The final test for certification of the rudder of the KC-390 was completed in September 2018. This load test completed the series of tests of the flight control surfaces of this aircraft marketed by Embraer: the flaps, ailerons and tailplane. All three components were developed by Aernnova.
This campaign which has been active since October 2015 involved the use of 20 actuators and force transducers to apply test loads, displacement transducers, multiaxial transducers to measure reactions and a total of more than 1,800 instrumentation channels to measure deformations at specific points of the different structures.
In total, the campaign consisted of nearly 3 years of different tests, including fatigue tests and static tests in different configurations.
The test specimens satisfactorily completed the entire campaign.
STAR3 Technology Alliance, the space alliance formed by CTA, CATEC and TECNALIA will develop novel structural components for launchers and satellites using additive manufacturing technologies.
This project, the first one contracted for ESA within GSTP programme, will allow CTA to show the space industry the test capacities and capabilities achieved in the past.
CTA will validate the components at Miñano facilities where is able to perform tests in vibration, structural, pyroshock and vacuum domain to fulfil the testing requirements for aerospace industry.
CTA’s Miñano facilities have been carrying out the fatigue tests for Aernnova on the horizontal tailplane of the ERJ190-E2 / ERJ195-E2 aircraft marketed by the Brazilian company Embraer.
These tests involve application of more than 3 million load cycles using 6 actuators with 48 application points to simulate the aerodynamic loads the component would undergo when in use.
The monitoring of these tests required use of over 600 strain gauges distributed across the specimen and 11 load cells to control the loads applied by each actuator and measure the reactions at certain points, along with 12 displacement sensors.
Following completion of the fatigue tests, static tests of residual loads will be performed using two additional actuators and the corresponding load cells.
During the months of March and April 2017 the Limit Load and Ultimate Load test campaign was carried out for certification of Flap Track 1 and Flap Track 3 of the Embraer E2 aircraft.
This campaign involved testing of two specimens, with each one corresponding to different Flap elements. During these tests, each of the two elements tested were subjected to different limit load and ultimate load cases.
A total of 6 actuators were used to apply the loads to each specimen. The tests also involved use of displacement sensors, strain gauges, 6-axis force sensors and the PONTOS contactless displacement measurement system in order to meet all the customer’s measurement and data requirements.
During the second week of January 2017 the shock tests were carried out on the APP mechanism for Airbus Defence & Space.
The tests were successfully performed using the pyroshock test bench developed by CTA, located on its premises in Miñano (Álava).
The tests consisted of the application of three shocks on each of the three axes of the specimen with an SRS profile of 100-10,000 Hz and levels of more than 1000g.
CTA and the other participants in the ACTIMAT project received an award from the Regional Minister Arantxa Tapia in recognition of their research efforts during the presentation of the new Basque Science, Technology and Innovation Network (RVCTi) in the Guggenheim Museum in Bilbao.
The ACTIMAT project focuses on development of New Materials for the strategy of intelligent specialisation in Advanced Manufacturing. The project is headed by Gaiker and apart from CTA also involves participation by Tecnalia, Tekniker, Ikerlan, Cidetec, Ceit, three departments of the UPV/EHU, Mondragon Goi Eskola Politeknikoa, Autotech Engineering, Azterlan and BC Materiales.
CTA recently announced the creation of the TRISPACE space technology strategic alliance together with TECNALIA and CATEC at the facilities of the CDTI in Madrid.
This initiative by these three centres with widely recognised technological resources and activities for the space industry aims to offer a more complete and attractive range of technological capabilities and services, enhance coordination of investment capabilities and stimulate technology transfer to other sectors with the aim of reinforcing the position and innovation potential of the space industry.
CTA recently began the tests for certification of various components of the Embraer KC-390. These tests consisted of initial static testing, fatigue testing and a series of final static tests in different configurations.
The specimens to be tested are the flap, the aileron and the rudder for the aircraft, all of which are being manufactured by Aernnova. The testing involves application of loads via multiple actuators, including aerodynamic loads, forced displacements at specific points of each component and loads applied to different joints.
Measurements will also be made of microstrains at over 1,500 points using strain gauges and the loads and reactions will be monitored at more than 80 points.
OUTCOME: “Out of autoclave composite manufacturing, wing and tail unit components multifunctional design,” the proposal by the Tier 1 company Aernnova, CTA and three other technology centres (Tecnalia, Fidamc and Catec) has been selected to participate as a Core Partner under the new Clean Sky 2 JTI as part of the Horizon 2020 framework programme.
The activities under OUTCOME began recently and are aimed at enabling and fostering the commercial availability of leading-edge technology for aeronautical structures with integrated systems, with a special focus on out of autoclave composite manufacturing.
CTA plans to develop new testing technologies under this project in the fields of load application, intelligent tooling and non-contact inspection with a view to their implementation in tests for its customers.
CTA is developing new impact testing technologies combining the impacts with structural loads applied simultaneously to the specimen, which will be validated in September on the main rotor blades of the EC175 helicopter by Airbus Helicopters.
CTA has a high energy impact test bench at its facilities capable of launching projectiles of more than 200 mm in diameter at speeds of over 100 m/s to test the structural resistance of different aerospace components.