ONERA, the French aerospace lab (Coordinator of the project)

BP72 - 29 avenue de la Division Leclerc
92322 Chatillon Cedex (France)

www.onera.fr

To contact the coordinator:
Dr. Stefan DRAWIN
ONERA - Metallic Materials and Structures Department

Phone: +33 (0)1 4673 4556
web_address

 

ONERA is a public, scientific and technical establishment with industrial and commercial responsibilities; it enjoys financial independence.

Its expertise, which makes it a key partner in the French and European research community, covers all the scientific disciplines involved in aircraft and spacecraft design (aerodynamics, propulsion, materials and structures, physics, information processing, etc.). ONERA promotes ongoing dialog between basic and applied research, medium and long-range approach, areas of special expertise and optimised overall approach. Dissemination of results towards non-aerospace sectors is encouraged (e.g. in the high temperature materials field: land-based turbine sector and automotive industry).

Two departments, in which research themes are developed in close consultation with industrial needs, are involved in the HYSOP project.

1 - Metallic Materials and Structures Department (65 permanent staff)

The mission of the DMSM department is to meet the demands of the aerospace industry in the field of materials and metallic structures. The main areas of expertise are:

- improving materials already in service and developing materials being introduced, prioritizing the materials-mechanics paired approach;
- studying and modeling behavior and the damage;
- prospecting new materials for the future;
- developing the numerical mechanical discipline.

Related to the HYSOP project, numerous manufacturing, testing and analytical facilities are available, from metallurgy to solid-state physics. Internationally renowned groups are active for over 30 years on turbo-engine hot materials development, for high pressure compressor and turbine blade and disk applications, with several patents with industrial applications in last generation land-based turbines, turboengines (N18, N19, AM1, AM3, MC2, MC-NG superalloys) and coatings and repair (various aluminides (Ni,Pd)Al, NiAl(Zr), diffusion barriers, MCrAlY and composite metallic coatings for superalloy protection; protective coatings for TiAl).

An eight-year experience on Nb-Si alloys has been developed, in alloy development, manufacturing and testing. Numerous similar and dissimilar joining solutions have been developed and patented, in collaboration with industry: γ-TiAl to Nimonic 75 superalloy (in the frame of the DOLSIG FP5 project) and titanium alloys (TA6V, IMI 834...), superalloys to themselves (autobrazing powders for refurbishment; manufacture of porous components...). In the past, ONERA joined C/C composites to Cu-, Ni-alloys and Au, TA6V to itself and alumina, and superalloys to alumina.

A substantial expertise has thus been gained in the topics related to the project:

- manufacture of HT alloys (arc and plasma melting, induction melting, powder compaction, hot-working), heat treatment optimisation, machining, development of joining solutions;
- microstructural studies (OM, SEM, EDS, TEM, EBSD, AFM, X-ray analysis, image analysis);
- investigation of mechanical properties of intermetallics and superalloys from room temperature up to 1300°C and analysis of deformation and fracture mechanisms;
- understanding of oxidation mechanisms, and design, deposition and test of coatings for various applications (high temperature oxidation and corrosion, bond-coat for TBCs, diffusion barriers).

ONERA-DMSM also gained substantial management experience as partner or coordinator in participating to numerous European Research and Technological Development projects (Brite-Euram, Joule, Eureka, Framework Programmes) in various fields (superalloys, TiAl, abradables, TBCs, silicide-based alloys).

2 - Composite Structures and Materials Department (45 permanent staff)

The activity of the DMSC department concerns the study and predevelopment of the three main types of composites (ceramic, organic and metallic matrix systems) for structural or functional applications. Researches are focused on the development and/or the improvement of materials, their processing and the evaluation of properties up to scaled demonstrators, including health monitoring.

For all these composites, multi-scale and multi-physics approaches have been set up with the aim to model the structural behaviour and the processing routes. To anticipate the materials requirements of the aerospace sector, mainly mass reduction and increased working temperature, a variety of ceramics and ceramic matrix composites have been developed at DMSC since the early 80's (glass-ceramics, oxides, silicon carbide).

More recently ultra high temperature ceramics (UHTC) have been developed (FP6 ATLLAS project) and work has been initiated several years ago on Si3N4-MoSi2 composites for high temperature applications. Regarding this last project, high temperature mechanical properties have been characterised, the in-situ matrix reinforcement has been tested, new manufacturing processes have been evaluated, and several prototypes have been produced. First results have shown good strength properties but toughness deficiency. The possibility of electro-discharge machining (which is not possible with Si3N4 ceramics) has also been demonstrated. A substantial expertise has thus been gained in the topics related to the HYSOP proposal.

ONERA-DMSC also gained management experience as partner of several European RTD projects, e.g. NOXICC (development of Al2O3/ZrO2/Al2O3 composites), CINDERS (SiC/SiC combustor liner improvements thanks to mullite thermal barrier development), and ABRANEW (development of HT abradable ceramics for turbine blades to enhance engine efficiency).