Particularly concerned with reducing fuel consumption and CO2 emissions, the aeronautical industry designs structures and materials to preserve the laminar regime as much as possible and reduce drag, allowing a reduction of 5 to 10% in fuel consumption to be targeted. Tiny disturbances in the airflow at the surface can cause an early transition from laminar to turbulent flow. The accumulation of insect debris on the leading edge of laminar wings has been recognized as one of the most significant operational problems associated with laminar flow. Debris of less than 150 ?m residual height is sufficient to generate turbulence and thus reduce to zero the benefit of the developed design. Thus, the Stellar project proposes a multidisciplinary approach to developing effective and sustainable anti-contamination solutions, designed on the basis of an in-depth understanding of the biochemical and physicochemical properties of hemolymph and its interaction with the surface. This project relies on the complementarity of 8 scientific and industrial partners from Belgium, France and Spain. Six research institutes are involved: MANO or Materia Nova, Cidetec, UMONS-IBS, VKI, ESPCI and CNRS, with recognized expertise in surface technologies, surface physicochemistry, biochemistry and aeronautics-specific tests. The development of innovative products and protocols are evaluated and validated by the industrial companies involved in the consortium: SOPURA and SONACA (and SONACA AIRCRAFT with the technological support of La Mesure Sur Mesure (LMSM). The different stages of the study will be detailed: from the design of the solution, its evaluation on a laboratory scale, to its implementation on an industrial scale and its validation in simulated (wind tunnel) and real (flight) conditions.
PVD deposition on aluminum
The Ionics company presentation will detail the technological advances in aerospace with the challenges of weight reduction and durability. The aerospace industry is continually looking for ways to reduce the weight of structures to improve energy efficiency and reduce operational costs. In this quest, lightweight and high-performance materials such as aluminum are gaining importance due to their low density. However, a major technical challenge lies in the application of specific surface coatings to ensure the weldability and durability of aluminum components. IONICS Surface Technologies has demonstrated that PVD (Physical Vapor Deposition) deposition can overcome these obstacles by providing optimal adhesion of coatings to aluminum. This technological advancement paves the way for the manufacture of lighter and more durable aerospace components. In particular, PVD-coated aluminum connectors could become essential in the manufacture of aerospace structures, enabling substantial weight savings and improved flight performance.
The Advancement of Ionics
It lies in the design of an advanced cathode, a cutting-edge technology that allows uniform coverage of substrates, regardless of their geometry. This approach minimizes waste and ensures superior coating quality. In addition, the integration of ion implantation technology strengthens the adhesion of coatings to difficult substrates, such as aluminum. The transition to a continuous PVD process, replacing traditional electroplating methods, also has major ecological and economic advantages. PVD eliminates the use of harmful solvents and chemicals, as well as the need for intensive rinsing, thus reducing water consumption and wastewater discharge. PVD also allows thinner coatings to be applied while maintaining the same functional properties, which contributes to a more efficient use of resources.
The new HVAF coatings
Presented by Stefan Verreyken from AIM3LEAD, The conference on new HVAF coatings in Tungsten Carbide are a sustainable alternative to Chrome The qualification of a new application in surface treatment such as HVAF (High-Velocity Air-Fuel) in aeronautics depends on the validation by the OEM manufacturer, which can take a long time. At the same time, these new technologies / alternatives of surface treatment application are important for innovation and more particularly both for competitiveness and to comply with regulations such as REACH. We will inform suppliers less familiar with aeronautics about this qualification process, what HVAF is as an example and the test campaign to be done for such a qualification. We plan in this way to increase the general knowledge of the surface treatment sector in relation to this growing aeronautics market.
Visit to Sonaca facilities
SONACA is one of the world leaders in the development, manufacturing, assembly and supply of elements in the aeronautical sector. Its skills extend to the civil, military and space markets. With recognized expertise in leading edges and complex fuselage sections, On the program of the visit, the aluminum surface treatment line for large elementary parts (up to 10m long). This line follows the requirements related to REACH, moving from chromic anodization to sulfo-tartaric anodization for parts intended to be painted and to sulfo-phosphoric anodization for parts intended to be glued and, the lines for applying liquid paint to assembled elements and the automation of its quality controls.
