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Issue 10

Aviation Manufacturer magazine

www.aviationmanufacturer.com

global aviation services interior the interior designer Engineer and entrepreneur Zeydan Ă–ncĂź has created a fully integrated one-stopshop for the refurbishment of helicopter cabin interiors and the installation of specialist equipment for civilian and military missions.


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the editor

Vahana

Urban air mobility

Editor

The

Martin Ashcroft

O

ne of the curses of modern life is the time it takes to travel the last mile to your destination in a city centre. Haven’t we all wished for an air taxi to whisk us away from the traffic jams? Urban mobility solutions are a complex undertaking, requiring coordination and collaboration across industries, regulatory agencies and other interest groups. Now, however, advances in processing power, flight controls, electric energy storage and electric motors, to name a few, are converging to open up new possibilities. Advances in automated composite manufacturing and assembly are also enabling the production of small lightweight vehicles in high volumes at relatively low cost. In July this year, Michael Thacker, executive vice president, technology and innovation at Bell, gave testimony to a US House of Representatives Committee. “Since the first skyscraper was built,” he said, “cities have been destined to become multi-dimensional, yet we still think, plan and build in a two-dimensional world, limited to places our feet can touch. With the rapid pace of technological advancement, however, small, urban aircraft may well play a role where the current solution set has failed to keep up with our needs.” Rodin Lyasoff is chief executive of A³ (pronounced A-cubed) the Airbus advanced projects centre in Silicon

Valley, California. Speaking at TED 2018 (the Technology, Entertainment and Design Conference) in Vancouver in April, Lyasoff said he expected self-piloting air taxis following predetermined flight paths to become a normal element of urban mobility, marking “another golden age for aviation.” Airbus is working on a self-piloted vertical take-off and landing demonstrator called Vahana, which has already undertaken successful test flights. Every bit as challenging as the vehicles themselves, however, are the ‘soft’ issues involved in the infrastructure, including the standards and regulations required to ensure a safe, efficient system of urban mobility. In an announcement made at Farnborough in July, Boeing said it had agreed to collaborate with artificial intelligence technology leader, SparkCognition, to deliver unmanned aircraft traffic management (UTM) solutions. Others are doing similar work, including Bell. “Bell has been developing air taxi concepts, along with the technology and infrastructure to enable them, for quite some time,” said Michael Thacker. “While we are not sharing all of our designs or timelines, we believe viable commercial operations could begin as early as the mid-2020s.” Technology moves so fast these days, that ideas born in science fiction are moving closer to reality all the time. Be sure to read about them in Aviation Manufacturer.

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global aviation services interior Page 6

Page: 3

• The Editor: Urban air mobillity

6

• Global Air Services Interior: The interior designer

14

• Bell: Above and beyond

24

• The Boeing Company: Flying into the future

36

• Axiom Resin and Innegra Fiber: A planet craving inflight connectivity

45

• Lightweighting and fuel efficiency drive high-performance plastics demand

46

• Boeing freighters fly off the shelves at Farnborough

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• Honda delivers first HondaJet Elite • National Research Council of Canada renews agreement with Airbus

49

• Airbus wins orders for 431 commercial aircraft at Farnborough • Allegiant chooses Honeywell for APUs and maintenance

51

• Michelin Aircraft Tire to supply entire Cirrus Aircraft line • Magellan Aerospace signs purchase agreement with Pratt & Whitney

52

• Embraer sells E-Jets all over the world from Farnborough

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aviation news page 45


contents

55

• Gulf Coast Avionics completes upgrade to Cessna Citation • Electric airplane developer, Eviation, establishes US headquarters in Arizona

57

• Alliance Magnesium receives $30.9 million in financing • NASA selects SSL to explore commercial satellite assembly in space

58

• World’s biggest equine airlift for FEI World Equestrian Games • United Technologies acquires analytics specialist Predikto

59

• UTC Aerospace Systems invests in wheel and brake MRO facilities • Spirit AeroSystems to build new R&D complex in Scotland

61

• Airbus reports half-year 2018 financial results

63

• Brazilian airline GOL commits to Boeing 737 MAX • Boeing to acquire Millennium Space Systems

64

• BAE Systems: Aviation innovation

80

• Lockheed Martin: Redesigning flight

100

the boeing company page 24

• Porcher Industries: Airbus Helicopters A new chapter in helicopter design

bell: above and beyond Page 14

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global aviation services interior Engineer and entrepreneur Zeydan Öncü has created a fully integrated one-stop-shop for the refurbishment of helicopter cabin interiors and the installation of specialist equipment for civilian and military missions. He tells Martin Ashcroft about his unique business model

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T

he conversion of a helicopter interior is a complex undertaking, especially when it is being kitted out with mission critical equipment for search and rescue or emergency medical services. It’s a painstaking procedure, given the meticulous detail required in both planning and installation. If you can reduce the time it takes to complete the conversion, without compromising quality, you are likely to attract some very discerning customers. With successful conversions in its early years for the Government of Turkmenistan, followed by the Crown Prince and President of the United Arab Emirates, Global Aviation Services Interior (GASI) has established an elite clientele and an unparalleled professional reputation. When I caught up with CEO Zeydan Öncü, he told me about his latest prestigious contract. “We have a new project in South Asia,” he said. “We are equipping four Super Puma helicopters

for a national Navy with dipping sonar systems, sonobuoy systems, radar and ESM systems, to enable long range search, location and attack of submarines in both shallow and deep water.” A dipping sonar system detects and maintains contact with underwater targets through a transducer lowered into the water from a hovering helicopter. It’s a crucial defence capability. The complementary sonobuoy system is also a core technology for anti-submarine warfare, using buoys dropped from the aircraft in canisters, which deploy when they hit the water. An inflatable float with a radio transmitter remains on the surface for communication with the aircraft, while hydrophone sensors descend below the surface. An ESM is a type of sensor providing technical information, usually integrated into the air defence systems of mobile crisis reaction forces. The work will all be carried out in GASI’s facilities in Germany and the UK. Another new project has been

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launched with the Ministry of Defence of Egypt for the refurbishment of the presidential fleet of twelve MI17 helicopters. These will also be refurbished in GASI’s UK and German facilities for delivery to the customer in Cairo, Egypt.

Origins

Founded in 2006, Global Aviation Services Interior combines the vision and attention to detail of the engineer with the flair and imagination of the entrepreneur. The company quickly become a prime supplier of aircraft interior equipment and a leader in the completion and refurbishment of aircraft cabin interiors, with services including design and certification, MRO (maintenance, repair and overhaul) and VIP conversions. The company now produces a range of its own cabin interior fittings in its EASA Part 21 certified facilities in Germany, the UAE and the UK, and has also expanded into the training of


global aviation services interior the interior designer pilots, crew, engineers and technicians through its Global Aviation Academy. The European Aviation Safety Agency (EASA) takes responsibility for the airworthiness and environmental certification of all aeronautical products, parts and appliances designed, manufactured, maintained or used by persons under the regulatory oversight of EU Member States. This is a remarkable story of an engineer with a solid background and a safe career with Airbus, who became an award-winning entrepreneur supplying government ministries and Middle Eastern royal families. Öncü came to Germany in October 1979 to study aerospace engineering, first at the Technical University of Munich and then at the University of Applied Sciences in Hamburg. Now a German citizen, the multi-lingual Öncü grew up speaking Arabic and Turkish at home, and now also communicates in German, French and English. He added knowledge and skills during his early career with DaimlerChrysler Aerospace (DASA) in Hamburg, which subsequently became EADS and later Airbus, progressing into

“We are equipping four Super Puma helicopters for a national Navy with dipping sonar systems, sonobuoy systems, radar and ESM systems, to enable long range search, location and attack of submarines in both shallow and deep water”

senior management positions. Along the way he trained in personnel management and staff training, learned presentation and communication skills, how to manage teams and conduct international negotiations, as well as adding to his professional development as an engineer. He also took on board the disciplines of six sigma and project management, as well as an understanding of financial issues and supply chain management. Öncü played a leading role in the development of the Airbus A380 as data processing manager and then from June 1999 as head of concurrent engineering in Toulouse, France, reporting to senior vice president Juergen Thomas. “After that I was seconded to the A400M programme, Airbus’s turboprop military transport aircraft, as head of the component management integration team in Bremen for the most complicated component on the aircraft, the centre fuselage.” The team consisted of six international component design build teams, with around 400500 engineers and related managers. “I was responsible for the delivery of the A400M centre fuselage in respect

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of time, cost, quality and performance parameters.” Öncü left in 2004 after receiving an invitation from Spekon, a supplier of thermal and acoustic insulation products to Airbus, to come in and restructure the struggling company. Spekon was renamed Olutex, moved its operations alongside Airbus in Toulouse, returned a profit at the end of 2004, and was subsequently acquired by Hutchinson Aerospace. People were surprised that Öncü took the job, but he was ready for a change. “The life cycle of an engineer,” he says with a wry smile, “is five years of creativity, followed by 25 years of modification. After completing two major projects I could see that happening to me, and it’s not what I wanted. They said I could go back to Airbus any time, but I never regretted leaving.” It would be hard to design a better preparation for an engineering entrepreneur. The only missing ingredient was an opportunity, which arrived by chance, as opportunities often

“Another new project has been launched with the Ministry of Defence of Egypt for the refurbishment of the presidential fleet of twelve MI-17 helicopters”

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do. The skill of the entrepreneur lies in recognising the opportunity and taking the chance. “While I was at Spekon I was talking to the head of procurement for Airbus one day about an order from Turkish Airlines. He thought this was ‘up my street’, so he invited me on a business trip to Turkey and I went along for the ride. I was not expecting anything, but I came away from that trip with my first contract. You don’t expect a major airline to award a contract to a company that was not already well known in the industry, but I didn’t even have a company at that time. It all happened through the trust of the Airbus management, and the senior management of Turkish Airlines.”

Growth

Öncü soon assembled some key personnel, then bought a factory in Llanelli in Wales, the dormant business of CF Taylor, a subsidiary of B/E Aerospace that had previously manufactured kitchen galleys for aircraft cabins, and sleeping accommodation


global aviation services interior the interior designer for flight crews. “We got CAA approval there and we produced the whole order to retrofit seven aircraft interiors for the Turkish Airlines A340 Retrofit programme and three A310 crew rest compartments, on our own.” The UK manufacturing facilities have since been moved to Milton Keynes. In 2007 GASI became the first company of its kind to open facilities at Abu Dhabi International Airport for the provision of MRO services, refurbishment and engineering services, where it soon earned an EASA Part 145 AMO (approved maintenance organisation) certificate. The first job there was to retrofit a Dash 8 Q300 from passenger configuration to VIP for the Crown Prince of UAE, and a Dash 8 Q400 for the President. “We also converted two helicopters for the United Armed forces of UAE, a Super Puma from VIP to utility and an AW 139 from passenger to VIP.” In 2010 GASI opened a retrofit centre in Rothenberg in Germany and was awarded a contract from Zodiac for the production of galleys. In 2013 it was awarded a contract by governmentowned Turkmenistan Airlines for eight helicopter conversions. “The first one was an EMS conversion (emergency

“GASI produces a range of its own cabin interior fittings in its EASA Part 21 certified facilities in Germany, the UAE and the UK, and has also expanded into the training of pilots, crew, engineers and technicians through its Global Aviation Academy”

medical systems) on a Super Puma for the Ministry of Health,” says Öncü, “and we did it in 86 days, including the design, production, installation, flight test and certification. That was an unbeatable time scale in the aerospace industry.” The second one, a conversion for SAR (search and rescue), was also a challenge. “We delivered a Super Puma L2 helicopter to the Ministry of Defence of Turkmenistan,” says Öncü. “As well as the installation of a searchlight, FLIR system (thermal imaging cameras), winch, command centre, EMS kit and the rest of the cabin, we replaced the hinged door with a sliding door – and that’s a major modification. We did that in five months.” The Turkmenistan Ministry of Internal Affairs took the other five helicopters, three EC145s and two Sikorsky S-76C VIP helicopters, the last of which was delivered in September last year converted into escort helicopters for the President of Turkmenistan. GAS now has three facilities where this work is carried out – Rothenburg in Germany, Milton Keynes in the UK, and Abu Dhabi in the UAE. “In Rothenburg we have our own runway and our own helipad,” says Öncü. “We also have

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hangars to accommodate both rotor and fixed wing aircraft, and our management is here, too.” A fourth facility is about to open in Cottbus, close to Berlin. This time last year, in October 2017, Öncü’s success was officially recognised in the European Business Awards at the International Tourism and Trade Fair in Essen, held in conjunction with the Turkish-German Culture and Tourism Association and Markaimaj Media. Öncü collected an honour award and a vision and innovation award, in addition to being named Businessman of the Year.

Experience

In a very short space of time, GASI has developed a unique way of working, using the latest, most advanced, conversion technology. “The design and development of a helicopter interior usually takes between four and six months,” says Öncü. “We have reduced that by 90 per cent by using 3D scanning and reverse engineering. We scan the helicopter directly to 3D which speeds up the engineering process. Within ten

“This is a remarkable story of an engineer with a solid background and a safe career with Airbus, who became an award-winning entrepreneur supplying government ministries and Middle Eastern royal families”

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days we can produce manufacturing drawings. This is an unbeatable time scale. We are the only ones who are using this. Airbus has quoted 18 months for the delivery of the EMS helicopter. We delivered it in 86 days. We managed that by using advanced technologies, rather than a huge number of engineers. This is what we won the Innovation award for.” The technology is a vital ingredient, but you also need skilled engineers. GASI has recruited some of the best from all over the world. “We use around 60 people, all skilled in their own disciplines, says Öncü. “Some specialise in the interior, others in the exterior. We have people from Canada, the US, the UK and Europe. Our capabilities include the black box implementation – the CVR (cockpit voice recorder) and FDR (flight data recorder). This involves a complete cockpit upgrade, including the integration of all the signal systems from nose to tail.” GASI ensures that the technology and the skills of the engineers are employed to best effect with a meticulous approach


global aviation services interior the interior designer to the organisation of the project. The production method is a crucial factor in achieving results that will delight the customer in an unprecedented timescale. “We have a multi-disciplinary way of working, with inter-disciplinary communication,” Öncü explains. “The first thing is to listen carefully to the customer’s requirements and agree on a common understanding with them. Then you must assess the capabilities of the helicopter so you don’t disturb anything that might affect the aerodynamics or its flight characteristics. After that we divide the job into different work packages, and we appoint a work package leader for each one, setting out time, cost, quality and performance (TCQP) parameters for each stage. Each work package leader has his own budget and his own time schedule, integrated to the TCQP for the whole project.” A typical project would be organised into defined work stages including the definition and consolidation of requirements, the parameters of each step, followed by conceptual design, definition of equipment required, then detailed 3D configurations of the internal layout of the equipment. Before anything can be added, of course, all the old fittings must be dismantled and removed. Many of the purpose designed components are manufactured on site, specifically for each project, including the lavatories, galleys, overhead bins, pelmets, glass dividers, and the like. “We don’t do mass production,” says Öncü. “We make individual components for specific aircraft – purpose built, one-off solutions. These are high quality fittings. That is what makes us a one-stop shop. We don’t produce the black boxes or the searchlights or the FLIR systems, obviously. We buy those in. We don’t make the medical equipment, either, but we design and manufacture everything involved in the installation of it.” Everything has to be fitted according to a carefully designed plan. You can’t have oxygen bottles and infusion hooks rolling around the floor of a helicopter. That means all the fitments and fittings have to be designed specifically for the particular appliance or equipment, and also for the particular helicopter. Seating for the crew, housing for the stretchers,

cabinets for medical implements and drugs. From ventilators to defibrillators, to electrocardiography unit, there’s a lot of equipment to fit in, and everything needs to be secure, yet easy to access.

Global Aviation Academy

“The design and development of a helicopter interior usually takes between four and six months. We have reduced that by 90 per cent by using 3D scanning and reverse engineering”

Another recent development for GAS is the Global Aviation Academy, launched in 2015, and accredited with EN 29990 and EASA 147 certification, the international standard for a learning provider offering non-formal education or training. “We have trained 28 pilots and 17 technicians based on EASA 147 certification, so far,” says Öncü. “We also train cabin technicians and cabin mechanics in retrofit and conversion. Ninety per cent of the people we train get a job immediately with Airbus!” The last time I spoke to Zeydan he had just opened a new branch of the Academy in Turkey, which has already registered a number of students –16 to train as commercial pilots, 12 as cabin crew, 20 in aircraft maintenance and 32 as cabin mechanics. Training will commence in October 2018.

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bell above & beyond

Creating the next-generation of vertical lift products means thinking above and beyond flight. With an 80 year history of innovation, Bell is committed to transforming the future of on-demand urban mobility by making the vertical dimension more accessible.

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O

ne of the biggest names in the world of aviation, Bell Helicopter dropped the word helicopter from its corporate identity in February this year, rebranding itself simply as Bell. “Bell has always been about more than just helicopters,” said president and CEO Mitch Snyder, announcing the new branding strategy. “Our team has spent the past 80 years pushing the boundaries of flight, and now we will accurately reflect that quest.” The new name is accompanied by a new logo; a dragonfly, representing the mastery of flight, sits under the word Bell inside a red shield, signifying security and strength. “This rebrand is not just about a new logo,” said Snyder. “We chose to do this because we see ourselves at the forefront of technology. We believe this refresh embodies the idea that we can make the vertical dimension more accessible.” The company has a distinguished heritage. Founded as Bell Aircraft

Corporation in Buffalo, New York in July 1935, Larry Bell’s company initially specialized in the design and production of fighter aircraft, including the famous P-39 Airacobra. A genuine pioneer in the industry, its achievements include the first fighter aircraft with tricycle landing gear, the first American jet fighter (P-59 Airacomet), the first aircraft to break the sound barrier, the first commercial helicopter, and the first tilt-rotor aircraft. Bell diversified into helicopters because he wanted to create a broader base for his company rather than rely entirely on government contracts, so in 1941 he hired Arthur M Young, a talented inventor, to provide expertise for helicopter research and development. Their first full-size helicopter, the Bell 30, took its first flight in December 1942. The Bell 47 subsequently became the first helicopter in the world to be certified by a civil aviation authority. In the 1950s the helicopter division moved to Texas and in 1953 the

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company produced its 1,000th helicopter. Bell Aircraft Corporation’s helicopter division was subsequently purchased by Textron in 1960, a multiindustry conglomerate that operates in the aviation, defence, industrial and finance sectors, with powerful brands including, Cessna, Beechcraft, Hawker, Jacobsen, Kautex, Lycoming, E-Z-GO, Greenlee, Arctic Cat, Textron Systems and TRU Simulation + Training. Now headquartered in Fort Worth, Texas, Bell has additional plants in Amarillo, Texas and Mirabel, Quebec, in Canada. Established in 1986, its facility in Mirabel assembles and delivers most of Bell’s commercial helicopters, delivering its 5,000th helicopter on 12 December 2017.

Commercial

Bell’s current range of commercial helicopters includes two light single engine models, the five seat Bell 505 Jet Ranger X and seven seat Bell 407 GXi. Introduced this year at Heli-


bell above & beyond Expo 2018, the latter features Garmin’s G1000H NXi Integrated Flight Deck which offers high-definition displays and faster processors that provide increased brightness and clarity, faster start-up and map rendering as well as an option for connectivity to tablets and smartphones. The Rolls-Royce M250C47E/4 dual-channel FADEC turbine engine delivers exceptional hot and high performance, fuel efficiency and the ability to cruise at 133 kts/246 km/h. “The Bell 407GXi delivers improved pilot awareness, higher precision navigation, enhanced engine controls, and improved connectivity,” said Susan Griffin, executive vice president, commercial business, at the launch. The 8 seat Bell 429/429WLG is a twin-engine helicopter, with best-inclass cabin volume. Bell says that the combination of metallic and composite parts in its construction creates the perfect balance between rigidity and flexibility, safety and durability. The Bell 429WLG adds retractable nose and main landing gear with electrical flight deck actuation and braking capability. Bell offers two helicopters in the medium range. The 15 seat Bell Huey

“This rebrand is not just about a new logo. We chose to do this because we see ourselves at the forefront of technology. We believe this refresh embodies the idea that we can make the vertical dimension more accessible”

ll is an upgrade of the world-renowned military model UH-1H, nicknamed ‘Huey’. The upgrade increases the max gross weight to 10,500lbs, while lowering direct operating costs. There is also a complete rewire, updated avionics and a comprehensive selection of mission specific kits and customization to equip the vehicle for troop transport into high altitudes, medical evacuation in hot conditions or transport to and from remote bases. Also seating 15 (including the pilot), the twin-engine Bell 412 EP is the daily workhorse that performs reliably in some of the most extreme climates around the world. Its expansive cabin provides multi-mission flexibility while its wide opening 7.7ft doors can accommodate loading by forklift truck. The Bell 412 EPI derivative adds the Bell BasiX Pro integrated avionic system, providing pilots with increased situational awareness and safety features, and its Pratt & Whitney PT6T-9 Twin Pac engines deliver enhanced hot-high performance as well as improved takeoff capability. At a ceremony held at Farnborough Air Show in July, Bell and Subaru

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Corporation announced their collaboration on a commercial enhancement of the Bell 412 EPI, certified as the 412 EPX, in support of Japan’s UH-X program. The Subaru Bell 412 EPX will benefit from a more robust main rotor gearbox dry run capability and increased internal maximum gross weight to 12,200lbs, providing operators the ability to transport more supplies and achieve better operational efficiency. A commercial prototype has undergone testing at Bell’s facility in Mirabel, Canada, and FAA certification was achieved on 5 July 2018. Also under development is the best in class Bell 525 Relentless, an 18 seat twin-engine helicopter with a range of 560 nautical miles and a cruising speed of 160 knots. With fly-by-wire flight controls, this model provides unparalleled crew situational awareness through the use of a fully integrated avionics flight deck.

“The Bell-Boeing V-22 Osprey is the world’s first production tilt-rotor aircraft, successfully blending the vertical flight capability of a helicopter with the speed, range, altitude and endurance of an airplane”

Military

On the military side, the BellBoeing V-22 Osprey is the world’s first production tilt-rotor aircraft, successfully blending the vertical flight capability of a helicopter with the speed, range, altitude and endurance of

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an airplane. This unique combination allows more effective mission execution and realization of missions previously unachievable in one aircraft. Comprehensively tested and currently in full-rate production, the Bell Boeing V-22 has proven to be a survivable and transformational platform in the most challenging environments. The V-280 Valor is a next-generation tilt-rotor that is designed to provide unmatched agility, speed, range and payload capabilities at an affordable cost. Still under development, it achieved its first flight in December last year. The design features integrated cabin armour, fly-by-wire component redundancy, state of the art countermeasures and performance. Delivering more than twice the speed and range of conventional helicopters, this aircraft combines rapid access to the objective with superior agility at the objective. The Bell V-280 Valor program is part of the Joint Multi Role Technology Demonstrator (JMR-TD) initiative and brings together the engineering resources and industrial capabilities of Bell Helicopter, Lockheed Martin, GE, Moog, IAI, TRU Simulation & Training, Astronics, Eaton, GKN Aerospace,


bell above & beyond Lord, Meggitt and Spirit AeroSystems— collectively referred to as Team Valor. The Bell UH-1Y is the ultimate tactical utility helicopter. The ubiquitous Huey family was developed for the United States Marine Corps in the 1950s as a medical evacuation and utility helicopter. Its first flight was in 1956 and in 1960 it became the first turbinepowered helicopter to enter production. The nickname derives from the designation of the first model as HU-1, and has stuck with the aircraft ever since, despite its being redesignated UH-1 in 1962. The UH-1 first saw service in combat operations during the Vietnam War and the latest version UH1Y was first deployed with the Marine Corps in 2009. The Yankee operates in the most extreme environments, from Arctic cold to desert heat. The Bell AH-1Z is a state-of-theart fully integrated weapons system attack helicopter, built to meet the expeditionary requirements of the United States Marine Corps. With virtually identical front and rear glass cockpits, fully integrated weapons, avionics and communications systems, the marinized Bell AH-1Z flies with the

“The ubiquitous Huey family was developed for the United States Marine Corps in the 1950s as a medical evacuation and utility helicopter. Its first flight was in 1956 and in 1960 it became the first turbine-powered helicopter to enter production”

most advanced aircraft weapons and survivability equipment in the world. The Zulu is the only attack helicopter with a fully-integrated air-to-air missile capability and its target sight system provides the longest range and highest accuracy of any helicopter sight in the world.

Innovation

Technology advances quickly in aviation, and Bell keeps itself at the forefront of innovation. In May this year Bell opened its new Advanced Vertical Lift Center in the Washington, DC metro area. The location offers demonstrations and expertise on how new aviation technology can deliver solutions for customers’ most pressing mission demands. Bell is increasing its presence in the region to offer opportunities for leaders to understand how advanced aviation technology such as the V-280 Valor can meet the urgent needs of the warfighter. “We have a long-standing history of forward thinking, and we are committed to delivering overmatch capabilities to our military,” said Bell CEO Mitch Snyder. “The AVLC was designed

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so we can demonstrate innovative and breakthrough technologies to those involved with national security interests.” The interactive demonstration and event space incorporates several options to experience advancements in aviation, including: • A flight simulator where users take control of the V-280 Valor and experience the agility and speed of the world’s latest tilt-rotor technologies; • A mission table that delivers an interactive and visual representation of how complex operational requirements can be met with the revolutionary speed, range and lethality of the V-280; • An augmented reality demonstration that shows how the use of Bell’s digital thread technology impacts design, build and sustainment by bringing hands-on training and maintenance support to the most remote locations; • And a virtual reality experience

“In June this year, at the Future of Transportation World Conference, Bell announced a new collaboration with French aerospace giant Safran, to develop hybrid electric propulsion systems for future air taxi and vertical take-off and landing (VTOL) systems”

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focused on giving operators and decision makers an immersive look at how the V-280 is designed to deliver tactical overmatch. Collaboration has always been a strong feature of innovation in aviation, as can be seen with Team Valor. In June this year, at the Future of Transportation World Conference, Bell announced a new collaboration with French aerospace giant Safran, to develop hybrid electric propulsion systems for future air taxi and vertical take-off and landing (VTOL) systems. “This announcement is another proof point of our commitment to providing transportation of people and logistics in new, innovative and more efficient ways,” said Scott Drennan, Bell’s director of innovation. “Our work with Safran is a historical milestone for future transport solutions.” Safran innovation teams have been exploring the potential of hybrid solutions for future propulsion systems for several years. The partnership’s shared vision for electric and hybrid electric aircraft is the successful


bell above & beyond deployment of Bell Air Taxis and new on-demand mobility systems in the future. In this collaboration, Bell will lead the design, development and production of VTOL systems and Safran will bring its technical expertise to bear in the development of a disruptive propulsion system.

The future

Bell unveiled its vision for the future of rotorcraft at Heli-Expo 2017 in Dallas, Texas in March last year, displaying a mock-up of its first concept aircraft, the FCX-001. The aircraft has been designed to address the evolving demands of customers and demonstrate key technologies that revolutionize the pilot and passenger experience, including: • A new anti-torque system in the tail boom designed to change the safety, noise and performance parameters of vertical lift aircraft; • Hybridized propulsion which combines advanced thermal engine cores for the main propulsion with, for example, electric distribution and motors to drive the antitorque system for more control and simpler vehicle operations and maintenance; • An airframe that is made from

• •

advanced sustainable materials to provide structural performance and offer configurations that customers desire; A landing gear with non-traditional geometries that facilitate function when combined with advanced materials and actuation; Morphing rotor blades that allow aircraft to optimize performance in different flight regimes; A single pilot seat and an entirely new flight deck experience with the pilot controlling the aircraft through augmented reality and an artificial intelligence computer assistance system - a stepping stone to the fully autonomous unpiloted VTOL air vehicle; A concept modular flooring system that allows for rapid seating configuration changes so that the cabin can be customized for many types of passenger, cargo or mission based requirements.

Urban mobility

Advances in processing power, flight controls, electric energy storage and electric motors, to name a few, are informing a new breed of aircraft concepts. The convergence of these

technologies is accelerating the ability to achieve real improvements in air mobility and opening new possibilities for flight, such as addressing the issues surrounding congestion in urban areas. In July this year, Michael Thacker, executive vice president, technology and innovation at Bell, gave testimony to the House Committee on Science, Space, and Technology on the subject of air taxis and urban mobility challenges. “Since the first skyscraper was built, cities have been destined to become multi-dimensional, yet we still think, plan and build in a two-dimensional world, limited to places our feet can touch,” he said. “We’ve dreamed of flying cars for decades, but until very recently, they’ve remained flights of fancy. With the rapid pace of technological advancement, however, small, urban aircraft may well play a role where the current solution set has failed to keep up with our needs.” Rather than focusing only on the VTOL aircraft themselves, Thacker points out, it is important to define the operational requirements they must meet, the transportation network they will operate within, and the regulatory environment required to enable innovation in the service of community

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welcome to highbury recruitment a personal approach to personnel

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bell above & beyond

needs without sacrificing safety expectations. Thacker described a network of ‘vertiports’, designated take-off and landing areas where aircraft will pick up and drop off passengers or cargo. These could be built on top of buildings and parking structures, limiting the need for ground-level real-estate or miles of physical infrastructure. “VTOL aircraft will travel, on-demand, from vertiport to vertiport, providing fast, quiet, comfortable transportation over crowded urban landscapes,” he said. “We are currently partnering with groups like Uber who will help define, develop and pilot these on-demand mobility operating models.” Bell has a strong legacy of breaking new ground in aviation, from America’s

first jet fighter, the P-59 Airacomet, to the first supersonic aircraft, the legendary Bell X-1, and the first tiltrotor aircraft, the XV- 15 and V-22 Osprey. Each required the development of new technology and new approaches to previously unknown obstacles. “The challenge we face today is developing a new breed of distributed propulsion aircraft that target the same benefits as a tilt-rotor – namely the combination of VTOL capability and high-speed flight – but that employ much simpler propulsion systems and an imperative to make them affordable enough for large scale commercial use,” said Thacker. “One key technology focus area is the man-machine interface. Rapid progress in autonomy will change the way we fly, and ultimately what it means to be

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a pilot or aircraft operator. In reality, this change has been ongoing for many years, with the move from simple analogue gauges to digital displays to today’s full glass cockpits, and from mechanical flight controls to fly-bywire and fly-by-light controls and flight control systems that intelligently manage flight and compensate for aircraft failures.” Bell has been developing air taxi concepts, along with the technology and infrastructure to enable them, for quite some time. While it is not sharing all of its designs or timelines quite yet, Thacker believes viable commercial operations could begin as early as the mid-2020s. It’s a tantalizing prospect.

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Aviation Manufacturer Magazine www.aviationmanufacturer.com

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the boeing company flying into the future

Boeing set out its vision of the future of aviation at the Farnborough International Airshow in July this year, collecting a haul of commercial, defence and services orders along the way. Martin Ashcroft looks at recent events and future possibilities   Aviation Manufacturer Magazine www.aviationmanufacturer.com  25


V

isitors to the 2018 Farnborough International Airshow experienced for the first time the new £30 million Exhibition and Conference Centre, which was opened in March this year. Visitors to the Boeing exhibit at the show will have taken a flight into the future of air and space travel. Titled The future is built here, the interactive exhibit showcased Boeing’s latest family of aircraft and services, but also offered an insight into what the company is developing in its second century as a pioneer of air travel. In a large 360-degree theatre, Boeing presented innovations that will revolutionize the way humans travel in the future, from hypersonic travel to the future of autonomous flight, and manned flights into space. While all this was going on, of course, the orders kept flying in. At the close of the industry section of the show, Boeing announced a total of $98.4 billion in orders and commitments for commercial airplanes (at list prices) and

$2.1 billion worth of services orders and agreements from commercial and government customers. The services business was spread across Boeing Global Services’ four capability areas, including supply chain; engineering, modifications and maintenance; digital aviation and analytics; and training and professional services. Among the highlights was an agreement with Atlas Air for 20 landing gear exchanges for its 747-8 fleet, and an agreement with Emirates to use the Optimized Maintenance Program for a fleet of 150 777-300ER (extended range), 777-200LR and 777-300 aircraft, the largest 777 fleet in the world with an OMP. Malindo Air signed a long-term partnership agreement with Boeing subsidiary Jeppesen to offer dispatcher training services at its operations centre in Kuala Lumpur, Malaysia, while Okay Airlines of China signed on to use Airplane Health Management (AHM) for its 737 MAX fleet. Boeing’s AHM uses predictive analytics in support of

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maintenance and engineering. WestJet became the 100th customer to sign on for AHM, which it will use to provide predicative analytics for its 787 fleet. The Royal Netherlands Air Force signed an agreement for Boeing to provide performance based logistics support for its fleet of AH-64 Apache and CH-47 Chinook helicopters. The five-year agreement is designed to combine Dutch Chinook and Apache support services into one integrated customer support program. Meanwhile the United States Air Force awarded Boeing a contract to provide crew instruction and operate, sustain, modify and upgrade the C-17 aircrew and maintenance training systems. The firmfixed price award has a contract period up to 6.5 years and a potential total value of $986 million. The USAF also awarded Boeing a four-year sole-source contract to repair, support, configure and provide parts obsolescence management for F-15 radars. It wasn’t a bad week for aircraft either, with commercial aviation


the boeing company flying into the future customers announcing 673 orders and commitments, reflecting a continued resurgence in demand for freighters and strong order activity for the 737 MAX and 787 passenger airplanes. Boeing benefited from the continued strengthening of the global cargo market. Volga-Dnepr Group and its UK subsidiary CargoLogicHolding signed a package of agreements, including a letter of intent to acquire 29 Boeing 777 Freighters and confirmation of an order for five Boeing 747-8 Freighters. International express carrier DHL signed up for 14 of the 777 Freighters and Qatar Airways finalized an order for five, meaning a total of 53 Boeing freighters were ordered at the show. On top of that, GE Capital Aviation Services (GECAS) signed an agreement for 35 additional 737-800 Boeing Converted Freighters. Customers also demonstrated the popularity of Boeing’s passenger airplane portfolio, with 52 orders for the 787 and 564 for the single-aisle 737 MAX, including a major commitment from VietJet for 100 airplanes and strong demand for the largest variant of the MAX family, with 110 orders and commitments for the 737 MAX 10.

“Boeing announced a total of $98.4 billion in orders and commitments for commercial airplanes and $2.1 billion worth of services orders and agreements from commercial and government customers”

San Francisco-based leasing company Jackson Square Aviation became the 100th customer of the 737 MAX program with an order for 30 Boeing 737 MAX 8 aircraft valued at $3.5 billion.

Embraer partnership

The major players often generate interest in a trade show by making an important announcement during the build-up. The ink was barely dry on the C Series Aircraft Limited Partnership contract between Airbus and Bombardier before Boeing announced it was entering a strategic partnership with Brazilian aircraft manufacturer Embraer. The new joint venture will align the commercial aircraft and services business of Embraer with Boeing’s commercial development, production, marketing and lifecycle services operations. Boeing will hold an 80 per cent ownership stake in the JV and Embraer will own the remaining 20 per cent. “By forging this strategic partnership, we will be ideally positioned to generate significant value for both companies’ customers, employees and shareholders – and for Brazil and the United States,” said Dennis Muilenburg, Boeing’s

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chairman, president and chief executive officer. “This important partnership clearly aligns with Boeing’s long-term strategy of investing in organic growth and returning value to shareholders, complemented by strategic arrangements that enhance and accelerate our growth plans.” The transaction values Embraer’s commercial aircraft operations at $4.75 billion and contemplates a value of $3.8 billion for Boeing’s 80 per cent ownership stake in the joint venture. On finalization, the commercial aviation joint venture will be led by Brazil-based management, including a president and chief executive officer. Boeing will have operational and management control of the new company, which will report directly to Muilenburg. Boeing and Embraer leaders held their first news conference together at Farnborough. Muilenburg, Boeing chief financial officer and executive vice president for enterprise performance & strategy Greg Smith and Embraer chief executive officer and president Paulo Cesar de Souza e Silva presented details of the proposed partnership, which includes ventures in commercial airplanes and lifecycle services, as well as defence. The JV will become one of Boeing’s centres of excellence for end-to-end design, manufacturing and support of commercial passenger aircraft, and will be fully integrated into Boeing’s broader production and supply chain. Assuming the necessary approvals are received in a timely manner, the transaction is expected to close by the end of 2019.

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In an announcement made at Farnborough, Boeing said it had agreed to collaborate with artificial intelligence technology leader, SparkCognition, to deliver unmanned aircraft system traffic management (UTM) solutions. Boeing and SparkCognition will use artificial intelligence and blockchain technologies to track unmanned air vehicles in flight and allocate traffic corridors and routes to ensure safe, secure transportation. Through the collaboration, they will also provide a standardized programming interface to support package delivery, industrial inspection and other commercial applications. Boeing HorizonX Ventures previously invested in the Austin, Texas-based SparkCognition in June last year to support its development of a cognitive, data-driven analytics platform for the safety, security and reliability of data technology. Commenting on the initial investment, Greg Hyslop, Boeing chief technology officer and senior vice president, engineering, test & technology, said: “SparkCognition is at the forefront of a technological shift in machine learning and artificial intelligence that will revolutionize every aspect of industry. They are leaders in AI, and they are pursuing the types of technologies that are critical to our future products and services.” “There is massive demand for our category-leading AI solutions,” said Amir Husain, founder and CEO of SparkCognition. “The world is well on its way to an AI-powered revolution — where cognitive systems will truly augment human capabilities, but at machine speed and big data scale. Our real world deployments and on-the-ground successes speak to the broad applicability of SparkCognition’s AI technology, and the tremendous promise of AI in general.” After the collaboration announcement at Farnborough, Husain said that opportunities in urban aerial mobility will lead to the creation of “the largest new market in our lifetimes, estimated by some analysts at $3 trillion.” To help advance UTM and next-generation travel, and evolve the transportation ecosystem, Boeing is starting a new organization, Boeing NeXt. This will leverage Boeing’s research and development activities and investments in areas such as autonomous flight and advanced propulsion, as well as focus on modelling smart cities and exploring new market opportunities to solve the

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the boeing company flying into the future transportation challenges of the future. “We’re at a point in history where technological advances and societal trends are converging to demand bold solutions and a different way to travel,” said Greg Hyslop, Boeing chief technology officer. Steve Nordlund, who will lead Boeing NeXt in addition to his role as vice president of Boeing HorizonX, expanded on the vision. “By taking a holistic approach that combines Boeing’s strength in technological innovation with new business models and non-traditional partnerships, we are laying the foundation for the future commercial mobility ecosystem,” he said. “We are shaping the physical and connectivity infrastructure to ensure new air vehicles safely operate in the global air space.” The Boeing NeXt portfolio will include the recently unveiled passenger-carrying hypersonic concept, as well as electric vertical take-off and landing (eVTOL) vehicles that will provide on-demand cargo transport and urban air travel in the future mobility ecosystem. Boeing also highlighted its commitment to future aerospace innovators with a $5 million investment

“Boeing’s 2018 Commercial Market Outlook raises the company’s 20year outlook for commercial airplanes and services to $15.1 trillion. The global market is forecast at almost 43,000 new airplanes, valued at $6.3 trillion, with demand for $8.8 trillion worth of commercial services through 2038”

in Newton Europe to launch science, technology, engineering and math (STEM) education “Newton Rooms” across nine European countries. Newton Rooms are themed, state-of-the-art classrooms focused on experiential learning. Boeing’s multi-year investment will establish Newton Rooms in the United Kingdom, Germany, Netherlands, France, Italy, Spain, Belgium, Poland and Sweden.

Market outlook

Boeing also revealed its 2018 Commercial Market Outlook at the Farnborough show, raising its 20-year outlook for commercial airplanes and services to $15.1 trillion. The global market is forecast at almost 43,000 new airplanes, valued at $6.3 trillion, and demand for $8.8 trillion worth of commercial services through 2038. Recognized as an industry benchmark for global air travel forecasting, the 2018 CMO projects the total number of airplanes increasing 4.1 per cent over the previous forecast. “For the first time in years, we are seeing economies growing in every region of the world,” said Randy Tinseth, vice president of commercial marketing for The Boeing

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Company. “This synchronized growth is providing more stimulus for global air travel. We are seeing strong traffic trends not only in the emerging markets of China and India, but also the mature markets of Europe and North America. Along with continued traffic expansion, the data show a big retirement wave approaching as older airplanes age out of the global fleet.” According to fleet data, there are more than 900 airplanes today that are over 25 years old. By the mid 2020s, more than 500 airplanes a year will reach that age – double the current rate – fuelling the retirement wave. Tinseth said the data explain why 44 per cent of the new airplanes will be needed to cover replacement alone, while the rest will support future growth. Including airplanes that will be retained, the global fleet is projected to essentially double in size to 48,540 by 2037. According to the CMO, the single-aisle segment will see the most growth over the forecast period, with a demand for 31,360 new airplanes, an increase of 6.1 per cent over last year. This $3.5 trillion market is driven in large part by the continued growth of low-cost carriers, strong demand in emerging markets, and increasing replacement demand in markets such as China and Southeast Asia. The wide-body segment calls for 8,070 new airplanes valued at nearly $2.5 trillion over the next twenty

years. Wide-body demand is spearheaded, in part, by a large wave of replacements beginning early in the next decade and airlines deploying advanced jets such as the 787 Dreamliner and 777X to expand their global networks. Additionally, Boeing projects the need for 980 new production wide-body freighters over the forecast period, up 60 airplanes over last year. In addition, operators are forecasted to buy 1,670 converted freighters. The massive global fleet generates a strong and growing demand for aviation services ranging from supply chain support (parts and logistics), to maintenance and engineering services, to aircraft modifications and airline operations. Over the next 20 years, Boeing forecasts an $8.8 trillion market for commercial aviation services with

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the boeing company flying into the future annual growth of 4.2 per cent. “We see a market in which airlines outsource more and more, a market in which data and data analytics help aircraft and airline networks become more efficient and reliable, and a market in which new technologies provide new services solutions,” said Tinseth. “All of these trends drive greater demand for integrated solutions over the life of an airplane.” Boeing’s CMO forecast that airlines in Asia Pacific would represent about 40 per cent of expected new deliveries over the coming 20 years, with 16,930 new aircraft tipped to enter service in that period, up from 16,050 new deliveries in the 2017-2036 CMO. The region is expected to be the biggest travel market in the world and tipped to represent about 40 per cent of global passenger traffic by 2036. It takes a long time to design and build an aircraft, so these analytics are essential to ensure that Boeing can meet the demands of its customers within a reasonable lead time. Anticipating their requirements gives a head start in determining the most appropriate product mix.

Boeing 737 MAX

“The 737 MAX incorporates the latest CFM International LEAP-1B engines, advanced technology winglets, Boeing Sky Interior, large flight deck displays and other features to deliver the highest efficiency, reliability and passenger comfort in the singleaisle market”

The narrow-body Boeing 737 series is the most popular aircraft of all time. As The Boeing Company celebrated its 100th anniversary in 2017, the 737 celebrated its 50th. The first production 737-100 was handed over to German national airline Lufthansa in December 1967. By July 2012, the 737 became the first commercial jet to surpass 10,000 orders. The series has been through a few iterations since then, with the 737 Classic followed by the 737 Next Generation. The 737 MAX is the fourth generation of the Boeing 737. The series will be offered in four lengths. The 737 MAX 7, MAX 8, and MAX 9 will replace the original 737-700, -800, and -900. Additional length is offered with the further stretched 737 MAX 10. The entire 737 MAX family has been designed to offer customers exceptional performance, flexibility and efficiency, with lower per-seat costs and an extended range that will open up new destinations in the single-aisle market. The 737 MAX incorporates the latest CFM International LEAP-1B engines, advanced technology winglets, Boeing Sky Interior, large flight deck displays

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and other features to deliver the highest efficiency, reliability and passenger comfort in the single-aisle market. Rather confusingly, however, the new models are not being released in numerical order. The first to appear, the 737 MAX 8, has already entered commercial service and will be followed by the MAX 9, MAX 7 and MAX 10, in that order. Said to be the industry’s most efficient and profitable single-aisle airplane, Boeing launched the 737 MAX 10 at the Paris Air Show last year, with more than 360 orders and commitments from 16 customers worldwide. Deliveries are expected to commence in 2020. The first Boeing 737 MAX 9 was delivered to the Lion Air Group in March 2018 for use by Thai Lion Air. One of the world’s largest operators of the 737, Lion Air was also the first operator to put the MAX 8 into service, and has announced a commitment for 50 MAX 10s. The 737 MAX 9 is designed for a capacity of up to 220 passengers and a maximum range of 3,550 nautical miles. With three additional seat rows compared to the 737 MAX 8, the airplane provides operators added capacity while maximizing profitability within their network. The 737 MAX 7, which is scheduled to enter service in 2019, took its first light in March this year and made its air show debut at Farnborough, with

flying displays throughout the week. Technology advancements allow the MAX 7 to fly 1,000 nautical miles farther and carry more passengers than its predecessor, the 737-700, while having 18 per cent lower fuel costs per seat.

Boeing 787-10 Dreamliner

“The 737 MAX 7, which is scheduled to enter service in 2019, took its first flight in March this year and made its air show debut at Farnborough, with flying displays throughout the week”

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The Boeing 787 Dreamliner is the family of new, super-efficient airplanes that brings big-jetliner comfort and economics to the middle of the market. The 787 incorporates advanced composite materials, systems and engines to provide superior passenger comfort and unprecedented performance, including a 20-per cent improvement in fuel efficiency and emissions over the aircraft they replace. In October 2009, Boeing selected its site in North Charleston, South Carolina for a new 787 Dreamliner final assembly and delivery line. The first airplane built in South Carolina rolled out of final assembly on 27 April 2012, took its first flight on 23 May 2012, and was delivered to Air India on 5 October 2012. Three members of the 787 family – the 787-8, 787-9 and 787-10 – are designed to serve the 200- to 330-seat market on flights as long as 8,500 nautical miles (15,750 km) in three-class seating. The first 787 built in Everett made its inaugural flight in December 2009, with first delivery of the 787-8 in September 2011 to launch customer ANA. Boeing


the boeing company flying into the future delivered the second member of the family, the 787-9, to launch customer Air New Zealand in June 2014. The third and longest version of the 787, the 787-10, completed its first flight in March 2017. Singapore Airlines took delivery of the first one in March 2018 at Boeing’s facility in North Charleston, South Carolina. The 787-10 is being built exclusively in North Charleston. Like the other 787 Dreamliners, the 78710 is designed with strong, lightweight composites, the most advanced systems, and comfortable cabin features. The 78710, though, features a longer fuselage which allows it to carry about 40 more passengers or a total of 330 seats in a standard two-class configuration. As a stretch of the 787-9, the 787-10 retains over 95 per cent commonality while adding seats and cargo capacity, setting a new benchmark for fuel efficiency and operating economics at 25 per cent better fuel per seat and emissions than the airplanes it will replace.

Boeing 777X

A new plane in development, being assembled at the Everett plant, is the third-generation of the wide-body Boeing 777, the 777X. Powered by GE9X turbofan engines the 777X is the largest two-engine jetliner in the world,

“The third and longest version of the 787, the 787-10, completed its first flight in March 2017. Singapore Airlines took delivery of the first one in March 2018 at Boeing’s facility in North Charleston, South Carolina”

carrying up to 425 passengers with a range up to 8,000 nautical miles. The original 777 first entered commercial service with United Airlines in June 1995. The 777X series was launched in November 2013 with two variants: the 777-8 and the 777-9. Like the 737 MAX 10, it is scheduled to enter service by 2020. As a competitor of the Airbus A330300 and A350 XWB, the 777 ranks as Boeing’s most-produced wide-body jet, surpassing even the Boeing 747. Airlines have taken to it as a comparatively fuelefficient alternative to other wide-body jets and have increasingly deployed the aircraft on long-haul transoceanic routes. The cabin interior of the 777X is inspired by the comforts and conveniences of the 787 Dreamliner and includes larger windows, a wider cabin, new lighting and enhanced architecture. Innovation on the flight deck includes touchscreens in the forward displays, a first in the air transport industry. Boeing opened its new 777X Composite Wing Center at the Everett campus in May 2016, after investing more than $1 billion for construction and outfitting of the building. The new facility will produce the largest wing the company has ever built. With a 235-foot

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wingspan, the tips of the wings fold up so that airports can accommodate their width. In the main factory, instead of cranes and scaffolding-like structures, computer-controlled automated guided vehicles will be used to position wings and fuselage sections for wing-to-body join. Boeing has also completed a 90,000 square-foot expansion of the parts facility in Montana that it acquired in 2010. Now more than 257,000 square feet, Boeing Helena has become a vital part of the supply chain, specializing in complex machining of hard metals for the Boeing 737, 747, 767, and 787 airplane models – and now the 777X. The new parts machined in Helena for the 777X will include side-of-body chords, and terminal end fittings which connect the wings to the fuselage.

Boeing 767

The Boeing 767 family includes the 767-300ER (extended range) and the 767 Freighter. Sized between the single-aisle 737 Next Generation and the twin-aisle 777, the versatile 767 has earned a reputation among airlines for its profitability and comfort. The 767 Freighter offers excellent fuel efficiency, operational flexibility, low-noise levels and an all-digital flight deck. Built in Everett, alongside the 747, The Boeing 767 is a wide-body, double-aisle jet carrying from 200 to

300-plus passengers. Like the smaller standard-body 757, it was designed for fuel efficiency. The 767-200ER entered service in 1984, the first commercial twin jet to fly regular routes across the Atlantic.

Defence

Boeing’s expertise in defence spans a broad range of products. Fighter jets, rotorcraft, embedded product support, cyber-security products, surveillance suites, advanced weapons, missile defence and commercial aircraft derivatives all fit in Boeing’s portfolio. Deployed by the US Navy since 2013, the P-8A Poseidon is an aircraft designed for long-range anti-submarine warfare, anti-surface warfare and intelligence, surveillance and reconnaissance missions. The P-8 is a commercial derivative aircraft, a process whereby a commercial airplane is converted for military purposes. A derivative of the Next-Generation 737-800, the P-8A combines superior performance and reliability with an advanced mission system that ensures maximum interoperability in the future battle space. The H-47 Chinook helicopter is an icon of the battlefield. Constantly being upgraded, the latest program will see an improved drivetrain to transfer greater power from the engines to the all-new, fully composite, swept-tip advanced

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Chinook rotor blades, which have been engineered to lift 1,500 additional pounds on their own. The current configuration of six fuel tanks – three on each side – will become two, allowing the aircraft to carry more fuel and shed weight. Additionally, the fuselage’s structure will be strengthened in critical areas to allow the aircraft to carry additional payload. The AH-6 is a light attack/armed reconnaissance helicopter specifically designed with superior performance characteristics and flexible, easily configurable mission equipment ideal for light attack, precision attack, close combat attacks, reconnaissance, security & escort, troop insertion/extraction, combat search & rescue. The AH-64 Apache is the world’s most advanced multi-role combat helicopter and is used by the US Army and a growing number of international defence forces. Boeing has delivered more than 2,200 Apaches to customers around the world since the aircraft entered production in the 1980s. The first AH-64A was delivered to the US Army in January 1984. The Boeing B-52 bomber is in its sixth decade of operational service. It primarily provides the United States with immediate nuclear and conventional global strike capability. The B-52H is the most combat capable bomber in the US inventory. Due to


the boeing company flying into the future its high mission-capable rate, long range, persistence and ability to employ accurate standoff weapons and joint direct attack munitions, the B-52H continues to be a major contributor to the US and allied forces. The bomber is another aircraft regularly upgraded to feature the latest technological advantages, most recently being equipped with enhanced internal weapons bay launchers allowing the B-52 to carry GPS-guided or ‘smart’ weapons in the weapons bay for the first time. When it comes to fighter jets, the F-15 is the backbone of the US Air Force’s air superiority and homeland defence

single-seat E model and the two-seat F model – are able to perform virtually every mission in the tactical spectrum, including air superiority, day/night strike with precision-guided weapons, fighter escort, close air support, suppression of enemy air defences, maritime strike, reconnaissance, forward air control and tanker missions. A variant of the F/A-18F Super Hornet, the EA-18G Growler provides tactical jamming and electronic protection to US military forces and allies around the world. The KC-46A Pegasus is a wide-body, multirole tanker that can refuel all US, allied and coalition military aircraft

aircraft can be configured to carry allpassengers, all-cargo, or a combination of both. The C-40A is part of Boeing’s C-40 series of aircraft, which also includes the C-40B and C-40C. The C-40A is currently on offer as the C-40Ai to countries around the world. A high-wing, four-engine, T-tailed military transport aircraft, the multiservice C-17 Globemaster can carry large equipment, supplies and troops directly to small airfields in harsh terrain anywhere in the world. The massive, sturdy, long-haul aircraft tackles distance, destination and heavy, oversized payloads in unpredictable conditions. It has delivered cargo in

missions. A twin-engine, all weather fighter, its proven design is undefeated in air-to-air combat, with more than 100 aerial combat victories. Its two engines provide 58,000 pounds of thrust, which enable the F-15 to exceed speeds of Mach 2.5. Boeing has built more than 1,600 of the aircraft for six countries around the world, providing unparalleled interoperability. The F/A-18 Block III Super Hornet is the newest tactical aircraft in US Navy inventory, the backbone of the US Navy carrier air wing. The combat-proven Super Hornet delivers cutting-edge, next-generation multi-role strike fighter capability, outdistancing current and emerging threats. Two versions of the Super Hornet – the

compatible with international aerial refuelling procedures and can carry passengers, cargo and patients. In February 2011, it was decided that Boeing would build 179 tankers for the US Air Force, to replace its KC-135 tanker program. Designated KC-46 Pegasus, the new aircraft is based on the 767-2C, a freighter version of the 767-200ER, making the 767 the only Boeing product that serves the freighter, passenger and tanker markets. The design received an amended type certificate from the US Federal Aviation Administration in December last year. Designed to offer mission flexibility, the C-40A is a versatile FAA-certified 737-700 convertible aircraft, optimized to transport passengers and cargo. The

every worldwide operation since the 1990s. The final Boeing C-17 Globemaster III military airlifter left the company’s plant in Long Beach, California in November 2015, marking the official end of aircraft production in Long Beach, although Boeing will continue to service the worldwide C-17 fleet, providing support, maintenance and upgrades. At Farnborough this year, the US Department of Defense displayed the AH-64 Apache attack helicopter, the CH-47 Chinook heavy-lift helicopter and the F-15E Strike Eagle, underlining Boeing’s contribution to national defense, as well as commercial aviation.

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axiom resin & innegra fiber a planet craving inflight connectivity

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adomes are protective housings for antennae, used in a wide variety of terrestrial, marine, and airborne communications applications. Shifts to higher frequency communications bands are driving an expanded need for lower dielectric materials, as system losses increase with frequency. Radome design must take into consideration not only electronic performance, but also mechanical performance, weather/impact damage resistance, system weight, and cost targets. When a radome is damaged by impact, the nature of the damage

can alter the electrical transmission characteristics of the structure. Structures that have greater damage tolerance, where the stress of an impact can be absorbed and/or distributed without compromising the integrity of the structure, are thus of high value. Structures designed using high-density materials, such as glass or quartz are increasingly under scrutiny to determine if a material substitution can be made to reduce the system weight. Lower density, low dielectric materials therefore offer an additional advantage to designers. Using a hybrid system of fiber reinforcement offers the opportunity to optimize the FRP composite system based on mechanical, electrical, and cost criteria. Previous mechanical studies of FRP composites reinforced with hybrids of Innegra S and glass have demonstrated improvements

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in impact resistance and damage tolerance, which would be an additional benefit in radome applications. Innegra S is a multifilament yarn comprised of high-modulus polypropylene (HMPP) treated with a fiber sizing. It can be easily fabricated into common reinforcement structures, such as unidirectional webs, non-crimp knits, woven fabrics, and braids. As a multifilament yarn, it can be hybridized with other fibers within a reinforcement structure or even at the yarn level. In this study, the Innegra S HMPP is examined as both a unitary yarn and in hybrid yarn form, combined with E-glass. The tensile properties of HMPP fall between those of high-performance fibers and commodity fibers. The increased elongation at break, relative


axiom resin & innegra fiber a planet craving inflight connectivity to high-performance fibers, gives the Innegra S fibers a higher toughness than typical composite reinforcement fibers. The structure of the Innegra S HMPP fiber is microporous, which results in a lower bulk density than is typical of conventional polypropylene materials. Previous research has demonstrated that incorporation of Innegra S HMPP into a FRP composite design can increase the impact resistance and damage tolerance of structures. While the modulus and strength of HMPP are lower than other fiber types conventionally used in FRP composites, the low permittivity, low density, low moisture regain, and high toughness of the fiber can help balance the electronic and mechanical properties of a structure to create a more optimal solution. The Axiom AX-3201M prepreg systems, based on a 121°C (250°F) curing epoxy matrix, are designed to produce composite components using either vacuum bag oven or autoclave cure cycles. The prepreg system is ideal for multi-ply laminates requiring

Hybrid System Dielectric Proper3es vs. Incumbent Materials 0.016 E-glass / Unsaturated Polyester

0.014

Loss Tangent

0.012

E-glass / Low Dielectric Epoxy

E-Glass

0.01

Quartz / Low Dielectric Epoxy

0.008

Quartz

H

0.006

aN

diz

ri yb

on Quartz / Cyanate Ester

70% Innegra S / 30% E-glass / Epoxy

0.004 0.002 0

Innegra S HMPP

2

2.5

3

3.5

4

Dielectric Constant

4.5

5

5.5

low dielectric properties. Parts built with combinations of E-glass, Quartz, Innegra fibers in the form of AX3201M prepregs exhibit low dielectric permittivity (Dk) and loss tangent (Df), providing flexibility to designers to tailor the material composition to meet the appropriate electrical and mechanical requirements. The epoxy resin is clear and contains no fillers. Components built with AX-3201M prepregs are reported to exhibit high thermal and UV stability and resistance to water and common industrial fluids. Three fabrics were chosen for this study: 100 % E-glass, used as a benchmark material; 100 % Innegra S; and a hybrid E-glass / Innegra S fabric, constructed of Innegra HIG06 hybrid E-glass/Innegra S yarns, chosen to represent a test point in composition between the two pure fiber fabrics. The composition of the hybrid fabric was approximately 70 % Innegra S / 30% E-glass by volume. Prepregs of the sample fabrics were prepared with a low-dielectric epoxy resin system, type AX3201, by Axiom Materials in a solvent-free hot-melt application process. Composite laminate panels were fabricated by the University of Delaware Center for Composite Materials from prepreg materials supplied by Axiom Materials. Each panel was composed of eight plies of prepreg with a stacking sequence of [0]8. Panel laminate quality was verified by ultrasound C-scan prior to testing. Measurement of the dielectric properties of the test panels was made over a frequency range of 18 GHz – 40 GHz by the University of Delaware Center for Composite Materials using the free space focused beam transmission method. Complex permittivity was calculated from the measured transmittance and reflectance using methodologies based on transmission of electromagnetic waves through a dielectric slab. The dielectric permittivity and loss tangent were obtained for the FRP composite panels over two frequency ranges, 18 – 26 GHz and 26 - 40 GHz, representing Ka, and Ku communication bands. The relative

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Aviation Manufacturer Magazine www.aviationmanufacturer.com

38


axiom resin & innegra fiber a planet craving inflight connectivity permittivity (dielectric constant) was found to be consistent over the frequency range studied within the limits of measurement error. The loss tangent also did not show a measurable change with frequency over the range studied, although is difficult to measure accurately at the low values obtained. The focused beam testing method has reduced accuracy below 0.010 loss tangent values. Permittivity and loss tangent were evaluated as a function of fiber content and permittivity was found to follow a linear rule-of-mixtures relationship based on volume fraction, which was expected. The loss tangent values were all below the detection accuracy limit of the measurement method so it is not possible to draw any reliable conclusions about the relationship between loss tangent and constituent volume fraction; further study using a different measurement method will be required to clarify the relationship. Those skilled in the art of electronic design will recognize that different hybridization methods may be used to tune the electronic properties of a hybrid FRP structure, just as they can be used to modify the mechanical properties. Hybridization of E-glass with Innegra S fibers is an effective way to reduce the relative permittivity of a FRP composite structure, potentially achieving permittivity values in the range of that achieved with quartz fibers. The use of a reinforcement fabricated from a hybrid yarn results in a uniform distribution of fiber types throughout the plane of the fabric. Other strategies for creating hybrid FRP composites, such as using hybrid woven (co-woven) fabrics or hybridization at a ply level, are also possible. Innegra S hybrid FRP composites have previously been shown to have higher impact resistance and damage tolerance than composites made from brittle reinforcement fibers alone. Hybridization of a FRP composite with Innegra S fibers can therefore allow designers to create a composite radome structure that is better able to satisfy the full range of requirements.

Thickness (mm)

Areal Weight (g/m2)

Average Density (g/ cc)

E-glass / AX 3201

1.95 ± 0.08

472.9 ± 7.3

1.835

4.85

<0.01 (0.008)

4.75

0.01

Hybrid Innegra / EGlass / AX3201

2.23 ± 0.07

267.7 ± 3.1

1.002

3.23

<0.01 (0.005)

3.25

<0.01 (0.008)

Innegra / AX 3201

2.70 ± 0.08

459.1 ± 3.4

1.299

2.57

<0.01 (0.002)

2.67

<0.01 (0.003)

Panel

18-26 GHz RelaEve PermiFvity Loss Tangent

26 – 40 GHz RelaEve PermiFvity Loss Tangent

ABOUT INNEGRA

Innegra™ fiber (HMPP), a high modulus polypropylene fiber, is used in composite and textile applications to increase toughness, durability, damping, and improve signal transmission, all with the opportunity to achieve a reduced weight at a lower cost. The textile and composite materials industries have made many technological advances in weight reduction, ballistic protection, and development of multi-functional materials since the introduction of synthetic fibers in the 20th century. The Innegra S fiber technology, commercialized in 2012, continues the expansion of technology in these fields through hybridizing with other high performance fibers. Innegra Technologies (http://www.innegratech.com/) is a U.S. based company located in Greenville, SC and is a leader in high-performance textile fiber materials engineering and manufacturing. The Innegra™S fiber commercial manufacturing technology was developed in part with support from the US Government Small Business Innovative Research (SBIR) grant program (NSF06598: “Lightweight Composites for Aerospace Applications”; A06-171:“High Strength, Low Cost Polymer Fibers for Protective Clothing and Equipment, Shelters and Airdrop Equipment”; AF06-056 “Tri Band Radome Design for Antennas”; N07-104 “Advanced Materials for Submarine Antenna Radomes”.) Today, Innegra Technologies advanced fibers are incorporated into a wide range products spanning multiple industries, including: aerospace, automotive, ballistics/blast, luggage, marine craft, netting and webbing, protective products, radomes, ropes, and sporting equipment. Innegra Technologies is a disabled veteran-owned company.

ABOUT AXIOM

Axiom Materials, Inc., is a progressive composite materials manufacturer founded with the goal of combining a quality prepreg, adhesive, and ancillary composite products platform with customer-focused service and forwardthinking design. Axiom Materials manufactures an extensive range of composite materials and engineered products. They include ceramic and polymer matrix prepregs consisting of various resins (e.g. epoxies, phenolics, Polyimides, BMI & CE), reinforcements (e.g. carbon, glass, Aramid & quartz) and forms (e.g. woven, UD & slit-tapes). Axiom also produces tooling prepregs, film adhesives and more! The company specializes in custom solutions for its customers; working closely with them to develop the correct solution for each project and specifications. Reputation for agility and flexibility sets the company apart in the industry. The company works closely with clients across the globe in aerospace, military, automotive, industrial, sports and medical industries to create exceptional, next-generation solutions. Axiom Materials, Inc. is certified to AS/ EN9100D and ISO9001:2015.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  39


Axiom resin and Innegra fiber

expanding the horizons of dielectric properties Axiom Materials manufactures an array of ceramic and polymer matrix prepregs and specializes in customer solutions. Innegra Technologies produces high performance fibers focused on customer application development. Together Axiom prepreg and Innegra fiber combine to offer improved durability and damping properties, increased signal transmission and overall extending the life of the part.


Innegra Technologies

www.innegratech.com sales@innegratech.com Tel: +1 864 631 2800

Axiom Materials

www.axiommaterials.com RDhawan @axiommaterials.com Tel: +1 949 261 6009


ENGINEERING AND MANUFACTURING MADE IN GERMANY

EVERYTHING FROM A SINGLE SOURCE

BUSINESSJET EQUIPMENT LATCHES · HINGES RODS · STRUTS STANDARD PARTS · FASTENERS BUILD TO PRINT SYSTEMS KITTING SOLUTIONS

DETAILS MAKE THE DIFFERENCE BETWEEN GOOD AND OUTSTANDING!

SACS GmbH Robert-Bosch-Straße 15 · 72186 · EMPFINGEN · GERMANY www.sacs.aero


Striving for Excellence

Aeronamic designed the APU Load Compressor and is the exclusive manufacturer and maintenance provider of this system for the US Air Force Boeing KC-46A Pegasus aerial refueling tanker.

For the F-35 Lightning II Aeronamic supplies the revolutionary APU starter/generator; an essential part of the Power & Thermal Management System.

Our business is the design, production, testing and repair & overhaul of highly complex turbo machinery, motor driven systems and critical high-precision components for the aerospace industry. Focussing on the technology development for next generation electrical machines and electronic control units we achieve low weight, low manufacturing cost and high reliability.

Planthofsweg 79, 7601 PJ Almelo, The Netherlands +31 546 545 570 - info@aeronamic.com www.aeronamic.com


Have a news story or press release you would like to be considered for publication in the next Aviation Manufacturer Magazine? Please contact Martin Ashcroft at martin@aviationmanufacturer.com www.aviationmanufacturer.com


news Lightweighting and fuel efficiency drive high-performance plastics demand

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rost & Sullivan’s recent analysis of the High-Performance Plastics (HPPs) Market in Automotive and Aerospace Industries, Forecast to 2024 reveals that the increasingly popular trends for lightweighting, engine downsizing and vehicle electrification are expected to drive demand and adoption of HPPs in automotive and aerospace applications. Frost & Sullivan anticipates the automotive and aerospace HPP market to grow at a CAGR of 6.2% until 2024 and reach $3.05 billion. “The aerospace industry is likely to present significant opportunities for HPP owing to growing passenger traffic and business travel around the world,” said Soundarya Gowrishankar, senior research analyst, chemicals and materials, EIA at Frost & Sullivan. From a regional perspective, APAC will remain a key market for HPPs in the automotive industry, owing to the high volume of production in South East Asia, whereas the demand for HPPs in the aerospace industry will come from Europe and North America due to the concentration of component

manufacturing in these regions. Key trends creating growth opportunities in the market include: • Growing performance requirements across various applications are accelerating the adoption of composite-grade HPPs due to their superior performance qualities;

compel manufacturers to adopt lightweighting strategies, thereby steering the use of plastics in more challenging applications; and • HPPs offer advantages over metal counterparts in a number of challenging applications such as engine components, fuel tanks, and bearing cages.

“Electric vehicles present significant opportunities for HPPs in battery components” • Developments in 3D printing in terms of material, process and technology readiness are accelerating the demand for HPPs in aerospace applications with stakeholders across the value chain focusing on research and development activities to drive 3D printing applications in aerospace; • Tightening regulations around carbon dioxide emissions

“Electric vehicles present significant opportunities for HPPs in battery components,” added Gowrishankar. “For instance, battery modules, battery housing, gaskets, connectors and sensors present robust growth opportunities for HPPs owing to their high-temperature stability, chemical resistance to electrolytes, dimensional stability, flameretardant nature, high-voltage resistance, and electrical insulation properties.”

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Boeing freighters fly off the shelves at Farnborough

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oeing confirmed orders for 88 freighters at the 2018 Farnborough International Airshow from some of the leading air freight and cargo companies, including an agreement with GE Capital Aviation Services (GECAS) for 35 additional 737-800 Boeing Converted Freighters. Volga-Dnepr Group and UK subsidiary CargoLogicHolding signed a package of agreements, including a letter of intent to acquire 29 Boeing 777 Freighters and confirmation of an order for five Boeing 747-8 Freighters. International express carrier DHL placed an order and commitment for 14 Boeing 777 Freighters and Qatar Airways also finalized an order for five 777 Freighters at the show, in a deal initially announced as a commitment in April. The GECAS deal, which includes 20 firm orders and an option for 15 more, would take GECAS’ 737-800BCF order book from 15 to 50 and enable GECAS to serve the growing express air cargo market. The commercial aircraft leasing and financing arm of General Electric is the launch customer of the new 737-800BCF. It took delivery of the first converted jet in April and leased it to a Swedish cargo carrier. “This order and future commitment

with Boeing reflects the confidence GECAS has in the 737800BCF to replace and grow the narrow body freighter market,” said Richard Greener, senior vice president and manager GECAS Cargo Aircraft Group. Alexey Isaykin, president of Volga-Dnepr Group and chairman of CargoLogicHolding, was pleased with his purchases, too. “This is a very significant day in our company’s history,” he said. ”With this package of agreements, we will grow our business with the unique and unmatched 7478 Freighter and open new market opportunities with the 777 Freighter, the world’s longest range twin-engine cargo jet.” Qatar Airways, one of the world’s top cargo carriers, operates a fleet of 13 777 Freighters and two 747-8 Freighters. With this latest order, the airline is set to grow its Boeing Freighter fleet to more than 20 jets. DHL was the first express operator in 2009 to introduce the 777 to perform long-haul time critical services. The new order will double the size of DHL’s global 777 fleet. Airbus is not competitive in the cargo market, an issue which chief commercial officer Eric Schulz said must be addressed.

“We will grow our business with the unique and unmatched 747-8 Freighter and open new market opportunities with the 777 Freighter, the world’s longest range twin-engine cargo jet”

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news

Honda delivers first HondaJet Elite

H

onda Aircraft Company has begun deliveries of its new advanced aircraft, the HondaJet Elite, at its headquarters in Greensboro, North Carolina. “We are proud to announce that deliveries of the HondaJet Elite have begun,” said Honda Aircraft Company President and CEO Michimasa Fujino. “This milestone showcases Honda Aircraft’s steadfast commitment to setting new standards in business aviation and enthusiasm for remaining at the forefront of an evolving industry. “We are excited about the very positive worldwide reaction to the HondaJet Elite’s market entrance and are pleased

to announce that, most recently, more than 10 orders in Japan were placed following our expansion to the region

“This milestone showcases Honda Aircraft’s commitment to setting new standards in business aviation” in June. Deliveries in Japan will begin following receiving type certification

from the Japan Civil Aviation Bureau early next year.” During the first half of 2018, Honda Aircraft delivered 17 HondaJets to customers, making it the most delivered aircraft in its class. Honda introduced the new HondaJet Elite during the 2018 European Business Aviation Convention & Exhibition, held in Geneva, Switzerland in May this year. Honda says the HondaJet Elite offers the best fuel efficiency in its class as well as best-in-class speed, altitude and range. The aircraft is type certified by the United States Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA).

National Research Council of Canada renews agreement with Airbus

A

irbus and the National Research Council of Canada have renewed their framework agreement on research and technology cooperation. Airbus has been present in Canada for over 33 years and employs 2,000 Canadians. The company recently identified Canada as its “fifth country” for research and technology developments in the areas of drones

and urban mobility. The new five year agreement will cover a wide range of technical subjects and technologies. “We are extremely pleased to continue our fruitful cooperation with the NRC,” said Grazia Vittadini, chief technology officer, Airbus. This is a logical step after the first agreement we signed 10 years ago to work jointly on research and technology.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  47


news

Airbus wins orders for 431 commercial aircraft at Farnborough

A

irbus announced strong commercial aircraft business during the 2018 Farnborough International Airshow, with successes across its broad product portfolio – including the new A220 and A330neo families. Airbus came into the show with 177 single aisle and 84 widebody orders in 2018, complemented by a pre-show order for 60 A220-300s. During the show the company won further new business for 431 aircraft

(93 firm orders and 338 MoUs). These commitments comprise 60 A220-300s, 304 A320 Family aircraft, 42 A330neos and 25 A350 XWBs. Notably, the 42 commitments for the new A330neo include both the -800 and -900 models. Business to date for 2018 is now up to 752 aircraft (354 firm orders and 398 MoUs). Eric Schulz, Airbus chief commercial officer said: “Our year to date and our end of show commitments confirm the strong market appetite for all our

leading aircraft product families, from our newest member, the 100-150 seater A220, complemented by our A320 Family up to 240 seats, seamlessly connected to our widebody family with the all-new A330neo and A350 XWB which span from 250-370 seats. I am especially pleased about the strong response that our widebody family is enjoying. Over 150 orders and commitments for our A330/A350/ A380 offerings in 2018 are a strong endorsement.

Allegiant chooses Honeywell for APUs and maintenance

H

oneywell has been selected by Allegiant Air to provide maintenance, repair and overhaul services for its auxiliary power units and select avionics components across its fleet of new Airbus A319 and A320 aircraft. The five year agreement also includes the replacement of non-Honeywell auxiliary power units (APUs) with

Honeywell’s 131-9A version, ensuring commonality across the Allegiant fleet. “This strategic decision will increase the longevity of our aircraft and ensure our fleet is equipped to provide our passengers with a seamless travel experience from gate to gate,” said Scott Sheldon, executive vice president, chief operating officer and chief financial officer, Allegiant Air. “These upgrades

not only make maintaining our new fleet easier and more efficient, they also bring extra reliability to our aircraft. That translates to reduced delays and an overall better experience for passengers.” Honeywell claims its APU, the 1319A, delivers lower maintenance costs, enhanced reliability and annual fuel savings of $7,000 to $13,000 per aircraft.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  49


finishing is only the beginning TNM is specialized in surface finishing for the aviation industry and its goal is to provide their customers with “one stop shop”.TNM is a fully approved facility for Bombardier, Airbus and Boeing along with many other major OEMs and we’re in the process of also getting fully approved for Lockheed Martin. Our Mission “Our mission is to be amongst the elite processors for surface finishing. We are committed to providing superior value and service to our customers and sustained profitability to our stakeholders by investing in our people and services. At TNM “FINISHING IS ONLY THE BEGINNING”. Why TNM?

• Approvals for all Major OEMs • Capacity for small, medium and Large Parts • Various Type of treatments • Aggressive Lead Time • On Time Delivery, Quality and Services are guaranteed • Certified for ISO 9001, AS9100, NADCAP

TNM has been awarded as one of Top Shops in North America for a second consecutive year and are a finalist for the Gilles Demers 2016 Award attributed by the Québec aerospace community for being a leader in commitment to innovation, wealth creation and outreach and business development and internationalization.

21 Chemin de l’aviation, Pointe -Claire, QC, H9R 4Z2, Tel: (514) 429-7777 Fax : (514) 429 -5108 www.tnminc.ca General Manager, Michel Martel : 514-209-1024

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news Michelin Aircraft Tire to supply entire Cirrus Aircraft line

M

ichelin Aircraft Tire has been selected as the new original-equipment provider for Cirrus Aircraft, the renowned manufacturer of piston aircraft and maker of the world’s first single-engine personal jet, the Vision Jet. All Cirrus Aircraft will now be equipped with Michelin Air tires, including the recently developed Michelin Air tubeless sizes for Cirrus SR Series aircraft. Michelin introduced the world’s first radial aircraft tire in 1981. Today, Michelin manufactures a broad line of radial (Michelin Air X) and bias-ply (Michelin Air) aircraft tires for commercial, regional, military and general-aviation aircraft. The Michelin Air, a line of bias tires, is designed to blend performance and cost for piston, turbo-prop and jet applications. A wide range of sizes, both tubeless and tubed, are available to cover popular general-aviation fitments. Compared to bias-ply technology, the Michelin Air X provides the advantages of more landings per tread and measurable fuel savings. The radial tire offers a 20- to 30-per cent weight reduction over comparable bias tires, an extrastrong carcass to restrict tire expansion, an optimized tread design for cut resistance, customized rubber compounds for ozone and ultraviolet light protection and a flexible casing for smoother taxis, take-offs and landings that improve passenger comfort.

Magellan Aerospace signs purchase agreement with Pratt & Whitney

M

agellan Aerospace has signed a six year agreement with Pratt & Whitney to manufacture aluminium castings for its next generation product family of engines, which will power the Airbus A320neo, Airbus A220 (formerly Bombardier C-Series), Embraer E2 series and Mitsubishi MRJ aircraft. The castings will be produced at Magellan’s facilities in Haley, Ontario,

Canada and Glendale, Arizona, USA. The agreement is expected to generate approximately C$81 million in revenue for

Magellan through 2023. Haydn Martin, Magellan’s vice president, business development, marketing and contracts said the

company’s ability to dual source the castings between two manufacturing facilities in Canada and the US would significantly de-risk the supply chain, enhancing security of supply for Pratt & Whitney. He added that Magellan would utilize the latest in advanced sand casting technologies, specifically 3D sand printing and automated pouring to produce the components.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  51


A

s the dust settles after the 2018 Farnborough International Airshow, it’s worth reflecting that aviation is not defined entirely by the rivalry between Airbus and Boeing. The big two can always be relied upon to give us good headlines, of course, and this year Airbus contributed with the conclusion of its acquisition of Bombardier’s C-Series programme (just before the show opened), while Boeing played its part by announcing (a few days later) a proposed deal with Embraer, the world’s third largest producer of civil aircraft. Embraer’s Current Market Outlook

forecasts worldwide demand for 10,550 new aircraft with up to 150 seats, over the next 20 years, with roughly two thirds of that demand being driven by market growth, and one third by the need to replace ageing aircraft. The segment up to 150-seats is expected to form an ever more integral part of the global air transport eco system, and this, of course, is home turf for Embraer. On the first day of the show Embraer and United Airlines announced the signing of a firm order for 25 E175 jets in a 70-seat configuration. The contract has a value of US$1.1 billion, based on

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52

current list prices, and will be included in Embraer’s 2018 third-quarter backlog. Deliveries will begin in the second quarter of 2019. The following day Embraer announced that Brazilian airline Azul Linhas Aéreas Brasileiras had signed a letter of intent for a firm order of 21 E195-E2 jets, worth $1.4 billion. On the same day it was confirmed that Nordic Aviation Capital had committed to three E190 aircraft, valued at US$156 million according to Embraer’s list prices. The Azul order comes on top of an order for 30 E195-E2 jets signed by the airline in 2015, raising Azul’s total order


news Embraer sells E-Jets all over the world from Farnborough purchase rights for an additional 100 E175 aircraft. If all purchase rights are exercised, the contract has a value of up to $9.3 billion based on current list prices. Its subsidiary Republic Airline operates a fleet of around 190 Embraer 170/175 aircraft under its major airline

has a list price of $1.5 billion. The order will be included in Embraer’s backlog as soon as it becomes firm, which will happen in the coming months. The first 12 E190-E2 aircraft will begin replacing Helvetic’s seven E190s and five Fokker 100s, starting in late 2019 and completing in autumn 2021.

“Embraer’s Current Market Outlook forecasts worldwide demand for 10,550 new aircraft with up to 150 seats over the next 20 years, with roughly two thirds of that demand being driven by market growth, and one third by the need to replace ageing aircraft” to 51 Embraer E2 aircraft. Azul is the launch operator of the E195-E2 and will receive the first aircraft in 2019. The sale of home made jets in Brazil is not a great surprise, but in a deal that will see the Middle East’s first E2 operator, Kuwaiti airline Wataniya Airways signed a firm order for 10 E195-E2 aircraft with an option on a further ten. Deliveries will commence in 2020. Meanwhile Indianapolis-based Republic Airways, the world’s largest E-Jet operator, signed a letter of intent for a firm order of 100 E175, with the right to convert to E175-E2 aircraft, and

partner brands of American Eagle, Delta Connection and United Express, providing scheduled passenger services with approximately 950 daily flights to 100 cities in 40 US states, Canada, the Caribbean and Central America. The E175 is also entering the African market for the first time with a firm order from Mauritania Airlines for two E175 jets. Embraer jets can also been seen in the skies over Europe, with Zurich based Helvetic Airways the latest to sign a letter of intent for 12 E190-E2 and purchase rights for a further 12, with conversion rights to the E195-E2. If all purchase rights are exercised, the deal

The purchase options for a further 12 aircraft (E190-E2 or E195-E2) will enable Helvetic Airways to grow according to market opportunities. “Being entrusted with an airline’s entire fleet refreshment is a deep honour for Embraer, and an important endorsement of the service Helvetic has already received as a long term E-Jet customer,” said Martyn Holmes, Vice President Europe, Russia, Central Asia & Leasing, for Embraer Commercial Aviation. Helvetic’s plans to operate to London City Airport in the future received a boost when the E2 made its debut at the airport on 13th July.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  53


proven engineering capabilities TJW has been manufacturing precision metal components for the world’s most demanding markets since 1983. Using cutting edge technology and advanced engineering techniques to provide outstanding services all from locations Dursley, Gloucestershire and Stourbridge, West Midlands. TJW provides a “one-stop shop” for finished components for the aerospace, automotive, oil & gas, nuclear, medical, OEM and metrology industries.

TJW offers: • Flexible production quantities through • CNC Milling & Turning • Wire Erosion • Spark Erosion • CNC Waterjet cutting • Anodising (ABP1 1023 & Nylon Coating ABP1 4045)

*** TSA (AIPS 02 01 003) capability from January 2017 ***


news Gulf Coast Avionics completes upgrade to Cessna Citation

G

ulf Coast Avionics has completed a dual Garmin touchscreen and transponder installation in a 1997 Cessna Citation CJ2. “This installation is a fantastic example of how an owner can add significant operational, situational awareness and safety capabilities to a legacy business aircraft, without the significant cost and downtime of a total panel upgrade,” said Rick Garcia, President and CEO, Gulf Coast Avionics. “We were able to accomplish all that the owner wanted, including engineering and fabricating new pilot-side and centre instrument panels, on time and on budget.” “Working with the Jettech GTN STC, this was a straightforward upgrade to the Citation’s legacy analogue radios,” said Gulf Coast Avionics’ sales manager,

Matt Schloss. “Probably the biggest challenge was the integration of the new Garmin avionics with the Citation’s Honeywell EFIS displays and the analogue autopilot and weather radar. “The STC had all of the primary system integration instructions covered, but

with how the airplane turned out,” Garcia said. “He primarily flies it single-pilot and is very happy to have the added workload reducing and safety enhancing features that the new Garmin touchscreen avionics offer. This upgraded Citation will efficiently meet

“This installation is a fantastic example of how an owner can add significant operational, situational awareness and safety capabilities to a legacy business aircraft” every time you open up the panel of a 21-year old airplane, you may well be in for a surprise,” he said. “Fortunately, this Citation was in exceptional condition so there were just a few unexpected issues.” “The owner is extremely pleased

his travel needs for years to come.” Gulf Coast Avionics was appointed the first Garmin avionics dealer in 1990 and has received Garmin’s prestigious Platinum Award for leading sales for 28 consecutive years.

Electric airplane developer, Eviation, establishes US headquarters in Arizona

I

sraeli electric aircraft developer Eviation Aircraft is setting up its US headquarters in Prescott, Arizona. The site, adjacent to the Prescott Municipal Airport, will serve as Eviation’s base for its expansion into the US market. Eviation’s ambition is to make clean regional air travel accessible for all. Its 100% electric solution, the Alice Aircraft, is targeted to be test flown at the 53rd Paris Air Show in June 2019. It will feature an IP portfolio that includes thermal management and autonomous landing, as well as distributed electric propulsion, industry-leading battery

“The US represents a high-growth, near-term target market for us”

technology, and cutting-edge composite body frames capable of carrying up to nine passengers on a single charge for 650 miles. “As we develop our regional electric aircraft, the US represents a highgrowth, near-term target market for us, given its many regional transit corridors and abundance of approved airstrips,” said Omer Bar-Yohay, CEO of Eviation. “We’d like to express our thanks to the city of Prescott for its support in our goal to bring clean, efficient, and affordable transit solutions to the US and the world.”

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  55


Piloting Next-Gen Technologies for Complete Aircraft Design Solvay’s lightweight material solutions include carbon fiber, composites, polymer pellets, powders, films and foams for: • Maximized performance through innovative components’ design and function integration • Meeting industry ramp rates through high-volume automated processes • Reduced total cost of ownership

www.solvay.com

Airframe

Electrical, Air and Fluid Systems

Interior Propulsion


news

A

Alliance Magnesium receives $30.9 million in financing

lliance Magnesium has signed a financing agreement with Investissement Québec and the Government of Quebec’s Economic Development Fund in the amount of $30.9 million, for the construction of its first commercial phase at its facility in Danville, Quebec. The investment is part of a $104.9 million financial package which includes other institutional partners. The financing is in the form of a $17.5 million loan and a $13.4 million equity interest. “We are delighted to have the Government of Quebec as a major partner in the commercialization phase of our project,” said Dr. Joël Fournier, president of AMI. “The metal produced by AMI will have a low carbon footprint and will be used in the production of parts for the automotive and aerospace industries.”

After a successful piloting phase, this first commercial phase will enable AMI to start commercial production of both primary and secondary magnesium totalling 11,700 tons per annum and sell its products in the North American and European markets. Alliance Magnesium has developed an innovative technology and process that gives it a cleaner and less expensive approach than those currently used by magnesium producers around the world. The magnesium produced by AMI is sold to the automotive and aerospace industries to reduce their products’ weight. Construction of the first commercial phase will begin in the fall of 2018 and will be completed by the end of 2019.

“The metal produced by AMI will have a low carbon footprint and will be used in the production of parts for the automotive and aerospace industries”

S

SL, a Maxar Technologies company, has been selected by NASA to perform a study exploring the use of commercial habitats in space as satellite manufacturing facilities. In support of NASA’s vision of a vibrant space economy, SSL will study the feasibility of habitable space platforms for building commercial satellites. Transferring spacecraft manufacturing to space

NASA selects SSL to explore commercial satellite assembly in space eliminates the constraints of launch vehicle volumes and schedules and the need for spacecraft to withstand the harsh conditions of launch. It allows for more simple and capable system designs that can be fielded more rapidly and economically.

“Today’s focus on commercial activity in space is undoubtedly accelerating innovation,” said Richard White, president of SSL Government Systems. “At SSL, we work closely with NASA to explore

concepts that implement next-generation business models to stimulate private demand for commercial human spaceflight. Bringing commercial and government innovation together will be a powerful driver of capabilities.”

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World’s biggest equine airlift for FEI World Equestrian Games Tryon 2018

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he largest commercial airlift of horses ever undertaken in the history of equestrian sport is underway for the FEI World Equestrian Games Tryon 2018, being held in North Carolina in September. A total of 550 horses will be flown from all over the world to join another 270 travelling overland to the Games at the Tryon International Equestrian Center. Specialist horse transportation company Peden Bloodstock, working alongside The Dutta Corp, has coordinated the highly complex logistics, with horses from six continents flying into Greenville-Spartanburg International Airport (GSP) in South Carolina and Miami, Florida. “This is the largest commercial airlift

“This is the largest commercial airlift of horses in history, so the military precision involved in the logistics is incredible” of horses in history, with only wartime shipments of horses coming close, so the military precision involved in the logistics is incredible,” said FEI President Ingmar De Vos. “These horses are finelytuned equine athletes and are not only

very valuable, but they must arrive in peak competition condition, just like their human counterparts.” The horses are flying on specially designed Boeing 777 freighter aircraft in customised stalls, with independently air conditioned zones maintaining the perfect temperature. The FEI (Fédération Equestre Internationale) World Equestrian Games Tryon 2018 will see human and equine athletes compete from 11-23 September for 29 medals in the Olympic disciplines of eventing, jumping and dressage, the paralympic sport of paradressage, alongside driving, endurance, reining and vaulting. The Games also offer qualifying slots for the Tokyo 2020 Olympic and Paralympic Games.

United Technologies acquires analytics specialist Predikto

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nited Technologies Corp has acquired Predikto, Inc, an Atlantabased predictive analytics software company known for its cloud-based predictive maintenance solution, which enables customers to forecast and improve asset reliability. “Data is the lifeblood of any digital strategy and actionable data is the way forward as we deliver real customer value,” said Vince Campisi, chief digital

officer for United Technologies. “By harnessing the best of our combined predictive analytics skillsets, we can better connect all critical assets, understand the reliability and health of our products and ultimately deliver an improved customer experience. Predikto’s capabilities will help us scale these efforts across United Technologies’ businesses with speed.” Predikto recently completed several

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pilots with Pratt & Whitney specifically focused on commercial engines using pre-existing data. Together, as a complement to Pratt & Whitney’s existing physics-based models, the models generated by Predikto identified factors related to unplanned engine events. These insights will increase the predictability of future issues and inform the development of key product improvements.


news UTC Aerospace Systems invests in wheel and brake MRO facilities

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TC Aerospace Systems is making critical investments in its global MRO infrastructure. In London, the company recently relocated to a new 50,000 square foot facility that is 50 per cent larger than the previous site. The London Service Centre is one of six that UTC Aerospace Systems’ wheel

that it had doubled the size of its Hong Kong wheel and brake MRO facility, moving to a new, 66,000 square foot location. The Hong Kong facility serves as the UTC Aerospace Systems’ hub for wheel and brake MRO support across the Asia Pacific region. “We are investing in the growth and capability of our MRO service centre

“We are investing in the growth and capability of our MRO service centre network to ensure we are ready for the expanding fleet of aircraft that operate with our wheels and brakes” and brake division maintains around the world, and it serves as the hub for wheel and brake MRO support across Europe, the Middle East and Africa. On average, the London centre services 14,000 wheels annually, along with 5,000 heat sinks and 2,500 brakes, for more than 60 airline customers. The company previously announced

network to ensure we are ready for the expanding fleet of aircraft that operate with our wheels and brakes,” said UTC Aerospace Systems Landing Systems President Jim Wharton. “This is in addition to the large investments we made over the past several years to expand our carbon brake disk manufacturing capacity.”

During the recent Farnborough International Airshow UTC Aerospace systems announced that it had exceeded $565 million in new commercial wheel and brake business since the beginning of 2018, encompassing more than 875 firm scheduled aircraft deliveries across 15 airlines, including multiple Boeing and Airbus platforms.

Spirit AeroSystems to build new R&D complex in Scotland

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pirit AeroSystems has announced the creation of a new research and development complex at its manufacturing site in Prestwick, Scotland. Innovation efforts will focus on infusion processes for composites materials, part handling, assembly automation, rapid prototyping and virtual/augmented reality. “The new facility will further enable our growth for industryleading aerospace technologies and innovations,” said Spirit president and

CEO Tom Gentile. “The next generation of aircraft doesn’t exist yet, and that’s what we’re concentrating on. Our engineers are inventing the future of flight. The new centre will include a training area and will grow the company’s research and development footprint in Prestwick from approximately 8,000 square feet to 70,000 square feet. Construction will begin later this year, and the company expects to celebrate a grand opening in 2019.

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news

Airbus reports half-year 2018 financial results

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eporting its half-year results for the period ending 30 June 2018, Airbus maintained its guidance for the full year. Consolidated revenues were stable at €25.0 billion (H1 2017: € 25.2 billion). Deliveries totalled 303 commercial aircraft (H1 2017: 306 aircraft), comprising 239 A320 Family, 18 A330s, 40 A350 XWBs and six A380s. “The first half financials reflect the back-loaded deliveries due to A320neo engine shortages, while on the positive side there was a strong improvement on the A350 programme,” said Airbus Chief Executive Officer Tom Enders. “A320neo aircraft deliveries picked up during the second quarter but challenges remain to meet our full year targets. Market demand remains strong for the expanded Airbus portfolio that

“Market demand remains strong for the expanded Airbus portfolio that now includes the A220 at the smaller end.

now includes the A220 at the smaller end.” Airbus has set a target to deliver around 800 commercial aircraft in 2018, without the A220 family. The number of A320neo aircraft ‘parked’ in Toulouse without engines is said to have come down from over 100 to around 80, but the Airbus statement said, “risks remain to meet the 800 aircraft delivery target, which is challenging.” On the A350 programme, the first A350-1000s were delivered to Qatar Airways and Cathay Pacific in the halfyear. During July’s Farnborough Airshow, Airbus announced orders and commitments for a total of 431 aircraft, although these are not yet reflected in the order book. Net helicopter orders totalled 143 units (H1 2017: 151 units).

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news Brazilian airline GOL commits to Boeing 737 MAX

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razilian carrier GOL is adding the newest and largest member of the 737 MAX family with a new contract that converts 30 current MAX orders to the 737 MAX 10. GOL also placed a new order for 15 more MAX 8 airplanes, growing GOL’s total MAX orders to 135. The Brazilian airline says the advanced airplanes will help GOL meet its commitment to further enhance operational efficiency. “This new order aligns with our strategic policy of reducing operating costs by operating a standardized fleet,” said CEO Paulo Kakinoff. “We are confident that the 737 MAX 10 will offer significant competitive advantages for GOL and enable us to continue to modernize with new aircraft. This airplane will allow us to continue lowering the cost of air travel across Brazil, as well as support a larger network, allowing us to add new destinations.” A 737 MAX 10 will enable GOL to comfortably serve more than 30 additional passengers compared to its 737 MAX 8, which seats up to 186 passengers in the airline’s configuration.

“Increased seat capacity per aircraft not only reduces the costs of providing passenger transportation, but also improves our ability to distribute passengers within our large domestic and

“This new order aligns with our strategic policy of reducing operating costs by operating a standardized fleet” growing international flight networks,” said Kakinoff. GOL took delivery of its first 737 MAX airplane in June, kicking off a fleet renewal that will continue through 2028. The all-Boeing operator is set to be the largest MAX operator in Latin America.

Boeing to acquire Millennium Space Systems B

oeing is expanding its satellite and space portfolio with the acquisition of Millennium Space Systems, a provider of agile, flightproven small satellite technologies. “Millennium Space Systems’ expertise in vertically-integrated small-satellite solutions perfectly complements Boeing’s existing satellite portfolio, and will allow us to meet the needs of a diverse customer set,” said Leanne Caret, president and CEO of Boeing Defense, Space & Security. “We look forward to incorporating Millennium Space Systems’ end-to-end mission solution

capabilities into our service offerings in satellite operations and data solutions.” Millennium Space Systems was founded in 2001 and is based in El Segundo, California. With approximately 260 employees, the company has developed high-performance satellites

for exacting missions ranging from 50kg to more than 6,000kg. “I am proud of the talented and dedicated team we’ve built at Millennium Space Systems over the past 17 years,” said CEO Stan Dubyn. “By combining our tools, talent, technologies and culture, we’ll be able to do even more incredible things as part of Boeing.” The acquisition is expected to close by the end of Q3 2018. Millennium Space Systems will become a Boeing subsidiary, operating under its current business model and reporting to Mark Cherry, vice president and general manager of Phantom Works.

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bae systems

aviation innovation

BAE Systems is the UK’s major defence, aerospace and security company, and the country’s largest manufacturer. Involved in some of the biggest and most technically advanced engineering and manufacturing projects in the world, the company is recognised for its relentless pursuit of innovation.

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BAE systems aviation innovation

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n common with all the other ‘majors’ in the industry, BAE Systems is the result of a huge consolidation in aerospace and defence in recent times. Formed on 30 November 1999 by the merger of British Aerospace (BAe) and Marconi Electronic Systems, BAE Systems is the successor to some of the most famous British aircraft, defence electronics and warship manufacturers. Predecessors of BAE Systems built the Comet, the world’s first commercial jet airliner; the Harrier ‘jump jet’, the world’s first operational vertical/short take-off and landing (VTOL) aircraft and co-produced the iconic Concorde supersonic airliner. In the aerospace sector the company is currently involved in the design, manufacture, upgrade and support of combat and trainer aircraft for customers around the world. It also supplies electronics equipment across a range of military and commercial aircraft and is helping to develop the next-generation of unmanned air systems. BAE Systems has world leading capabilities in prime contracting, systems integration, rapid engineering, manufacturing, maintenance, repair and upgrade, as well as military training for

advanced combat and trainer aircraft. It is a global operation, with a skilled workforce of over 80,000 people in 40 countries, but it purchases many of the goods and services it needs in the domestic market, supporting significant economic activity and employment across the UK. In 2016, BAE Systems spent £4 billion on inputs from some 8,900 suppliers in the UK, representing 79 per cent of its total procurement.

Eurofighter Typhoon

Major defence projects are rarely undertaken by a single entity (or even country) these days. As Europe’s largest collaborative defence programme, the Eurofighter Typhoon is an example of what can be achieved through a global partnership of allies, in this case Italy, Germany, Spain and the United Kingdom, through a consortium consisting of Leonardo, Airbus Defence and Space and BAE Systems. Each member has a production line for the assembly of its own national aircraft, but also specialises in the production of specific parts for the whole programme. Leonardo builds the left wing, outboard flaperons and rear fuselage sections, Premium AEROTEC builds the main centre fuselage, EADS CASA the right

wing and leading edge slats. BAE Systems takes responsibility for the front fuselage, canopy, dorsal spine, tail fin and inboard flaperons. Eurofighter Typhoon is an advanced multi-role combat aircraft. In service since 2003, more than 500 Eurofighter Typhoon aircraft have since been delivered to seven countries: Germany, United Kingdom, Italy, Spain, Austria, Oman and Saudi Arabia; and ordered by two more: Kuwait and Qatar. In December last year, BAE Systems and the Government of the State of Qatar entered into a £5 billion contract for the supply of 24 Typhoon aircraft to the Qatar Emiri Air Force, along with a bespoke support and training package. Delivery is expected to commence in late 2022. BAE Systems is the prime contractor for both the provision of the aircraft and the agreed arrangements for the in-service support and initial training. BAE Systems and its partner companies continue to upgrade the capabilities of Eurofighter Typhoon through a series of phased enhancements, ensuring the aircraft evolves to meet operational demand. Delivered in 2014, the Phase 1 Enhancement (P1E) package saw the

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platform become a high-end multi-role weapon system, with air-to-air capability including ASRAAM (Advanced Short Range Air-to-Air Missile) and AMRAAM (Advanced Medium-Range Air-to-Air Missile) and the integration of Paveway IV for precision air-tosurface operations. Phase 2 Enhancement (P2E) will bring a range of new, long-range capabilities, and P3E will introduce a low collateral, high precision strike capability through integration of the Brimstone air-tosurface weapon, giving a precision effect with low collateral damage against fastmoving armoured targets. In August 2016 BAE Systems commenced a 10 year partnership agreement with the UK Ministry of Defence to transform support of the UK Typhoon fleet. The Typhoon Total Availability eNterprise (TyTAN) arrangement introduced new ways of working to further reduce the costs of operating the fleet at RAF Coningsby and RAF Lossiemouth by more than a third. The arrangements will enable an estimated £500 million of savings to be reinvested to develop new capability enhancements for the aircraft.

F-35

F-35 is the world’s largest defence programme. Led by the US, with participation from the UK, Italy, Netherlands, Australia, Canada, Denmark, Norway and Turkey, it is a truly collaborative programme aimed at delivering a stealthy, multi-role attack aircraft capable of operating from land and sea. BAE Systems brings its military aircraft expertise to the development, manufacture, integration and sustainment of the F-35 along with its partners Lockheed Martin, the programme’s prime contractor, and Northrop Grumman. The programme will deliver three variants of the aircraft, the conventional take off and landing (CTOL), the carrier variant (CV) and the short take off and vertical landing (STOVL), to meet customers’ individual needs. BAE Systems holds a 13-15% work share of each aircraft, excluding propulsion, bringing decades of experience in short take-off and vertical landing from its Harrier aircraft. It is also the lead design authority on crucial capabilities including the fuel system, crew escape and life support system, and the company conducts durability testing at its unique structural testing facility

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BAE systems aviation innovation in East Yorkshire, while its engineering teams work alongside its partners on flight testing and weapons integration work for the UK. When it reaches peak production, the programme will be worth some £1 billion to UK industry alone, with an estimated 25,000 UK jobs sustained across more than 500 companies in the supply chain. The aft fuselage and vertical and horizontal tails - effectively the rear section - of every F-35 are built at BAE Systems’ state of the art advanced manufacturing and assembly facilities in Lancashire, UK, and Adelaide, Australia. These facilities use purpose-built robotic technology to manufacture the component parts from both titanium and aluminium, with the majority delivered from the UK and the vertical tail sections for the F-35 CTOL variants produced in Australia. Over recent years, BAE Systems has invested over £150 million in new facilities and equipment to ensure it can meet the demands of the F35 programme. The integrated assembly line, or ‘Pulse line’ as it’s often referred to, has undergone a gradual expansion to gear up for the demanding rates of the programme. In November last year, a full scale durability test airframe of the F-35A aircraft successfully completed its third life testing, equivalent to 24,000 hours of ‘flying’, in a unique testing facility at BAE Systems’ site in Brough, East Yorkshire. The airframe, known as AJ-1, is representative of the F-35A conventional take-off and landing (CTOL) variant of the jet. This test rig is the only one of its kind in the United Kingdom and has supported the testing of AJ-1 since it arrived in Brough in 2009. It is fitted with more than 20 miles of wiring, 2,500 strain gauges and 160 loading actuators which are attached to the airframe during testing. The role of BAE Systems does not stop at the airframe, however, as it also delivers key systems and electronics onboard the jets. BAE Systems is a world leader in electronic warfare capability and its engineers in New Hampshire and Texas in the US provide the electronic warfare suite for the F-35, which includes fully integrated radar warning,

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“BAE Systems brings its military aircraft expertise to the development, manufacture, integration and sustainment of the F-35 along with its partners Lockheed Martin, the programme’s prime contractor, and Northrop Grumman”

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BAE systems aviation innovation

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targeting support and self-protection, to detect and defeat surface and airborne threats. To date, only around five per cent of the anticipated F-35 fleet is currently in service, but as the fleet grows, so will the need for spares and repairs, technical support and training. BAE Systems is part of the emerging global sustainment network being set up to support the growing F-35 fleet. The UK will be a significant repair hub for maintenance, repair, overhaul & upgrade (MRO&U) services for F-35 avionics and aircraft components. It will carry out this work as part of a team alongside the Defence Electronics and Components Agency and Northrop Grumman, operating out of the DECA site at RAF Sealand from 2018. BAE Systems is also part of a programme which will deliver engineering and training facilities at RAF Marham in Norfolk in preparation for the arrival of the RAF’s F-35 Lightning II fleet in 2018.

The BAE Systems team in Australia will be responsible for airframe MRO&U of the F-35 fleet in the Southern Pacific region. Forming an important part of the global sustainment capability for the fleet, its depot in Williamtown, New South Wales, will support all F-35 aircraft operating in the region from 2018. Like the UK, Australia will be a significant repair hub for MRO&U services for F-35 avionics and aircraft components, acting as lead provider of these services alongside its industry partners.

Tornado GR4

Tornado has been a vital part of air forces from the day it went into service nearly 40 years ago, and has thrived and survived through a combination of upgrade packages and capability improvements. The aircraft was conceived in the late 1960s, flew for the first time in 1974 and entered service in 1979. Built by Panavia Aircraft GmbH, a consortium between the UK, Germany

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and Italy, the Tornado is a formidable aircraft that is renowned for its ability to operate in any weather conditions, at low level, and at any time of the day or night. When the initial agreement was set up, the companies involved were the British Aircraft Corporation (which later became British Aerospace and is now BAE Systems), MBB in Germany (now part of Airbus SE) and Aeritalia (now part of Leonardo) in Italy. With a maximum speed of 1.3 Mach and an expansive range of integrated weaponry including Paveway IV, Tornado is still a frontline aircraft. As well as being in service for the three partner nations who developed Tornado, it is also in use by the Royal Saudi Air Force. The latest incarnation, Tornado GR4, is a highly capable frontline aircraft, iconic for its impressive swing role capabilities. In 2014, BAE Systems signed a £125 million extension to its contract with the Ministry of Defence to maintain Britain’s fleet of Tornados until they are


BAE systems aviation innovation retired in 2019. Following the withdrawal of the RAF’s Tornado F3 fleet from service in 2010, BAE Systems created the Reduce to Produce programme in which a team based at RAF Leeming in North Yorkshire strips down the decommissioned F3 fleet and recycles parts that can be used as spares for the GR4 fleet. The scheme was designed to help cut costs on support for the Tornado Squadrons while still maintaining a fully comprehensive spares supply chain for the aircraft. It has been a resounding success since its introduction with the teams able to recover between 800-1200 parts per airframe, creating a huge saving for the RAF.

Hawk Trainer

The BAE Systems Hawk is a singleengine, jet-powered advanced trainer aircraft. It was first flown in 1974 as the Hawker Siddeley Hawk, and subsequently produced by its successor companies, British Aerospace and BAE Systems, respectively. With an unrivalled pedigree of delivering the pilots of the future for air forces across

the globe, Hawk is the world’s most successful military aircraft trainer - with operational capability. Outperforming and outselling other aircraft in its class, its advanced airborne simulation technology and new generation cockpit environment provides a smoother and more cost effective transition to the front line, allowing for student pilot and weapons system officer output at the most appropriate skill levels in readiness for front line operations. The most famous users of the Hawk are the Red Arrows aerobatic team, who adopted the plane in 1979. The Hawk has seen many variants since then, but in May 2015, Indian aerospace manufacturer Hindustan Aeronautics Limited (HAL), which was already building Hawks under licence, announced an interest in carrying out its own Hawk upgrades, including armed light attack variants. The latest concept, an Advanced Hawk, is now being developed by a joint venture of BAE Systems and Hindustan Aeronautics. A single example of the aircraft was unveiled at Aero India 2017 and flew for the first time in June 2017 at

BAE Systems military facility in Warton, Lancashire. Equipped with a new type of pilot display, a redesigned wing and defensive aids, the Advanced Hawk will meet market requirements for the next generation of fast jet training aircraft. While the existing Hawk continues to be the world’s most successful jet trainer, the Advanced Hawk concept demonstrator builds on these proven successes. The concept demonstrator features an upgraded cockpit equipped with BAE Systems’ LiteHUD® (a lowprofile head-up display) and a new, large area display that introduces a new student/pilot training experience. It also features a redesigned wing that increases performance in areas such as turn rates, angles of attack and both take-off and landing. “The successful first flight of the Advanced Hawk concept demonstrator is the latest step in the aircraft’s development and marks a significant milestone in Hawk’s capability upgrade,” said Steve Timms, Managing Director Defence Information, Training & Services at BAE Systems. “We already have the world’s leading advanced jet trainer and the new features in

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“The most famous users of the Hawk are the Red Arrows aerobatic team, who adopted the plane in 1979”

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Advanced Hawk have been developed after listening to our customers’ views on where fast jet pilot training will go in the future and how we ensure the Hawk continues to meet their requirements. “By using this demonstrator aircraft we have highlighted to existing users of Hawk that many of the proposed features of an Advanced Hawk, such as the large area display and new wing, could be achievable as upgrades.”

Taranis

Named after the Celtic god of thunder, Taranis is an advanced technology unmanned combat aircraft system. The Taranis demonstrator is the result of one-and-a-half-million man hours of work by the UK’s leading scientists, aerodynamicists and systems engineers from 250 UK companies. The aircraft was designed to demonstrate the UK’s ability to create an unmanned air system which, under the control of a human operator, is capable of undertaking sustained surveillance, marking targets, gathering intelligence, deterring adversaries and carrying out strikes in hostile territory. The findings from the aircraft’s test flights show that the UK has developed a significant lead in understanding unmanned aircraft which could strike with precision over a long range whilst remaining undetected. The technological advances made through Taranis will also help the UK MOD and Royal Air Force make decisions on the future mix of manned and unmanned

fast jet aircraft and how they will operate together in a safe and effective manner for the UK’s defences. Costing £185 million and funded jointly by the UK MOD and UK industry, the Taranis demonstrator aircraft was formally unveiled in July 2010. Initial ‘power-up’ or ground testing commenced later in 2010 at BAE Systems’ military aircraft factory in Warton, Lancashire. Taranis has now undergone a series of successful flight trials and the team continues to develop the aircraft’s capability. About the size of a BAE Systems Hawk aircraft, Taranis has been designed and built by BAE Systems, Rolls-Royce, the Systems division of GE Aviation (formerly Smiths Aerospace) and QinetiQ, working alongside UK MOD military staff and scientists. In addition to prime contracting the project, BAE Systems led on many elements of the Taranis technology demonstrator, including the low observability, systems integration, control infrastructure and full autonomy elements (in partnership with QinetiQ). In addition to the existing industry partners, the project also works with a significant number of other UK suppliers who provide supporting technology and components.

Adaptable UAVs

Within the next few decades, armed forces could be using unmanned aerial vehicles (UAVs) with adaptable aircraft technologies that alternate between

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fixed-wing flight and rotary-wing flight. Engineers from BAE Systems together with students from Cranfield University, have revealed a new technology concept – named Adaptable UAVs – which can alternate between the two different flight modes in the same mission. When in rotary wing mode the UAVs can be launched and recovered from battlefields and docked on a special pole. The Adaptable UAVs are a hybrid between fixed- and rotary-wing aircraft, and would use adaptive flight control and advanced navigation and guidance software, which would allow the aircraft to benefit from the greater speed and range afforded to fixed-wing aircraft, before alternating to rotary-wing mode to hover and achieve vertical take-off and landing. The pole constrains the lateral or sideways movement of the UAV when being launched or recovered so strong winds cannot dislodge them. This is particularly important when recovering a UAV to the aft of a ship or a land vehicle. The pole’s gyro-stabilised element also ensures that it remains upright independently of the host vehicle’s orientation, which may be rolling if on a ship, or in the case of a land vehicle driving up or down a slope at the time of the launch or recovery. “The battlefield of the future will require novel solutions to meet emerging threats and to keep human operators safe wherever they may be,” said Professor Nick Colosimo, BAE Systems’ futurist and technologist. “The Adaptable UAVs concept and related


BAE systems aviation innovation technologies are one of a number of concepts being explored through close collaboration between industry and students in academia.” Cranfield University is one of BAE Systems strategic university partners. Research staff and students have explored a range of UAV technologies including research into adaptive flight control and advanced navigation and guidance software. “Working with BAE Systems on the Cranfield University MSc in Autonomous Vehicle Dynamics & Control has provided a great opportunity for the students and research staff to explore a range of novel concepts and technologies,” said Professor Antonios Tsourdos, head of the Centre for Autonomous and CyberPhysical Systems at Cranfield University.

MAGMA

BAE Systems has developed some of the world’s most innovative technologies and continues to invest in research and development to generate future products and capabilities. Another of its university partners is The University of Manchester with whom it is exploring some unique flight control technology.

MAGMA is a small scale unmanned aerial vehicle which will use a unique blown-air system to manoeuvre the aircraft - paving the way for future stealthier aircraft designs. The first phase of flight trials has been successfully completed. The new concept for aircraft control removes the conventional need for complex, mechanical moving parts to move flaps to control the aircraft during flight. This could give greater control as well as reduce weight and maintenance costs, allowing for lighter, stealthier, faster and more efficient military and civil aircraft in the future. The two technologies to be trialled first using the jet-powered UAV, MAGMA, are: • Wing circulation control, which takes air from the aircraft engine and blows it supersonically through the trailing edge of the wing to provide control for the aircraft. • Fluidic thrust vectoring, which uses blown air to deflect the exhaust, allowing for the direction of the aircraft to be changed. The flight trials are part of an ongoing project between the two organisations and wider long-term collaboration

between industry, academia and government to explore and develop innovative flight control technology. Further flight trials are planned for the coming months to demonstrate the novel flight control technologies with the ultimate aim of flying the aircraft without any moving control surfaces or fins. If successful, the tests will demonstrate the first ever use of such circulation control in flight on a gas turbine aircraft. “The technologies we are developing with The University of Manchester will make it possible to design cheaper, higher performance, next generation aircraft,” said Clyde Warsop, engineering fellow at BAE Systems. “Our investment in research and development drives continued technological improvements in our advanced military aircraft, helping to ensure UK aerospace remains at the forefront of the industry and that we retain the right skills to design and build the aircraft of the future.”

Cyber defence

Another recent initiative is the development of cyber defence capabilities to help aircraft detect and mitigate cyber attacks in real time. The new capabilities — including system

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BAE systems aviation innovation

analysis, reverse engineering, and intrusion detection — will build upon the company’s state-of-the-art threat management solutions and help protect war fighters and aircraft from a variety of cyber threats. While future platforms are designed with cyber security in mind, this was not always the case with the current fleet of military aircraft, which may be vulnerable to cyber attacks. These platforms were developed to be in service for decades and need periodic upgrades. They are complex systems packed with processors, computers,

networks and data links, creating an interconnected digital environment that may expose war fighters to cyber threats. These cyber defence capabilities expand the company’s threat management portfolio, including the recently announced 3-Dimensional Advanced Warning System (3DAWS) product suite, which is designed to protect aircraft from firstencounter kinetic threats with layered countermeasures. Innovation is a key focus at BAE Systems, as witnessed by an R&D spend of £1 billion in 2016 and £4.4

billion in the past five years. Whether in collaboration with world class partners from allied countries, building aircraft and systems for our mutual defence, or researching with leading UK universities in areas such as UAVs, novel materials, advanced manufacturing or artificial intelligence, BAE Systems is firmly at the centre of aviation innovation.

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Lockheed Martin is a global security and aerospace company engaged in the research, design, development, manufacture, integration and sustainment of advanced technology systems, including missiles, rockets, space vehicles and communications systems. It is the suite of military aircraft, however, that captures the imagination, and none more so than the latest jet, the ultimate fighter, the F-35.   Aviation Manufacturer Magazine www.aviationmanufacturer.com  81


L

ockheed Corporation and Martin Marietta, two distinguished aerospace companies with origins in California over 100 years ago, combined in March 1995 in “a merger of equals” to form Lockheed Martin. Now headquartered in Bethesda, Maryland, the company has become one of the world’s major aerospace, defense, security and advanced technologies companies. Its list of legendary products includes the C-130 Hercules and F-16 Fighting Falcon (Lockheed) and the Space Shuttle External Tank and Viking 1 and 2 Mars landing craft (Martin Marietta).

The majority of Lockheed Martin’s business is with the US Department of Defense and US federal government agencies. Sikorsky (a Lockheed Martin company) provides military and rotarywing aircraft to all five branches of the US armed forces along with military services and commercial operation in 40 countries. The remaining portion of Lockheed Martin’s business comprises international government and commercial sales of products, services and platforms. Lockheed Martin’s operating units are organized into four broad business areas, aeronautics, missiles and fire control, rotary and mission systems, and space. Lockheed Martin Aeronautics, home of the world renowned Skunk Works, has been designing, building and sustaining the finest military aircraft in the world for more than 100 years. The business unit is headquartered in Fort Worth, Texas, with additional production and operations facilities in Clarksburg, West Virginia; Greenville, South Carolina, Johnstown, Pennsylvania; Marietta, Georgia;

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Meridian, Mississippi; Palmdale, California; and Pinellas Park, Florida. Lockheed Martin Missiles and Fire Control (MFC) is a recognized designer, developer and manufacturer of precision engagement systems for the US and allied militaries, including missiles, rockets, manned and unmanned systems. Lockheed Martin Rotary and Mission Systems provides surface, air and undersea applications for US military as well as intelligence, civil, commercial and international military customers. Its portfolio features more than 1,000 programs, including helicopters, integrated air and missile defense, undersea warfare, radar, electronic warfare, cyber solutions and training and logistics systems. Lockheed Martin Space Systems is developing advanced capabilities to usher in a new era of exploration, traveling deeper into space than ever before, where greater discoveries await and where future generations will be inspired. Lockheed Martin is developing a variety of spacecraft that


lockheed martin redesigning flight will explore planets and asteroids in our solar system. These capabilities will help scientists and researchers gain new insights about the solar system, universe, Earth and life origins.

Aircraft legacy

Lockheed Martin’s aircraft leadership is earned through relentless research and development of high-performance combat, air mobility and reconnaissance and surveillance aircraft, the continuous search for innovative, low-cost design and manufacturing strategies and the provision of world-class training, focused logistics support and advanced targeting and navigation technologies. Lockheed Martin puts everything together to create an integrated system of systems where the value of the whole is greater than sum of its parts. The F-35 brings advanced technology to every stage of the aircraft life cycle. From production techniques to testing methodologies and from pilot and maintainer training to sustaining the global fleet, the Lightning II is the culmination of decades of experience in fighter technology. We’ll talk in detail about all that in due course, but let’s first give it some

perspective by looking at a few of the achievements and landmarks of the first 100 years. Conceived in 1943, the Skunk Works division—a name inspired by the comic strip Li’L Abner—was formed by Lockheed’s chief engineer, Clarence ‘Kelly’ Johnson, to build America’s first jet fighter to combat German jets in Europe. Creating a blueprint for future Skunk Works projects, the mission was secretive and the deadline was remarkably tight. Johnson promised a prototype in 150 days, but his engineers turned it out in 143 days, creating the P-80 Shooting Star, a sleek, lightningfast fighter that went on to win history’s first jet-versus-jet dogfight over Korea in 1950. Just four years later, amidst growing fears over a potential Soviet missile attack on the United States, Skunk Works engineers created the U-2, the world’s first dedicated spy plane. It cruised at 70,000 feet, snapping aerial photographs of Soviet installations. This vital reconnaissance, unobtainable by other means, averted a war in Europe and a nuclear crisis in Cuba. But high altitude was not enough. By 1960, Soviet radar and surface-to-

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“During Operation Desert Storm, more missions were flown by F-16s than any other aircraft”

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air missile technology had caught up with the U-2. President Eisenhower needed something quicker, stronger, and more elusive. Using sheets of titanium coated with heat-dissipating black paint, engineers created the SR-71 Blackbird. On 3 July 1963, the plane reached a sustained speed of Mach 3 at an astounding 78,000 feet, and remains the world’s fastest and highest-flying manned aircraft. Though lightning-fast, the Blackbird was not invisible. By 1973, Pentagon officials were calling for the creation of an attack aircraft that could fly undetected past enemy radar. Building on obscure research that showed radar beams could be diverted by angled triangular panels, the Skunk Works team designed the F-117 Nighthawk. Unusual looking and aerodynamically challenged, the Nighthawk wasn’t pretty, but it did what no aircraft had done before. Slipping past Iraqi radar on the morning of 17 January 1991, Lockheed’s Nighthawk bombed thirty-seven critical targets across Baghdad, a surgical strike that led, in just forty-three days, to the

successful conclusion of Operation Desert Storm. Another veteran of Desert Storm is the F-16 Fighting Falcon, originally conceived in the early 1970s as an alternative to fighter aircraft that had grown increasingly heavy and hard to manoeuvre. A team at the aerospace division of General Dynamics in Fort Worth, Texas (which Lockheed would acquire in 1993) set out to trade excess weight and heavy payloads for speed and manoeuvrability, to develop a simple, inexpensive fighter that would fly so fast and turn so quickly that adversaries would be unable to strike it with either missiles or machine gun fire. Beginning in 1975, the F-16 design team translated those ideas into the most advanced combat aircraft of its day, leaning on new technologies that had never before been integrated into a single aircraft. During Operation Desert Storm, more missions were flown by F-16s than any other aircraft. Since its first production order in 1975, more than 4,500 F-16s have been produced for 26 countries.

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Although scheduled to remain in service with US forces until at least 2025, when the F-35 will shoulder much of the Falcon’s workload, Lockheed Martin continues to produce new versions of the F-16 with a backlog of international orders from Morocco, Turkey and Iraq. While jet fighters might be the stallions of the military aircraft fleet, spare a thought for the workhorse—in this case, the C-130 Hercules. In 1951, the US Air Force needed an aircraft capable of hauling large bulky equipment, including artillery pieces and tanks, over long distances. It had to land in tight spaces, slow to 125 knots for paratroop drops, and fly, if need be, with one engine. What the Air Force wanted, in other words, was a tough, versatile heavy-lifter with plenty of ‘trunk’ space. Later officially nicknamed Hercules, the prototype had a cargo deck that was capable of carrying an astonishing 300 pounds per square foot, lifted into the air after a ground roll of a mere 855 feet, an astoundingly short distance considering most aircraft of that size required 5,000 feet. After 60 years, over


lockheed martin redesigning flight 70 variants and more than 2,400 aircraft, the Hercules has more than proven its worth. Today there is literally a Hercules airborne somewhere in the world every minute of every day.

F-35 Lightning II

“The first production F-35A rolled out of the assembly in Fort Worth, Texas, in February 2006. Later that year, the F-35 Joint Strike Fighter was renamed the Lightning II, in homage to two earlier fighters”

The F-35 Lightning II is a 5th Generation fighter, combining advanced stealth with fighter speed and agility, fully fused sensor information, networkenabled operations and advanced sustainment. Three variants of the F-35 will replace legacy fighters for the US Air Force, the US Navy, the US Marine Corps, along with ten other countries around the world. In 1997, Lockheed Martin was selected as one of two companies to participate in the Joint Strike Fighter concept demonstration phase. In October 2001, the Lockheed Martin X-35 was chosen as the winner of the competition and teamed with Northrop Grumman and BAE Systems to begin production. The first production F-35A rolled out of the assembly in Fort Worth, Texas, in February 2006. Later that year, the F-35 Joint Strike Fighter was renamed the Lightning II, in homage to two earlier fighters. The F-35 completed its first flight in December 2006, and over the next few years, three variants rolled off the production line and began collecting test points. The first production F-35 conducted its first flight in February 2011 with deliveries of the aircraft beginning that very same year. The F-35A is the conventional takeoff and landing (CTOL) variant, built for traditional air force bases. Virtually undetectable, the F-35A is an agile, versatile, high-performance 9g multirole fighter that provides unmatched capability and unprecedented situational awareness. The US Air Force declared the F-35A ready for combat in 2016, and F-35A aircraft have now been delivered to five US Air Force Bases where they are being flown for system development and demonstration test, operational test and training missions. The F-35B short take-off/vertical landing (STOVL) variant is the world’s first supersonic STOVL stealth aircraft. It is designed to operate from austere bases and a range of air-capable ships near front-line combat zones. It can also

take off and land conventionally from longer runways on major bases. The US Marine Corps’ F-35B aircraft reached initial operational capability on 31 July 2015, when a squadron of 10 F-35Bs was declared ready for world-wide deployment. The F-35B STOVL operation is made possible through the RollsRoyce patented shaft-driven LiftFan® propulsion system and an engine that can swivel 90 degrees when in short take-off/vertical landing mode. Because of the LiftFan, the STOVL variant has a smaller internal weapon bay and less internal fuel capacity than the F-35A. The F-35C carrier variant (CV) is the world’s only 5th Generation, long-range stealth strike fighter designed and built explicitly for carrier operations. The US Navy is the largest customer for F-35Cs, with the US Marine Corps also planning to acquire the C variant in addition to the F-35B. The F-35C combines the unique capability of operating from a carrier deck with the unmatched 5th Generation capabilities of stealth, fused sensors and reliability, making the F-35C the Navy’s future first-day-of-thewar strike fighter. The F-35C variant has larger wings and more robust landing gear than the other variants, making it suitable for catapult launches and fly-in arrestments aboard naval aircraft carriers. Its wingtips also fold to allow for more room on the carrier’s deck while deployed. The F-35C also has the greatest internal fuel capacity of the three F-35 variants, carrying nearly 20,000 pounds of internal fuel for longer range and better persistence than any other fighter in a combat configuration. And, like the F-35B, the F-35C uses probe and drogue refuelling. This allows the Navy to operate its carriers a safe distance from the threat while its fighters reach remote targets.

Lightning production

More than 300,000 individual parts come together to produce the F-35 Lightning II at Lockheed Martin’s mile+-long factory in Fort Worth, Texas. In addition, final assembly and checkout is also performed at facilities in Cameri, Italy and Nagoya, Japan. The F-35 program brings together the

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“The F-35C carrier variant (CV) is the world’s only 5th Generation, long-range stealth strike fighter designed and built explicitly for carrier operations”

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Picture courtesy of Paul Howe Photography

world’s most experienced aerospace industry leaders, including Lockheed Martin, Northrop Grumman, BAE Systems and Pratt & Whitney. The global team also includes more than 1,400 suppliers from domestic and international companies around the world. This landmark project combines team expertise with sophisticated manufacturing, engineering and technological capabilities. In May 2017, Lockheed Martin’s Aeronautics business designated 27 small and large businesses as top-performing suppliers for 2016, representing the top two per cent of its supply base. “This award recognizes suppliers holding a 98 percent ontime delivery rating with a 98 percent quality rating. Their role with us makes an impact far beyond performance – it ensures the ability to offer safety and security to customers across the globe,” said Janet Duffey, vice president,

Aeronautics Supply Chain Management. “As a leader in engineering, production and sustainment of aircraft, operational excellence and supplier performance are key tenants of our business model.” The F-35 production strategy is based on flow-to-takt manufacturing implementation. Flow-to-takt is the movement of component assemblies, like wings and forward fuselages, from one build station to the next at a rate equal to the delivery rate. This production rhythm increases efficiencies, lowers costs and reduces span times while synchronizing the delivery of parts, timing of tasks and positioning of personnel to achieve standard work in each line position. The F-35 production strategy is already paying tremendous dividends. Production learning curves are beating legacy aircraft like the F-16. Costs have come down 62 per cent since the procurement of the first production

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aircraft, and the time it takes to build the F-35 has been reduced by nearly half. As the F-35 prepares to enter full rate production, these key manufacturing indicators are projected to continue to improve. Underpinning the F-35’s unrivalled capabilities is more than 8 million lines of software code – more than four times the amount of the world’s first 5th generation fighter, the F-22 Raptor. Currently, more than 400 F-35 pilots and 4,000 maintainers have qualified through the F-35 Training System, and eight partner nations have pilots and/ or maintainers in training. Simulation plays a prominent role in the F-35 training process, more so than legacy platforms. Because of the advanced capabilities of the F-35, it is not possible to adequately challenge pilots in the live environment alone. With simulation, the F-35 team is redefining how pilots train to provide the range of experience


lockheed martin redesigning flight required to maximize the jet’s 5th Generation capabilities. Three training centres across the United States host the latest courseware, electronic classrooms, simulators, flight events and event-based maintenance training. To support mission rehearsal and tactics development, F-35 training technologies are also located at operational locations.

F-35 in Europe

“The first F-35B to be assembled outside the United States rolled out of the Final Assembly and Check Out (FACO) facility in the Cameri Production Facility in Italy in early May 2017”

The first F-35B to be assembled outside the United States rolled out of the Final Assembly and Check Out (FACO) facility in the Cameri Production Facility in Italy in early May 2017. The rollout of this short take-off/vertical landing version of the F-35 demonstrates Lockheed Martin’s commitment to international partnerships. The Italian FACO is owned by the Italian Ministry of Defense and is operated by Leonardo in conjunction with Lockheed Martin with a current workforce of more than 800 skilled personnel engaged in full assembly of the F-35A and F-35B aircraft variants and F-35A wing production. At the time of writing, seven F-35As have been delivered from the Cameri FACO, four of which are now based at Luke Air Force Base, Arizona, for international pilot training and three are at Amendola Air Base, near Foggio on the Adriatic coast. The Aeronautica Militare (Italian Air Force) has already flown more than 100 flight hours in its Amendola-based F-35As. The next Italian F-35B aircraft is scheduled for delivery in November 2018. The Cameri FACO has the only F-35B production capability outside the United States and is programmed to produce a total of 30 Italian F-35Bs and 60 Italian F-35As, along with 29 F-35As for the Royal Netherlands Air Force, and retains the capacity to deliver to other European partners in the future. The Italian FACO is also producing 835 F-35A full wing sets to support all customers in the program. The FACO was selected by the US Department of Defense in 2014 as the F-35 Lightning II heavy airframe maintenance, repair, overhaul and upgrade facility for the European region. Air Force officials announced on 6 May 2017 that the F-35A Lightning II aircraft

would participate in the Paris Air Show in June. In April, eight F-35A Lightning II fighters and several hundred airmen deployed to Europe demonstrating the aircraft’s readiness to conduct operations with America’s European partners. The first major overseas training deployment for the aircraft is providing an opportunity for the combat-ready aircraft to integrate alongside allies in a realistic training environment. Participation in the Paris Air Show will further demonstrate the ability of the Air Force to deliver a broad range of combat airpower.

Portfolio highlights C-130J Super Hercules

The C-130J Super Hercules is the world’s most advanced tactical airlifter, offering superior performance and new capabilities, with the range and flexibility for every theatre of operations and evolving requirements. This rugged aircraft is regularly sent on missions in the harshest environments, and is often the first aircraft to touch down, usually on austere landing strips before any other transport to provide humanitarian relief after natural disasters. Designed and developed with mission flexibility in mind, the C-130J has a unique mix of agility and performance to complete any mission, anytime, anywhere. The C-130J airframe has proven it’s reliable, efficient and highly operational in harsh environments and combat theatres like Iraq and Afghanistan. Among its missions, the C-130J also counts capabilities as diverse as special ops, aerial refuelling, close air support, search and rescue and personal recovery. The focus on flexibility and multi-role, multi-mission capabilities can be traced back to the original C-130A, which was designed in response to a need for US forces to tactically resupply troops on the front lines. The latest C-130J Super Hercules is the airplane of choice for the Air Force Reserve Command’s weather reconnaissance squadron, known as the Hurricane Hunters. They fly their WC130Js straight into the eye of hurricanes, travelling from the outskirts of the storm to its centre and then out again, making repeated trips to measure

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“The latest C-130J Super Hercules is the airplane of choice for the Air Force Reserve Command’s weather reconnaissance squadron, known as the Hurricane Hunters” Picture courtesy of Paul Howe Photography

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wind speed and barometric pressure. The results offer critical predictive data about the severity and direction of tropical storms, increasing the accuracy of the National Hurricane Center’s forecasts by 30 per cent.

LM-100J Commercial Freighter Lockheed Martin unveiled the latest member of the C-130J Super Hercules family, the LM-100J commercial freighter, in February 2017. The original L-100, the commercial variant of the C-130 Hercules, was produced from 1964 through 1992 at the then Lockheed-Georgia Company facility in Marietta, Georgia. More than fifty of those airlifters are still in service worldwide. Like its multi-tasking military counterpart, the LM-100J will support a variety of tasks, including delivering oversize cargo such as oil and natural gas drilling equipment to short and often unimproved airfields that have no infrastructure other than maybe a forklift and a flatbed truck. In addition, L-100s, recognizable by the absence of

the two lower windows underneath the aircraft’s windscreen, are also used for humanitarian aid, airdrop, aerial spray, VIP transport, aerial firefighting, and other, similar operations. While the L-100 is highly regarded for operations at the edges of the commercial air cargo spectrum, the existing fleet now has some operational challenges including CNS/ ATM compliance (communications, navigation, surveillance/air traffic management). Furthermore, the Allison (now Rolls-Royce) T56 engines powering the L-100 fleet do not meet the FAA’s Stage IV noise requirements for civilian transports, nor do these engines meet today’s more stringent emission standards. To respond to these challenges, Lockheed Martin submitted a Program Notification Letter to the Federal Aviation Administration on 21 January 2014 for a type design update for the Model L-382J transport, a civil-certified variant of the C-130J Super Hercules. This commercial variant will be marketed as the LM-100J.

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Time and payload equal money to air freight operations. Anything that puts more cargo in an aircraft and gets that payload it to its destination faster means more money in an operator’s pocket. All of the features of the LM-100J result in a civil-certified transport that will carry one-third more payload, with twenty per cent or more greater range, and at ten per cent faster speeds than the L-100.

C-5 Galaxy

As the Air Force’s largest and only strategic airlifter, the C-5 Galaxy can carry more cargo over longer distances than any other aircraft. With a payload of six Mine Resistant Ambush Protected vehicles (MRAPs) or up to five helicopters, the C-5 can haul twice as much cargo as any other airlifter. As part of Lockheed Martin’s sustainment offerings, C-5 modernization provides greatly improved reliability, efficiency, maintainability and availability, while ensuring this critical national strategic airlift resource continues serving the warfighter well into the 21st century.


lockheed martin redesigning flight

“Over the last 10 years, the U-2S has undergone a complete technology rebuild, further improving its performance and mission capability”

The C-5M Super Galaxy is the result of a two-phase modernization effort: the Avionics Modernization Program (AMP) and the Reliability Enhancement and Re-engining Program (RERP). AMP adds a new, modern cockpit with a digital, all-weather flight control system and autopilot; a new communications suite; flat-panel displays; and enhanced navigation and safety equipment. AMP is the digital backbone to support RERP. Now with more powerful GE commercial engines and 70 major enhancements, the C-5M Super Galaxy can deliver the globe in one flight, without refuelling. The C-5M is an airlift revolution. With more capability, reliability and affordability than its predecessors, the world record-setting C-5M is rewriting the strategic airlift playbook. With improved reliability

and unmatched range and payload capability, the C-5M provides the US with the ability to respond to a crisis anywhere in the world with the largest payload of vital supplies on a moment’s notice. The newly modernized C-5M Super Galaxy will be the global leader in strategic airlift for decades to come.

U-2 Dragon Lady

No other high-altitude ISR asset operating today – or in development – can accomplish the daily peacetime strategic reconnaissance operations of the U-2S, or compete with its future capabilities. U-2S flies more than 10,000 feet higher, 100 mph faster, and has larger bandwidth links than any other high-altitude ISR platform. Flying 24/7 around the world at record-high operational rates, U-2S collects critical targets no other platform can.

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While early models of the U-2 began service in the mid-1950s, production of today’s U-2S fleet was completed in the late 1980s, and is capable of delivering unparalleled performance beyond 2050 as the next generation of an American icon. Today’s generation U-2S operates with a 30 per cent larger airframe and a new GE F118 engine. It has been completely upgraded with a glass cockpit, fiber optic communication capabilities, and state-of-the-art avionics and sensor systems. Over the last 10 years, the U-2S has undergone a complete technology rebuild, further improving its performance and mission capability. The U-2S is reliable, responsive and survivable, delivering an average 97 per cent mission success rate; open architecture and modular payload capabilities, enabling new or unique sensors without customizing the aircraft or removing it from the fleet; and, the ability for field commanders to readily tailor sensors to the mission.

Sikorsky helicopters

The Sikorsky Aircraft Corporation, based in Stratford, Connecticut, was established by Igor Sikorsky (an immigrant from Kiev) in 1925 and

was among the first companies to manufacture helicopters for civilian and military use. Previously owned by United Technologies Corporation, Sikorsky was acquired by Lockheed Martin in November 2015. Helicopters sold for commercial use carry the prefix ‘S’, while military versions are designated by letters relating to their use (CH for cargo helicopter, for instance). One of the latest models to be developed is the CH-53K King Stallion, which builds on Sikorsky’s 50 years of success with its CH-53A, CH-53D/G, and CH-53E predecessors. Built to thrive on the modern battlefield, including shipboard operations, the CH-53K aircraft is designed to be intelligent, reliable, low maintenance and survivable in the most austere and remote forward operating bases. The CH-53K helicopter will serve as a critical land and sea based logistics connector. The new heavy lifter will allow the US Marine Corps and international militaries to move troops and equipment from ship to shore, and to higher altitude terrain, more quickly and effectively than ever before. Operational and deployed today with the US Navy as the primary antisubmarine warfare anti-surface weapon

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system for open ocean and littoral zones, the MH-60R SEAHAWK helicopter is the world’s most advanced maritime helicopter. It is the most capable naval helicopter available today designed to operate from frigates, destroyers, cruisers and aircraft carriers. The UH-60 BLACK HAWK multirole helicopter serves with the US military and the armed forces of 26 other countries worldwide as a tough, reliable utility helicopter. During the last 35 years, this remarkable aircraft has fought its way in and out of countless combat zones to deliver and extract troops, save lives as a MEDEVAC or casualty evacuation platform, provide critical supplies to troops, deliver emergency supplies during natural disasters, and perform as an aerial firefighter and border patroller. Now the modern variant of this utility aircraft is taking on a new mission set — as an armed helicopter to provide fire suppression when supporting ground troops, as well as armed escort. With digital avionics, powerful GE engines, high strength airframe structures and composite wide chord rotor blades, today’s BLACK HAWK platform has better survivability and situational awareness, and can fly higher and carry


lockheed martin redesigning flight

“The S-92 helicopter has become the industry standard for offshore transportation, search and rescue and VIP/head of state transport. In May 2014, the Sikorsky S-92 won the US Navy contract to replace the Marine One Helicopter Fleet serving the President of the United States”

more than its predecessors ever did. The same aircraft sold commercially by Sikorsky acquires the S-70 designation. Introduced in 1977, the S-76 series has had a long legacy of supporting customers with reliability and comfort. Originally built for the rigorous demands of offshore oil & gas transportation, its capabilities fit naturally into other market segments, such as executive transport, SAR, airline and helicopter emergency medical/air ambulance services. Since its introduction in the 1990s, the S-92 helicopter has become the industry standard for offshore transportation, search and rescue and VIP/head of state transport. In May 2014, the Sikorsky S-92 won the US Navy contract to replace the Marine One Helicopter Fleet serving the President of the United States. The S-92 accommodates 19 passengers with comparable seating space to a fixed-wing commercial airliner, making vertical transport practical in highly congested or limited access areas.

we took action to ensure Lockheed Martin is well positioned for the future, by identifying emerging opportunities and adapting to new challenges we see developing around the world,” said Marillyn A. Hewson, chairman, president and chief executive officer, in her preface to the Annual Report. “One of the most important ways we did this was by reshaping our portfolio. Most notably, we integrated our Sikorsky acquisition and realigned Mission Systems and Training into a new business area named Rotary and Mission Systems (RMS). RMS now has unrivalled integrated capabilities.” Throughout its history, Lockheed Martin has set the standard for innovation and advancement. In 2016, the company continued to develop new technologies and expand its capabilities, while meeting aggressive production goals. “We look forward to building on these achievements as we do our part to continue to engineer a better tomorrow,” concluded Hewson.

2016 was an outstanding year for Lockheed Martin, with strong financial results in all four quarters. “In 2016,

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Airbus Helicopters H160

A new chapter in helicopter design Carbon fibre reinforced PEEK prepreg rotor hub developed with Airbus Helicopters. Airbus Helicopters, a division of the Airbus Group providing civil and military helicopter solutions, has developed the H160 helicopter as the first new member of the H generation of civil aircraft. First unveiled at the Heli-Expo, Florida in March 2015, the H160 is currently undergoing its flight test program, with planned service entry in 2018. The H160 is a medium duty, twin-engine helicopter, with a capacity of 12 passengers, designed for operations in sectors such as oil & gas, air ambulance and coast guard roles as well as private business aviation services. Airbus Helicopters aims to offer clients more performance, safety and comfort with the new 160 as well as improving the overall cost effectiveness and operating efficiency. One of the key factors in delivering these requirements is a significant increase in the usage of composite materials in the H160 program.

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The H160 is the first civil helicopter to use a full composite material airframe structure, providing massive weight savings as well as producing a tough and more robust aircraft. Another key component, Airbus Helicopters’ proven Spheriflex bearingless main rotor hub, has been enhanced with the introduction of a unique thermoplastic composite technology developed with Porcher Industries.

Innovative thermoplastic composite solutions

Airbus Industries had previously introduced composite materials in its main rotor hubs with the Starflex hub, which used a thermoset resin based composite in place of the traditional metallic component. With the H160 being a completely new design from nose-to-tail, every component was evaluated and the target for the new rotor hub was to reduce weight, improve long


term performance and optimize damage tolerance. A thermoplastic composite solution, and in particular a PEEK resin matrix, was selected as it provided significantly higher toughness and long term resistance to fatigue in the finished part. Another significant benefit of using a thermoplastic composite is that components can be recycled more easily at the end of their life, helping to meet environmental and sustainability targets for the program. PEEK composites also exhibit particularly high resistance to aviation fuel, hydraulic oil and other common flight service fluids, further reducing the maintenance requirements for the main rotor hub. With the engineering design completed and resin matrix selected, the next challenge for Porcher Industries was to finalize the high temperature impregnation process, to ensure precise control of the mechanical properties of the finished carbon fibre reinforced prepreg. Porcher’s cutting-edge expertise in processing specific carbon fibres, and its ability to carefully control fibre sizing, allowed it to optimize the prepreg interface bonding and mechanical performance.

Test sections and prototype parts were subjected to a detailed set of mechanical tests which lead into a very stringent program of extended fatigue testing and monitoring. Happily, the Porcher Industries carbon fibre PEEK prepreg passed with flying colours, meeting the quality requirements of this safety critical application and receiving the green light for production by Airbus Helicopters. Thanks to the success of this partnership with Airbus Helicopters, the next generation of high performance thermoplastic composite parts for structural applications in aerospace is already under development. Porcher Industries is confident that this technology will also be applicable in other market sectors such as the automotive industry, and is looking forward to further challenging thermoplastic prepreg projects in the future.

www.porcher-ind.com

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  101


TRELLEBORG SE ALING SOLUTIONS

From design to delivery, we seal the global aerospace industry

Trelleborg Sealing Solutions is one of the world’s leading developers, manufacturers and suppliers of seals to the aerospace industry. We are uniquely placed to offer a dedicated seal design and development service to the aerospace market locally through our global network of engineering and manufacturing facilities. BENEFITS OF PARTNERING WITH TRELLEBORG SEALING SOLUTIONS: • A complete polymer sealing range for the aerospace industry • Proven-engineering excellence – servicing all major aerospace programs • Industry-leading design and materials expertise • Best practice manufacturing • Customized distribution capabilities – direct line feed, subassembly and kitting • Aftermarket expertise • 24-hour worldwide support • Full service provision – design concept to aftermarket support

W W W.T S S .T R E L L E B O R G .C O M/A E R O S PAC E

YO U R PA R T N E R F O R S E A L I N G T EC H N O L O GY


Lift-off with key technologies for global OEM and MRO in the Aerospace Industry

Proprietary Technologies • Ardrox® • Naftoseal® • Oakite® • Tech Cool®

Fuel Tank

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• Cleaners • Multi-Purpose Sealants • Pretreatment Technologies

• Cleaners • Corrosion Inhibiting Compounds (CIC) • Metalworking Fluids • Non-Destructive Testing (NDT) Products • Sealants

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Fuselage Outer Shell

Engine • Cleaners • Metalworking Fluids • Non-Destructive Testing (NDT) Products • Overhaul Products • Pretreatment Technologies

• Aerodynamic Smoothing Sealants • Exterior Cleaners • Paint Removers • Temporary Protective Coatings


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Aviation Manufacturer Magazine  

Issue 10. Cover Story: Global Aviation Services Interior

Aviation Manufacturer Magazine  

Issue 10. Cover Story: Global Aviation Services Interior