validate a 0D global model of the GTE lubrication system and validate it based on experimental data from all partners. • University of Liège and ULB : estimate with this model the benefits obtained from the ELubSys novel aspects introduced by the different WPs using the ELubSys obtained experimental and simulation data • Techspace Aero: experimental validation of the full 0D model • ULB : organisation of the complete scientific coordination (e.g. between the different CFD and CSM softwares used) and of the scientific dissemination.

28. WP5 - Oil circuit (in Proosis) Outside Conditions RPM BP RPM HP Primary Fluid Secondary Fluid • Every red point defines 3 variables: T (K), P (Pa), mdot (kg/s) Liege, May 2010

29. WP5 Lub system 0D model

30. Achievability of the final objectives • Conclusion • Risk analysis at T0+18M No High Risk, only 3 medium risks (rigs delays on WP1 and WP2 and risk on technology transfer for WP4) • Limited delays on the experimental activities • Budget spending under technical status allows increased effort for the remaining 18 months • Sticks to the 36 months objective • Budget well under the effort • Compliant with Budget allocation • Public Web site: www.elubsys.eu and www.elubsys.com

31. ELUBSYS Partner’s • WP1: Advanced Brush Seals for Bearing Chambers • Partners : MTU, RRUK, Sn, ITP, ULB, FIT, UNOTT • WP2: Bearing Chamber Flow and Heat Transfer • Partners : RRD, TA, RRUK, Sn, TM,ULB,INSA, UoB, UNIKARL, UNOTT • WP3: Externals • Partners : TA, MTU,Sn, WSK, ULB, Cenaero • WP4: Oil Quality and Coking • Partners : Sn, TA, RRUK, ULB, USFD, TK • WP5: Scientific coordination and benefit evaluation • Partners: ULB, TA,ULG ELUBSYS PARTNER’S THANK YOU FOR YOUR ATTENTION!