ADDIFLAP project’s general aim is the development of a new concept of flap track system by combining a novel flap track support manufactured by Laser Wire Direct Energy Deposition (W-DED-LB) with a new design of carriage system based in sliding pad concept, made using a self-lubricant MMC coating. Deployment of W-DED-LB process will be supported by numerical models to reduce the distortion effect on the final flap track structure and establish the manufacturing strategies for process manufacturing and by online process monitoring & control. Sliding pad design for the flap carriage system will be based on self-lubricant surfaces approach. ADDIFLAP involves the following objectives: • Development of simulation models and optimized manufacturing strategies will reduce the effort in reducing the distortion on the flap track support up to 50% regarding the trial-and-error approach. This will impact in the time to market, reducing even further the time from design to manufacturing. • Flexibility (on design, enabling part consolidation…) provided by AM technologies (W-DED-LB) will enable to reduce the time to market into 20%. • Reduction of 60% on material waste regarding conventional manufacturing is expected (Reduction of the BTF ratio). • Reduction of 20-30% on component distortion will be achieved by combination of simulation, and optimization of WDED-LB process parameters and online monitoring & control developed in ADDIFLAP Project. • The sliding carriage system will increase the component flying hours for a conventional Business Jet in a factor of two regarding conventional roller system. The technology developed in ADDIFLAP will enable the design of a multifunctional flap which combines aileron and high lift functions in one flap body having direct impact on weight reduction.

TriFluorium largely expands current circular economy capabilities for highly stable organofluoride waste (PFAS, including fluoropolymers) and provides safe, sustainable and efficient regeneration of fluorine into safe, stable inorganic fluorides as industrial resource, such as fluorspar. Fluoropolymers are indispensable for many critical (e.g., semiconductors) and green (e.g, hydrogen production, fuel cells, EVs) applications and their disposal options are very limited. Needed fluorspar resource is listed as EU’s critical raw material and is acquired outside of the EU with recycling rate at 1% due to the lack of proper technologies. TriFluorium wants to achieve proof of the tribolysis recycling principle for organofluorides (TRL 3) irrespective of particular chemical structure, molecular weight, or liquid/solid form under properly designed controllable tribocontact site, which promotes chemical reactions initiated by mechanical stimuli. Tribolysis shall within one processing step generate local dense-energy spots to initiate decomposition of very stable organofluorides, including the perfluorinated ones, and to activate safe reactants, such as alkaline earth metal (Group II) salts or oxides to efficiently convert organofluorides into safe, stable inorganic products (mineralization). TriFluorium will also develop a dedicated Tribo-Reactor for laboratory scale validation of tribolysis F-recycling (TRL 4) for process scaling and enhancement of tribolysis technology development towards industrial application. The locally initiated reactions with benign reactants have inherently safe operational and energy-efficiency features. Supporting toxicological and LCA assessments will be carried out to comprehensively evaluate tribolysis recycling process and Tribo-Reactor performance from all relevant perspectives. The foundation of tribolysis recycling for organofluorides answers urgent technological needs and contributes to current environmental, economic, and social goals.

LUBGEAR aims at demonstrating gear design solutions which can withstand off-design conditions in geared turbofans without additional means (secondary/auxiliary lubrication). Those solutions combine 1) optimized gear geometry providing low power loss conditions; and 2) Surface and material combinations providing low friction. The solutions aim at reducing friction losses and frictional heat, leading to reduced temperatures and risk of scoring. This will allow producing gears which do not face catastrophic damage even under loss of lubrication in off-design conditions. An investigation of new enabling technologies regarding off-design conditions will be carried out in simulation and experiment at contact level (TRL2). The combination of material systems (roughness, coating and hardening), contact load, sliding speed, rolling speed, lubricant type and lubricant supply will be considered through a Design of Experiments, allowing LUBGEAR to create a unique database and extend contact modelling tools. Gear Design Optimisation takes into account the results from contact level and derives solutions coming from geometry, material systems, operating conditions and passive lubrication. A demonstration of the most promising design and technology solutions for gears will be validated in an experimental component test rig at TRL3 level. Gear modelling addresses the predictive design of off-design conditions. LUBGEAR project gathers 4 strategic partners based on a multidisciplinary approach combining uniquely engineering, tribology, mechanics and advanced chemistry. This will allow developing a gear design with an increase of over 100 % in scoring load and a reduction of over 50 % of frictional losses resulting in remarkable improvements in loss of lubrication conditions. LUBGEAR will assess the benefits of different gear designs including gear geometry, new material systems and passive lubrication technologies in reaching the efficiency and load capacity required for gearboxes.

Environmental remediation for safeguarding human health is difficult. Effective processes enabling scalable operability are lacking. triboREMEDY aims at solving this impasse by providing the foundational steps towards the novel technology called “tribolysis” for safe, controlled, and efficient degradation of hazardous chemicals and effective inactivation of the pathogens. The scientific and technological breakthrough of triboREMEDY is based on the generation of nascent surfaces, high pressures, and shearing forces that will supply the required activation energy for dissociation of polychlorinated biphenyls (PCBs) and cell disintegration of pathogens. The centrepiece of triboREMEDY is the fully-controlled “triboreactor” in which mechanically (tribologically) induced chemical reactions take place as viable alternative to A) highly costly incineration or storage of hazardous waste, notably PCBs, and B) chemical, thermal inactivation or ultra-violet irradiation of pathogens in drinking water. The main project aim is to set scalable design rules for the “triboreactor” (proof of concept) based on the identification of PCB degradation products and pathogen inactivation pathways together with their relationships to operational parameters. In addition to this, the long-term vision beyond halogen elimination of PCBs and disinfection of drinking water avoiding chlorine treatments, will cover other toxic organic chemicals, application in chemical synthesis, catalysis free of critical raw materials, coating processes, requiring sensors for the monitoring of trace components, opening a wide new scientific and technological field. triboREMEDY will be driven by a multidisciplinary team of excellent researchers in mechanical engineering, chemistry, physics, biology, and medicine enabling the required unique breakthrough and interdisciplinary approach. In last FETOPEN call, triboREMEDY reached score 4.15/5.00 and the suggestion of evaluators were considered for this new application.