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HTCoils: Optimized Materials for High Temperature Coils

LKR led high-level consortium in European Clean Sky 2 project

Electrical Environmental Control Systems (E-ECS) feature many low power electromechanical actuators to ensure control and tuning of items such as high temperature valves of electrical systems in future airplanes. They also include motorized turbomachines with power electrical motors.

The aim of the Cleany Sky 2 project HTcoils and its partners (HPW High Performance Wires, PEAK Technology and coordinator LKR Leichtmetallkompetenzzentrum Ranshofen) was the development of high-temperature, high performance wires, impregnating varnishes and potting ingredients (resins) with an increased thermal index value . Besides required materials development it was further goal to manufacture sufficient wire materials for sub-assembly coils tests, final demonstration and qualification of high temperature coil systems and to test their functionality in electromagnet actuators for different applications in an aeronautic Electrical Environmental Control System (E-ECS).

Stephan Ucsnik, Thematic Coordinator for Wire-based Additive Manufacturing at the LKR, reports on the results of this recently finished project: “Within the scope of HTCoils, we have succeeded in developing electrical coil wires, impregnating varnishes and potting resins for higher working temperatures with a thermal-like index value of 274°C which is +14% compared to state of the art actuator coil materials. These offer various novel applications in electrical systems of future aircrafts as well as all mobility systems on earth.”

This project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 785582.