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 meetcomplex and restrictive aircraft engines specifications. This major five-year collaborative project bringstechnological solutions for creating novel, multifunction acoustic materials to replace traditional engine liners.The research is motivated by increasingly stringent requirements from international regulatory boards onaircraft noise, CO2 and NOx emissions. Sound absorption over a broad frequency range is sought in order torespond adequately to new, high-efficiency engine configurations. The project is carried out by ÉcolePolytechnique 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 highmechanical performance flight-certified resins. (1) Micro-meshed materials are produced using state-of-the-artadditive manufacturing of polymeric composites. (2) Low mechanical performance foams that are recognizedfor having excellent acoustic properties are replicated with high-performance polymers using an ingeniouscasting 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 acousticmaterials in engine components will be tested for airworthiness. Representative-size cylindrical prototypes willbe tested with internal flow on a special engine test platform. The final outcome is a full scale technologicaldemonstrator, 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 multidisciplinaryindustry problems. They will engage in developing advanced technical and scientific know-how andinternational soft skills useful to the Canadian industry. Implementation of the innovative acoustic materials isforeseen on next generation ultra-high bypass ratio engines. Devired applications to Canadian-made aircraftsare expected through Safran Nacelles and Safran Ventilation Systems, and eventually Safran Landing Systems.