1 October 2013 www.aeromag.com www.aero-mag.com THE EUROPEAN MAGAZINE FOR A GLOBAL INDUSTRY CIVIL & DEFENCE/SPACE/SUPPLY CHAIN JULY 2023 TAKING A LOAD OFF YOUR MIND Page 10 AIRCRAFT PROGRAMMES
Tooling Automation Integration 877-936-4906 info@ascentaerospace.com www.ascentaerospace.com Ascent Aerospace is a world renowned, single-source provider of turnkey production and automated assembly systems for the aerospace, defense, and space industries. As the industry’s largest tooling and automation group, Ascent produces a full suite of composite tooling, including layup molds, mandrels, bond tools, and trim and drill fixtures, including the largest Invar molds ever made for aerospace. Leveraging tooling expertise and internal design capabilities, Ascent can also evaluate the use of 3D printed jigs and fixtures as part of sub-assembly and final assembly processes and print them in-house. In addition, Ascent offers automated, high-precision drilling and fastening systems. As an assembly line integrator, Ascent works with airframers to develop their project and see it through from process design and engineering through build and installation, to ensure it is an efficient and cost-effective solution. Contact us today to talk to one of our experts.
Silence is golden Editor | Mike Richardson | newsdesk@aero-mag.com | Tel: +44 (0) 1634 825709 Deputy Editor | Ed Hill | ehill@mitpublishing.co.uk | Tel: +44 (0) 1634 825705 Digital content coordinator | Michael Tyrrell | mtyrrell@mitpublishing.co.uk Tel: +44 (0) 1634 825713 Business Development Manager | David McCauley dmc@aero-mag.com | Tel: +44 (0)7557 308369 Sales Director | Andy Morley amorley@aero-mag.com | Tel: +44 (0) 1634 825701 Art Editor | Sarah Blake sarahblake@sablemedia.co.uk | Tel: +44 (0) 1233 770781 Production Coordinator| Ewa Hodden ehodden@mitpublishing.co.uk | Tel: +44 (0) 1634 825703 Circulation, Subscriptions and Database Research | Perception SAS aero@mitpublishing.com | Tel: +44 (0) 1825 701520 Financial Controller | Valerie Prentice | accounts@mitpublishing.co.uk Publisher | Liam McCauley Director | David Rose Published by | MIT Publishing Limited | Featherstone House | 375 High Street | Rochester | Kent ME1 1DA | United Kingdom | Tel: +44 (0) 1634 830566 Published 10 times a year, Aerospace Manufacturing is distributed free of charge to applicants in the UK and certain other countries who meet the publishers criteria. Subscriptions are also available at £150 per annum which represents a 40% saving on the single issue price. While every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they may arise. Authors opinions do not necessarily reflect those of the publisher. All rights reserved. No part of this publication may be reproduced or transmitted without the consent of the publisher. Copyright: MIT Publishing Ltd 2023 Printed by: Pureprint Group 4 NEWS EVENTS 8 An international defence showcase – DSEI show preview AIRCRAFT PROGRAMMES 10 Taking a load off your mind – Military aircraft ADVANCED MATERIALS 12 One step process builds blade success – Composites 15 A fount of tooling knowledge – Tooling TECHNOLOGY FEATURE 18 A sum of the parts – Engines SUPPLY CHAIN 20 Aiming sky high for success – Locations SPECIAL REPORT 21 A clean dream machine – Parts cleaning 22 It’s all about readiness – Quality & inspection DIGITAL MANUFACTURING 25 Bridging the skills gap – Production control software 26 Knowledge is power – CAD/CAM FINAL APPROACH 30 The demand for change – ELE Advanced Technologies’ CEO, Manesh Pandya Next issue: Events: DSEI and EMO previews, Helicopters, Technology feature: Interiors, Materials: Machining, Special report: Assembly techniques, Supply chain: Accreditations, Digital manufacturing: Production control software, Final approach A press release landed on my news desk recently concerning audio technology specialists, Sonarworks’ findings on Gen-Z’s content consumption and how it affects their productivity levels at work. The study found that 93% of respondents reported wearing headphones, with 26% of Gen-Z indicating that they always use them during working hours. Gen Z stands out as the generation consuming the most entertaining content, ranking music as the least preferred type of content to listen to through headphones. Interestingly, the study highlights Gen-Z’s acknowledgement that headphones could hinder their productivity. Reading the report took me back to the dim and distant past when I used to listen keenly to the cutting tool vibrations of my CNC turret lathe when drilling into extremely tough Hastelloy billets. I’d be ‘all ears’ ready to reduce the machine’s feed rate as soon as I heard the drill ‘graunch’ (is that a word?), or I’d stop the lathe chuck before the drill point fused itself to the workpiece. I would have certainly scrapped the part had I been concentrating on what was on my headphones! This potentially stressful example of cognitive overload leads me nicely to an article our deputy editor, Ed Hill has written in this issue (read more on page 10). Ed hears from BAE Systems, and how the company has been focusing on the best ways to draw a fighter pilot’s attention to a particular issue when they are fully engaged with other complex tasks in the cockpit. BAE employs a ‘haptic’ gaming vest - more commonly used to simulate the feel of action in virtual reality video games - using it to create vibration alerts across a pilot’s chest and back. I don’t know about you but for me, silence is golden. To really be productive, I need to hear myself think! Mike Richardson, editor ISSN 2056-3434 www.aero-mag.com Aerospace Manufacturing July 2023 3 COMMENT & CONTENTS Volume 18 Issue 168
4 October 2013 www.aeromag.com NEWS July 2023 Aerospace Manufacturing www.aero-mag.com Ford Aerospace makes £1m outlay Ford Aerospace has announced it is investing over £1 million in advanced manufacturing equipment and strengthening its team with senior skills as the business continues to grow. The business, which was acquired in April 2023 by SPIROL, has invested in equipment which will allow the team to grow production capabilities, to increase the size of the components that are able to be produced and to enable more accurate inspection of parts. Recruitment is also underway for a new managing director to lead the business alongside former managing director Chris Ford, greatgrandson of founder Robert Ford, and who is staying with the business in a consultancy capacity. “The business is in a strong position and there is an exceptional management team in place and staff who make me feel comfortable that now is the time to take my career in a different direction,” stated Chris Ford. “I am proud of what we have achieved as a family, especially the work to establish our skills academy in the region and I am excited to see the business go from strength to strength under new leadership and as part of the SPIROL group.” www.ford-engineering.com Airbus is investing further in its UK innovation capabilities, with the opening of a new Wing Technology Development Centre (WTDC) at its Filton site. The facility, which will be used to build and test demonstrators for a range of programmes and research projects, was opened by Nusrat Ghani, UK Minister of State at the Department for Business and Trade. The new facility will help Airbus accelerate the design, build and testing of wings for next generation aircraft, by using the latest technology and world-leading demonstrators to further improve the performance of its wings. “The new Wing Technology Development Centre will help us to ground our research in practicality,” stated Airbus head of Filton site and Wing of Tomorrow Programme, Sue Partridge. “A key element of how we deliver technology for next generation aircraft wings is through Wing of Tomorrow (WoT), our largest research and technology programme led by the team in the UK. “Last week, we achieved a critical milestone in the programme when our second wing demonstrator was completed by the team in Broughton, Wales and delivered to the WTDC. Here it will be prepared for structural testing in our Aerospace Integrated Research and Technology Centre (AIRTeC).” www.airbus.com Airbus opens new Filton wing centre Millions of pounds worth of business have been generated by Farnborough Aerospace Consortium (FAC) at the Ohio Global Aerospace and Supplier Summit. US businesses will now be setting up in the UK, and British businesses are planning to put down roots in the US, according to Alan Fisher, the FAC’s chief executive officer. Ohio and Farnborough represent the centres of their countries’ aerospace industries, and newly forged links will benefit both economies. At the Farnborough Airshow last year FAC and the Ohio Aerospace Institute signed a ‘memorandum of understanding’. This has oiled the route for companies to cross the Atlantic and following the Ohio summit three UK firms have plans to open in the US and three US firms want to set up in the UK or expand their presence. www.fac.org.uk Millions generated for UK economy Alan Fisher, centre, with representatives of Materion
www.aero-mag.com Aerospace Manufacturing July 2023 5 The International Composites Summit (ICS), has announced it has formed a partnership with JEC with the aim of facilitating international trade, fostering innovation, and strengthening economic ties between the UK and global composites industries. Bringing together industry leaders, researchers, and innovators from across the composites sector, ICS is scheduled to take place from 6-7 September 2023, at the Marshall Arena, Milton Keynes. ICS promises to be a unique platform for knowledge sharing, networking, and exploring the latest advancements in composite materials internationally, bringing people together to do business. Through this strategic partnership, ICS will be used as a primary platform to highlight the advantages and potential of trading with the UK composites sector, connecting international companies with the wealth of resources, expertise, and innovations available. With its extensive global network and industry expertise, ICS will leverage the JEC partnership to provide a platform for European and global companies to explore and seize business opportunities. Through targeted initiatives, intensive promotional activities, and networking events, the partners will facilitate connections and collaborations, fostering mutually beneficial trade relationships. JEC will support the event through its media channels and provide a digital solution for exhibitors and attendees to connect and meet during the event in September. This solution will connect qualified business partners with an aim of connecting composites industry buyers with ICS exhibitors. Support will be offered prior to the show and will help attendees plan and organise quality meetings. “We are excited to partner with JEC to spotlight the outstanding trade opportunities that exist within the UK Composites Sector,” said Gemma Smith, co-director of ICS. “The International Composites Summit provides the perfect platform for companies wanting to meet and trade with the UK composites sector. We look forward to developing the relationship with JEC and the growth potential it offers to the industry.” Registration for the International Composites Summit 2023 is free and is now open via the official event website below. www.internationalcompositessummit.com JEC announced as partner to the ICS show GKN and Materialise sign AM LOI GKN Aerospace and Materialise have announced the signing of a Letter of Intent (LOI) aimed at advancing the research, design, and production of polymer additively manufactured (AM) parts for the aviation industry. The LOI was signed at the Paris Airshow and represents an extension of their existing collaboration. Together, the partners aim to accelerate the certification of the AM process and push the boundaries of additive production of functional and flight-critical aerostructures. The collaboration ranges from prototyping to the production of functional and flight-critical parts, aligning with the industry’s emerging sustainability trends and opportunities. In particular, the partnership will focus on eVTOL aircraft. “This powerful alliance aims to leverage our combined expertise and the exceptional benefits of 3D printing to push the boundaries of innovation in the aeronautics industry,” stated Jurgen Laudus, vice-president of Materialise Manufacturing. “Together, we aim to drive technological advancements, respond more effectively to customer requirements, and shape the future of aerospace manufacturing.” www.materialise.com
6 October 2013 www.aeromag.com Xxxxxxxx 2014 www.aeromag.com NEWS Aviation leather manufacturer, Muirhead has signed an exclusive representation agreement with Douglass Interior Products, a leading supplier of aircraft interior furnishings in the US. This partnership will enable Muirhead to supply high performance, sustainable Scottish aviation leather to commercial operators across North America. Douglass will now carry Muirhead’s diverse portfolio of sustainable aviation leather products including LightCore, a lightweight innovation that weighs up to 33% less than standard leather without sacrificing performance, safety, or comfort. Muirhead’s CareGuard anti-soil product and its self-disinfecting ActiveHygiene leather will also be available through Douglass. Myles Hobbs, head of aviation EMEA and the Americas at Muirhead, said: “As we continue to grow our operations in the US, we’re confident that the Douglass team’s local expertise and trusted reputation will continue to be instrumental in providing a local touch and first-hand expertise for our valued customers.” www.muirhead.co.uk Muirhead strengthens Douglass partnership Dassault Systèmes has announced a new partnership with specialist postgraduate institution Cranfield University, which will deliver a new 3DEXPERIENCE Edu Centre of Excellence, opening this September. The campus facility will provide experiential, initial and lifelong learning with Dassault Systèmes’ 3DEXPERIENCE platform to enable the existing and future workforce to accelerate the digital and sustainable transformation of the aerospace industry. Cranfield University will deliver courses and curricula designed in collaboration with aerospace employers and taught by platform-certified instructors to students and professionals wanting to upskill. It will help learners to boost employability by developing in-demand skills in virtual twin processes, data-driven manufacturing and sustainable design in the context of existing and future job roles. “We’ve chosen to partner with Dassault Systèmes because of the ecosystem it already has within the aerospace industry, as well as the cutting-edge technology it has developed through its modelling, simulation and optimisation industry software,” explained Professor Dame Helen Atkinson, pro-vice chancellor, School of Aerospace, Transport Systems and Manufacturing at Cranfield University. www.3ds.com Dassault UK centre ready for launch
www.aeromag.com Xxxxxxxx 2014 7 Avio purchases Velo3D metal 3D printers Velo3D has announced that Avio has purchased a Sapphire XC 1MZ printer and an original Sapphire printer to support the development and production of its propulsion systems and accelerate the advancement of the space industry. Velo3D’s solution was selected for its ability to produce quality parts with optimised geometries for the highest performance, and the large build volume of the Sapphire XC 1MZ. Both printers are calibrated to produce parts in nickel-based alloy that delivers strength and corrosion resistance at extreme temperatures. With one of the largest build volumes for laser powder bed fusion 3D printers, the Sapphire XC 1MZ 3D printer has a print volume that is 600mm in diameter and 1,000mm in height. The original Sapphire has a print volume of 315mm in diameter and 400mm in height. Both printers enable Avio to overcome the constraints of traditional manufacturing methods, including conventional additive manufacturing solutions. The printers accomplish this by providing a wide breadth of geometric design freedom and a high degree of precision. The solution from Velo3D empowers Avio to optimise its designs and manufacture quality, high-performance components with intricate geometries that were previously unattainable. The result is improved performance, reduced weight, enhanced reliability, and ultimately, a more efficient and accessible space industry. “Avio is one of the leading space companies in Europe and we are thrilled to partner with them in their pursuit of groundbreaking propulsion systems,” said Benny Buller, founder and CEO of Velo3D. “They work with some of the most innovative companies and agencies in Europe and around the world to provide them with the technology they need to reach space. The Sapphire XC 1MZ will help Avio further accelerate the development of its propulsion systems and contribute to the ongoing transformation of the space industry.” www.velo3d.com Airshow cements Lockheed Martin bond Lockheed Martin has announced its participation and sponsorship of the Bahrain International Airshow (BIAS) 2024. The partnership signifies the global aerospace and defence manufacturer’s longstanding ties with the airshow and the wider Gulf region. The contract was signed during meeting at the Paris Airshow by Yousif Mahmoud, director general of the Bahrain International Airshow and Craig Spyhalski, international air and show trade lead at Lockheed Martin, in the presence of His Excellency Mohamed bin Thamer Al Kaabi, Bahrain’s Minister of Transportation and Telecommunication. BIAS will return to the aerospace calendar 13-15 November 2024 at Sakhir Airbase Bahrain. www.bahraininternationalairshow.com Messe Frankfurt Group Honorary sponsor 7 – 10.11.2023 FRANKFURT / GERMANY Demand for increasingly complex and customized parts is rising, product cycles are becoming shorter, established supply chains are being called into question and sustainability is playing an ever greater role. In short: Industrial production is becoming more demanding. Additive Manufacturing offers solutions to meet these challenges and inspire your customers. Be ahead of your competition: Visit Formnext, the international expo and convention for Additive Manufacturing in Frankfurt am Main, Germany. Where ideas take shape Reconfigure manufacturing! Early bird discount until 10 October 2023 Secure tickets! formnext.com/tickets Pictured L-R: Yousif Mahmoud, director general of the Bahrain International Airshow Craig Spyhalski, international air and show trade lead at Lockheed Martin
8 October 2013 www.aeromag.com July 2023 Aerospace Manufacturing www.aero-mag.com EVENT PREVIEW: DSEI t this year’s Defence & Security Equipment International (DSEI) event held in London ExCeL from 12-15 September, aerospace manufacturing professionals can expect a bustling showfloor with outstanding displays of military capability from around the world. This includes a host of helicopters and aircraft from the highest calibre of exhibitors. The Global Combat Air Programme (GCAP) will have its own dedicated exhibition stand that will feature truly immersive, digital displays to showcase some of the innovative technologies that are driving this programme. Colleagues from the UK, Japan and Italy will be on hand to talk to visitors about GCAP and the rapid progress that is being made across all areas of the programme. Typically, what kinds of companies and associations does DSEI attract to the event? From the largest primes to the smaller SMEs, DSEI is open to companies of all sizes throughout the supply chain. There will be representatives from the whole defence ecosystem present, but we have also seen a major influx from companies outside the traditional industrial base, such as Sony, IBM, Oracle and Panasonic. The ADS pavilion at DSEI will host many different aerospace companies, including Collins Aerospace, GE Aviation and smaller companies such as Standard Aero. There is a range of valuable opportunities for networking, platforms for business and extensive access to relevant content and live-action demonstrations. The DSEI community can strengthen relationships, share knowledge and allows visitors to view the latest capabilities across the exhibition’s Aerospace, Land, Naval, Security and Joint Zones. How does the aerospace domain at DSEI integrate with other domains for a joined-up approach? Integration at a national level across the frontline commands is essential and I know that they are all in constant dialogue. ‘Multi-domain operations’ was the underlying theme of DSEI 2021, and ‘achieving an integrated force’ is this year’s focus. The most effective fighting forces are those who can integrate best across all environments. But it’s more than that – it includes integration from supply chain, SMEs and large Primes alongside the UK Government – and all set in an international context. A hackneyed phrase – but together the component parts are much more powerful than the individual sum. Therefore, the whole aerospace domain will play a prevalent part in DSEI 2023, but it always works best when it’s connected with other domains for a joined-up approach. DSEI is a key learning platform and a way to bring together people from different branches of the military to share best practice, discuss ideas and scale capabilities from one domain and apply them to others. This learning from other domains ties in with the overarching Hosting over 2,800 companies and showing the broadest range of military equipment for land, sea, air, security and joint applications, air vicemarshal (ret’d) Gary Waterfall, DSEI senior military adviser – aerospace, reveals what visitors to DSEI 2023 can expect to see at the event. A AN INTERNATIONAL DEFENCE DSEI 2023 will host over 2,800 military equipment companies at the event (below) Showcase
www.aero-mag.com Aerospace Manufacturing July 2023 9 theme for DSEI 2023 of “achieving an integrated force”. What will be the chief highlights of the aerospace domain at DSEI? There are broadly three key reasons why people should visit the Aerospace Zone at DSEI. Firstly, DSEI will represent a key forum for updates on, and how to sell into, the Global Combat Air Programme (GCAP). GCAP is a trilateral collaboration between the UK, Japan and Italy to develop the next generation of fighter jet. Two months ago, the UK Ministry of Defence (MOD) awarded a major contract to BAE Systems on behalf of British defence firms, Leonardo UK, MBDA UK and Rolls-Royce, to progress the design and development of this aircraft. Tempest is the UK name for the aircraft in development under GCAP. Team Tempest has been researching and evaluating a host of future combat air system capabilities since 2018 and is continuing to develop the technologies needed to deliver the next generation combat air capability. Secondly, there will be extensive Unmanned Aerial Vehicle (UAV) capabilities being exhibited, such as Mitsubishi’s counter-UAV laser prototype. Since Russia’s illegal invasion of Ukraine in February 2022, UAVs have been in the spotlight both in terms of increased usage in warfare and the development of new UAV capabilities. Thirdly, sustainable aviation that maintains an operational advantage will feature heavily. The UK Government is committed to netzero carbon emissions by 2050 and we know that defence is a significant contributor. It will be fascinating to see how the RAF and large aerospace companies approach the challenges of being both sustainable and competitive. Scan here for more DSEI articles How will the Global Combat Air Programme feature at DSEI? In addition to the GCAP feature stand there will be two GCAP panel discussions taking place at DSEI. The first will be in the Aerospace Forum and will include the international programme directors from the UK, Japan and Italy. They will be joined by the senior responsible owners from BAE Systems, MHI and Leonardo Italy. This promises to be a fascinating update from the international partners, who will talk about the overall direction of the programme; the capability that it is delivering; interoperability with allies and other domains; people and skills; and programme milestones. The second panel is titled ‘How supply chains are supporting future combat air’ and will see UK industry analyse the procurement challenges and opportunities that lie ahead for the Global Combat Air Programme. The panellists will discuss how GCAP is integrating SMEs, leveraging on their knowledge, capability and skills, which in parallel is creating a productive and robust supply chain. Q) How do you expect the show to grow this year and what are your targets for the 2023 event? In terms of scale, DSEI is currently on target to surpass pre-pandemic levels of exhibitors and visitors, which is hugely encouraging. This year, there has been an increase in non-traditional defence companies exhibiting solutions, so it’s expected that there will be a broader variety of approaches on display than in previous years. This year’s targets also factor in a sustainability dimension. In collaboration with the ExCeL, DSEI organisers are working to deliver a more sustainable trade show as part of a long-term commitment to addressing the carbon footprint of large-scale events. DSEI 23 will act as a basis to facilitate meaningful reduction targets for all Clarion events going forward. Finally, in summary, what has changed since DSEI 2021 and how will this affect the show? The major change since DSEI 2021 is unquestionably the war in Ukraine. The brutal and illegal invasion by Russia has focused minds on how to deter, and if necessary, defeat, a peer/nearpeer adversary in order to maintain our hard-won freedoms. The conflict represents a significant shift in how allied forces think about warfare. President Zelenskyy made a plea to allies for fighter jets in February this year and a few months later Prime Minister Rishi Sunak and Dutch leader Mark Rutte agreed to build an ‘international coalition’ to help procure F-16 fighter jets for Ukraine. Ukraine has been seeking to obtain F-16s for some time to augment its small Soviet-standard air force because they are widely available, with about 3,000 in service in 25 countries. Depending on where this situation is in September at DSEI, conversations about military aid, particularly the gifting of more aircraft, may still be continuing. DSEI is a global event, but as its based in the UK will have a significant UK MOD presence. The UK can be proud to be one of the largest donors to Ukraine having committed £2.3 billion in military assistance in 2022 and has pledged to match that assistance in 2023. DSEI always attracts the biggest brands in the defence industry but increasingly has many companies who are coming from outside of the defence enterprise either exhibiting for the first time or returning, bringing novel applications of their technology into the sector. www.dsei.co.uk DSEI includes a host of helicopters and aircraft from high calibre exhibitors (top) Gary Waterfall, DSEI senior military adviser – aerospace (above)
10 October 2013 www.aeromag.com July 2023 Aerospace Manufacturing www.aero-mag.com AIRCRAFT PROGRAMMES: MILITARY AE Systems delivers a broad range of solutions and services enabling its customers to successfully carry out missions. The company has a long legacy of providing large-scale systems in engineering, integration, and sustainment services across air, land, sea, space, and cyber domains. Working alongside academic and industrial leaders it develops emerging and game-changing technologies to ensure it continues to provide the world’s most advanced, technologyled defence, aerospace, and security solutions. What was the thinking behind developing systems that can help with pilot cognitive overload? Fighter pilots operate in a complex environment; they are exposed to extreme G-forces, engine noises, changing light levels, and visual instruments, all while performing fast jet operational manoeuvres – making cognitive overload a likely outcome. This can have dire consequences, especially when compounded by stressful situations like system failures or combat operations. At BAE Systems we have been measuring cognitive loads on pilots for many years and wanted to explore ways to give pilots more room to think, with the goal of alleviating the physical demands and mental workload of a cockpit environment. Can you tell us more about the haptic vests that you are developing? Why are these better than visual interfaces with the aircraft? We have been focusing on the best ways to draw the pilot’s attention to a particular issue when they are fully engaged with other operational tasks. We took a commercial off-the-shelf ‘haptic’ gaming vest, more commonly used to simulate the feel of action in virtual reality video games, and used it to create vibration alerts across a pilot’s chest and back. In airborne trials, the initial feedback has been incredibly positive, as vibration uses an entirely different part of the brain to the audiovisual cortex, which means it can be consciously registered more easily, especially in stressful situations. We have done multiple tests on pilots, comparing reaction times between visual and haptic vest cues. We have increased their cognitive load by giving pilots tasks to do on a computer tablet, simulating their attention being diverted elsewhere when the cue arrives. These trials showed the pilots were much more responsive to cues from the haptic vest, as they reacted more quickly and intuitively in comparison to other cues. Following positive trials of this technology in Dr Jacob Greene, senior human factors engineer and Chris Forrest, innovation, and growth engineer at BAE Systems, discuss with Ed Hill the development of so called ‘haptic’ or tactile technology to provide improved prompts for pilots during complex and stressful combat situations and mitigate cognitive overload. B TAKING A LOAD OFF YOUR BAE Systems has caried out research into haptic feedback for pilots using its active stick technology (right) Mind Dr Jacob Greene, senior human factors engineer, BAE Systems (below) Chris Forrest, innovation and growth engineer, BAE Systems (bottom)
www.aero-mag.com Aerospace Manufacturing July 2023 11 small commercial aircraft, our next step is to progress it with military customers and sophisticated combat aircraft, as well as rolling it out in a training environment. Tell us more about the automation of aircraft management systems and evading missile attacks, etc.? Our new aircraft management system helps pilots under attack in the air by automatically tracking missile threats, and giving the pilot a haptic signal to help avoid them, mitigating the risk of cognitive overload. In the event of an inbound missile accelerating towards the aircraft, the haptic signal would move the flight stick just at the right time to take evasive action. We have been testing the technology at our simulator facility in Rochester to improve pilot performance and aircraft safety through threat warnings. In one scenario, we simulated very difficult flying environments for pilots, including reduced visibility and enemy attacks. We tested the impact of various inputs, including haptic feedback from the active flight stick, as well as 3D audio and visual cues through augmented reality glasses. Our tests aimed to determine what information we can efficiently deliver to the pilot when they are under a high cognitive load, in order to ensure that they perform to their maximum potential. Like the haptic vest trials, haptic cues via the active stick were the most effective medium in these high-stress environments. In fact, it was able to give more than one cue at a time! The flight stick technology has been adapted for both military aircraft, such as the F-35 and commercial jets such as the Gulfstream G500/600. Will there be a role for AI in the development of these systems? AI will undoubtedly play an increasingly significant role in the development of these systems as we create ever more realistic and complete synthetic environments to test and refine the capabilities that bring the most operational benefit. As an example, AI could generate the flight path and behaviour of airborne drone swarms in response to a variety of tactical situations, to test how our systems could assist a pilot interacting and managing those assets. As AI expert systems become more capable, and most importantly more reliable, we expect to see their staged deployment into these intelligent systems. Such a capability would be able to monitor both aircraft situation and pilot awareness in order to, for Scan here for more BAE Systems articles example, provide priority information to the pilot. Eventually we will see such systems able to respond to priority threats, be it through launching of defensive countermeasures, or actively controlling the aircraft to avoid an immediate threat such as an incoming missile, or collision hazard during low level manoeuvres. We are already seeing the significant benefit of employing this technology, particularly in terms of driving critical pace and efficiency across our programmes. This is allowing us to break the rising time and cost cycle of our ever more complex work. In partnership with academic and industrial leaders, for example, we are using data from the complex systems used in fast jets or gathered at our testing facilities to create simulations and prototypes more quickly and effectively than ever before. These can be used to test things like platform aerodynamics, real-time aircraft radar object recognition and stealth capability. Can this technology be retrofitted to aircraft and how will it develop from concept to being manufactured at scale? Our systems are constantly being refined in terms of their size, weight, and power footprint, and as such can be retrofitted to a range of aircraft, from lightweight two-seater propeller driven platforms, to future fast jet platforms. Design for manufacture is always a primary consideration in the development of our systems so they are manufacturable at scale and can be maintained and supported through life. We have a good track record of adapting our new technology to replace and enhance existing legacy capabilities, such as the digital LiteHUD retrofit replacing cathode-ray tubebased head-up displays. Will this research and technology contribute to the Tempest/FCAS programme? Absolutely, the capabilities required by Tempest in the future will be fulfilled through research and development projects such as this taking place today. With so much research going into automating various aspects of flying and deploying weapons, would it not be easier to develop more sophisticated UAVs? We are very clear that there are significant benefits to unmanned systems, an area we have been working in for many years, but there should always be a human ‘in the loop’ when it comes to key decisions. This technology instead brings mission benefits of freeing up the pilot to focus on higher order tasks, such as commanding assets and collaborating with multi-domain forces, while the lower order tasks are handled automatically and safely by the onboard systems. www.baesystems.com Haptic feedback research is likely to be part of the development of the sixth generation fighter Tempest (above)
12 October 2013 www.aeromag.com ADVANCED MATERIALS: COMPOSITES July 2023 Aerospace Manufacturing www.aero-mag.com any aerospace companies working in composites have a knee-jerk reaction and automatically reach for the autoclave if they are faced with a new or complex problem. This even extends to organisations that specialise in the composites industry more specifically. However, this is always an expensive solution, even with energy prices coming down - and there are simpler, more elegant ways to address these issues. Other solutions are available and one of the leading capabilities is compression moulding, of which few in the industry understand the full potential. A good example of this was a particular knotty challenge for propellers used in the emerging vertical take-off and landing (VTOL) aircraft market. However before delving into this particular problem, let us examine the general plusses and minuses of autoclave vs out-of-autoclave (OOA) production. Autoclaved processes are excellent for large surface areas where parts are not required to be net edge moulded, and with only one surface to be controlled. However, autoclaves are expensive to buy, expensive to install and to run and labour-intensive. Also, it is not possible to make adjustments once a process cycle has begun. These cycles are often lengthy which limits production volume. The OOA process achieves the same quality as an autoclave in most applications while eliminating voids and achieving the required material structures by placing the layup within a closed mould. Vacuum, pressure, and heat can also be applied. A positive spin Now let us get back to propellers. The customer set the challenge to several respected composites organisations to manufacture propellers using a multi-stage, autoclaved process, where pre-manufactured structural parts of the blades would be bonded or encapsulated together. Not only is this expensive, but it is also complicated and produces a lot of waste. First the spar had to be made with When one solution for a challenging VTOL blade proposed an expensive multi-stage, autoclaved process, Rockwood Composites suggested a one-step vacuum compression moulding process which can produce the blades to the required quality and quantity. M ONE STEP PROCESS BUILDS BLADE SUCCESS Rockwood is paving the way for a more efficient and cost-effective future in aerospace manufacturing (left) Rockwood proposed a onestep process involving vacuum and compression moulding (below)
• Turn-key systems for composites cutting • Maximum material yield • Highest level of productivity • Individually configurable www.zund.com Technology for maximum Performance
14 October 2013 www.aeromag.com ADVANCED MATERIALS: COMPOSITES July 2023 Aerospace Manufacturing www.aero-mag.com Scan here for more Rockwood articles curing, which was inserted with foam into a mould tool, wrapped in composite and curing again in an autoclave. An alternative process required making two half-propellers, two skins, each to be autoclaved after which they were cold, fine-line bonded. This gave a final structure, though with the obvious potential weakness around the bond. Compression moulding specialists, Rockwood Composites approached the problem from a different perspective – a single shot compression moulding, where the entire structure is moulded in a single, quick operation, requiring no post manufactured gluing and results in one fully integrated structure; which means no bonds to fail. It is also produced in half the time of its autoclaved alternatives. “The specified process was clunky and we always try to minimise the number of steps, which minimises cost and waste,” explains Rockwood’s managing director, Mark Crouchen. “Our development team looked at the problem from every direction – both technical and commercial - and came up with a one-step process involving a vacuum and compression moulding process that met all the stringent aerospace material standards. This was able to produce the blades to the required quality and at the required rate. The process required careful tool and process design to optimise the moulding pressure on all the critical internal structures. “It also required careful orientation of the blade in the tool in order to allow for compression in both directions, horizontal and vertical. We set the tool at an angle to enable this. This particular process took place at a temperature of 135˚C, which is within our usual range of 120-180˚C depending on the prepreg. “We can accurately control the consolidation pressure on the prepreg across different core densities in the same moulding. This is a key factor in laminate quality in determining physical properties. “The consolidation pressure comes from very accurate core machining, and material selection. With this accuracy, we can exert different pressures at different points on the structure. And it is the core that is critical for the pressure. “By adjusting these cores, we can change the pressures and we can push one component up against another. We need to be very precise in crushing the core and in machining it to regulate the pressure that the crush imparts on the prepreg. “For example, for a high density core, you might want to limit the pressure whereas for a low density core you might want a higher pressure. You need to adjust all these aspects for an efficient manufacture. “Material selection is linked to core densities and resin weights because it all has a bearing. If core is specified, we optimise the design to give the right pressure. Where the core is not specified, then the whole manufacturing process will need careful consideration in its entirety. We are super critical over core density and surface accuracy. “This is not just about making a mould cavity in an aluminium block. It all comes from, firstly, the design of the part within the tool and the second element is the size and shape of the cores, because this is what gives you the pressure.” A question of balance Post-moulding operation, and as part of the quality control, it is necessary to balance the blades, normalising the centre of gravity of each blade to the heaviest in the set. The mass moment had a tolerance of 500g/mm. The process was so sensitive that Rockwood found it was affected by engineers simply moving around the room. This problem was fixed by bolting the measuring rig to the floor, which give the required level of stability. Rockwood designs and manufactures composite components using the out-of-autoclave techniques of compression and bladder moulding of prepreg composite material in metal tooling. The team’s pioneering work with compression moulding showcases the immense potential of this technique in addressing the challenges faced by aerospace companies. By embracing innovative and efficient manufacturing processes, the industry can continue to drive progress, reduce costs, and improve sustainability in the field of composites. As more companies recognise the advantages of compression moulding and explore its full potential, we can anticipate further advancements and breakthroughs in aerospace composites. By shifting away from knee-jerk reactions and embracing alternative solutions, Rockwood Composites paves the way for a more efficient and cost-effective future in aerospace manufacturing. Indeed, the company’s success story serves as an inspiration and a testament to the transformative power of innovative thinking in the industry. This highly-effective manufacturing technology can produce parts in volumes and accuracy needed by the industry, though it is a highly skilled operation. As Crouchen concludes: “Compression moulding has all the key attributes for cost-effective, highvolume propeller manufacture, while optimising the properties of the most advanced composite materials.” www.rockwoodcomposites.com Compression moulding can optimise the properties of composite materials (above) Rockwood’s consolidation pressure comes from accurate core machining (below)
www.aero-mag.com Aerospace Manufacturing July 2023 15 ADVANCED MATERIALS: TOOLING andvik Coromant’s new state-of-the-art technology centre in Halesowen represents the very latest in cutting tool support, services and research for its UK customers. Part of a global network of Sandvik Coromant Centres that allow the organisation to share engineering expertise with its customers in a physical environment, the new centre, which historically has also been home to the tooling specialist’s UK headquarters, has undergone significant investment and will operate as a national hub for metalcutting expertise. The facility contains two education stations with two machine tools equipped for tooling demonstrations, application training and engineering projects: a 5-axis DMG Mori DMU 80 eVo milling machine, and a Mazak Integrex i-200S AG lathe. These versatile CNC machines have been chosen to ensure the facility can demonstrate any turning or rotating metalcutting application. Within the education stations, Sandvik Coromant’s engineers – easily recognised by their yellow jackets – are on-hand to deliver training and demonstrate trials and tests of cutting tools for customers and partners. Digital developments Machine demonstrations at the education stations include CoroTurn Prime for all-directional turning, which can be programmed with Sandvik Coromant’s specialist PrimeTurning methodology and in combination with its CoroPlus Tool Path software. The centre is also wellequipped to demonstrate Sandvik Coromant’s expanded digital offer and its knowledge of metalcutting applications. CAD/CAM, simulation software as well as tool presetting and measuring equipment is all utilised at the centre for optimum machining. “Digitalisation is speeding up development of metalcutting processes and it is a new and very important ingredient in the engineering solution mix,” comments Magnus Ekbäck Sandvik Coromant’s vice-president of strategy and business development. However, it presents a challenge for our customers to keep pace and get the full benefits of it. “Because we operate in the industry that we serve, it puts us in a great position to help our customers solve their challenges. Digitalisation underpins many activities for our customers and will be essential for the sector as it progresses into Industry 4.0. Many of our customers are already in the design stages of using digital twins and automation in their metalcutting processes. Collaborating and supporting customers at our centres places us at the centre of this innovation.” Sandvik Coromant has wellestablished links to the UK aerospace industry. It was one of the first Tier 1 members of the Advanced Manufacturing Research Centre (AMRC) in Sheffield where much metalcutting research is carried out by companies involved in the sector. Sandvik Coromant’s new UK headquarters and technical centre in Halesowen, West Midlands, will give customers access to the global cutting tool specialist’s immense accumulation of engineering expertise as well as the latest industry advances. Aerospace Manufacturing hears more. S A FOUNT OF TOOLING Sandvik’s centre is well-equipped to demonstrate its knowledge of metalcutting applications (above) Magnus Ekbäck vice-president of strategy and business development, Sandvik Coromant (below) Knowledge
16 October 2013 www.aeromag.com ADVANCED MATERIALS: TOOLING July 2023 Aerospace Manufacturing www.aero-mag.com Scan here for more Sandvik articles It has developed cutting tools and coatings such as its S205 grade insert to tackle the challenges of machining materials being used in the sector, such as HRSA and the CoroMill MH20, a high-feed milling tool optimised for pocketing applications in ISO S, M and P materials. This insert’s cutting edge geometry delivers a gradual and light cutting action to help support vibration-free production in aerospace component manufacturing. It also has a range of cutting tools for composite materials found in aerospace to tackle issues such as delamination and fibre breakout or metal matrix composites that include both materials. Sandvik Coromant has a longstanding relationship with the site in Halesowen, being the location of its UK arm since 1958. “In addition to hosting customers physically at our centres, we can also provide digital live machining (DLM) sessions,” explains Michael Eneberg, vice-president of global sales at Sandvik Coromant. “These virtual sessions use technology to give customers an interactive experience of the centre, including multiple cameras inside the machine tools that provide live twoway dialogue between customers and our global specialists.” DLM sessions were demonstrated at the centre’s opening providing a closeup look at the metal cutting process on the machines. Sandvik Coromant says the sessions will also be used for educational purposes. Examples of advanced metalcutting using Sandvik Coromant tools on its inauguration included a large aerospace-style turned part with additional machined features on the Mazak Integrex lathe to demonstrate what could be achieved. Other equipment at the centre includes a CoroPlus Tool Supply automated tool vending machine with software that enhances shopfloor inventory control for improved profitability, productivity, and sustainability. “Our ambition is that customers, both present and future, can immerse themselves in the Sandvik Coromant experience here and will receive a world-leading level of support,” adds David Harborn, Sandvik Coromant managing director for the UK and Ireland. “Our vision is to create a true innovation hub for metalcutting in the UK.” Commenting on the centre and industry trends Ekbäck concludes: “Today, just supplying tools and cutting tool data isn’t enough for our customers. They want total solutions and we need partners to provide them, so together our solutions can interface with each other and give the customer a more holistic and comprehensive solution. I believe this new building will be the site of a lot of collaboration and innovation with our customer’s and our partner’s projects.” www.sandvik.coromant.com Sandvik Coromant’s new UK headquarters and technical centre (above) The centre includes the latest machine tool technology (below)
EMO2023, the countdown is on…. We’re keeping the world moving Apply for your free ticket here.... we can’t wait to see you! Hall 005, stand number D69 - September 18th - 23rd 01189 795 200 | saleseu@kyocera-sgstool.com | kyocera-sgstool.co.uk Hello visitors! Welcome to the world’s leading trade fair for production technology.
18 October 2013 www.aeromag.com July 2023 Aerospace Manufacturing www.aero-mag.com TECHNOLOGY FEATURE: ENGINES s the race to Net Zero is well and truly underway, businesses in every sector across the globe are facing mounting pressure to use energy responsibly and use renewable energy sources where possible. As a result, it’s no surprise that the International Renewable Energy Agency has predicted that hydrogen will cover 12% of all global energy demands by 2050 and cut carbon emissions by 10% in a Net Zero scenario. This is equally applicable to both aviation and aerospace sectors. In 2021 aviation accounted for over 2% of global energy-related CO2 emissions, having grown faster in recent decades than road, rail or shipping. Although new aircraft are up to 20% more efficient than previous models, this has not been enough to keep up with the growing demand and activity, in-short, fuel efficiency improvements are far below what they need to be in order to achieve the Net Zero goal by 2050. The sobering facts and the slow pace towards efficiency have caused the aerospace sector to look towards renewable energy to help fuel the future, particularly hydrogen. Hydrogen is crucial in finding a solution that can alleviate climate change due to its exceptional energy density and ability to eradicate CO2 emissions. With hydrogen still in its development stages, the industry has the scope to mould and develop this fuel type to fit its agenda, making it an exciting opportunity for the sector to capitalise on. Sustainability in the aerospace sector will occur as emission concerns steer R&D towards newer technologies. These advances will help develop the aircraft of the future – which may not be powered by today’s fuels. One of these sustainability regulations can be seen in practice in France, with the nation banning short-haul domestic flights between cities, linked by a train journey of less than two and a half hours. Approved by the European Commission, it comes as the country starts implementing its 2021 Climate Law to reduce its carbon emissions. A rapidly changing global energy landscape has resulted in disruptive technologies emerging in the sector. Such disruptive innovation in the energy domain has sparked a revolution in technological capabilities, digital transformation, cost reduction, and the business environment itself. This is mirrored with hydrogen battling CO2 emissions in our industry. Hydrogen is often seen as a one fits all solution for the aerospace sector, but that is not necessarily the case. Aviation fuel will not change completely in the near future however; hydrogen will offer an opportunity to become a part of the solution. In the coming years, the aircraft that fit differing range markets will see a variation in fuel sources being used which is not common today. Long haul flights will be more committed to conventional fuels for far longer, with short-range missions undertaken with Urban Air Mobility and electrification options. Hydrogen will find its niche in short to medium-range space, with the transition aided by emergent legislation, According to Lee Evans, client director transport, mobility and aerospace, EuroNorth, Dassault Systèmes, hydrogen is only one of the solutions to future aerospace sustainability. A A SUM OF THE PARTS With the 3DEXPERIENCE platform, companies can create and produce fuel in the most cost-effective and sustainable manner (above) Lee Evans, client director transport, mobility and aerospace, EuroNorth, Dassault Systèmes (below)
RkJQdWJsaXNoZXIy MjQ0NzM=