Integration of absorbing materials in composite structures for turbofan engine noise reduction

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Innovative manufacturing technologies bring unprecedented opportunities for creating new materials that meet**complex and restrictive aircraft engines specifications. This major five-year collaborative project brings**technological solutions for creating novel, multifunction acoustic materials to replace traditional engine liners.**The research is motivated by increasingly stringent requirements from international regulatory boards on**aircraft noise, CO2 and NOx emissions. Sound absorption over a broad frequency range is sought in order to**respond adequately to new, high-efficiency engine configurations. The project is carried out by École**Polytechnique de Montréal and Safran, an international high-tech group and leading equipment manufacturer.**Three new disruptive technologies are investigated to produce functionalized light structures made of high**mechanical performance flight-certified resins. (1) Micro-meshed materials are produced using state-of-the-art**additive manufacturing of polymeric composites. (2) Low mechanical performance foams that are recognized**for having excellent acoustic properties are replicated with high-performance polymers using an ingenious**casting method. (3) Exotic resonator materials with twisted cavities are made through additive manufacturing.**Face sheet textures and original perforations will be explored. Various designs for integrating acoustic**materials in engine components will be tested for airworthiness. Representative-size cylindrical prototypes will**be tested with internal flow on a special engine test platform. The final outcome is a full scale technological**demonstrator, where novel acoustic liners will be integrated to a LEAP engine composite fan case.**This ambitious project is a unique opportunity to train 36 highly qualified personnel on multidisciplinary**industry problems. They will engage in developing advanced technical and scientific know-how and**international soft skills useful to the Canadian industry. Implementation of the innovative acoustic materials is**foreseen on next generation ultra-high bypass ratio engines. Devired applications to Canadian-made aircrafts**are expected through Safran Nacelles and Safran Ventilation Systems, and eventually Safran Landing Systems.