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magazine

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2018 farnborough international airshow edition

Issue 9

Aviation Manufacturer


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the editor

First and foremost

Editor

The

E

veryone loves an anniversary. Here at Aviation Manufacturer we’re celebrating two years in business. This may seem a modest achievement, but plenty of new magazines fail to get that far. In July 2016 I was writing my first editorial during the Farnborough International Airshow. Two years later, Farnborough has come around again and we’re still here. Of course, other anniversaries are more significant than ours. The Boeing Company celebrated its 100th anniversary at Farnborough 2016, and the Royal Air Force is celebrating its centenary this year with lots of events around the UK, culminating in a spectacular fly-past over Buckingham Palace in which 22 Typhoons flew in the formation of the figure 100 – every bit as exciting as the World Cup! Anniversaries are all very well, but if you can’t claim one of those, a first is just as good. Before anyone dreamed of an airshow, the first powered flight in Britain, by American showman Samuel Cody, took place at Farnborough Aerodrome in 1908. A first is forever. Visitors to the 2018 Farnborough International Airshow will experience for the first time the new £30 million Exhibition and Conference Centre, which was opened in March this

Martin Ashcroft

year. The 2016 Farnborough International Airshow saw the first Cargo Village and this year, for the first time, a dedicated two-day conference curated by IATA will be held there. Also new for FIA 2018 is Aerospace 4.0, a dedicated exhibition sponsored by Deloitte and focused on the digital technologies transforming aerospace manufacturing. In the aviation industry, more perhaps than any other, the quest to be first has driven invention and innovation for over 100 years. I find it fascinating to watch the manoeuvres of Airbus and Boeing in their quest to be the foremost manufacturer. Aviation is a fast moving industry in more ways than one, but the speed of the latest developments has been breathtaking. Five minutes after Airbus completes its deal with Bombardier, Boeing announces a partnership with Embraer. Ten minutes after that, Airbus renames the C Series as the A220. Hope I haven’t missed anything while I’ve been writing this. Farnborough is the shop window for the global aviation industry and there will be plenty of people shopping there this year. Whether buying or selling, we hope our readers enjoy a week of good business. There are always a few firsts announced at Farnborough, too. I wonder what they will be this year.

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farnborough international airshow Page 6

Page: 3

• The Editor: First and foremost

6

• Farnborough first: Inside the 2018 Farnborough International Airshow

10

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

16

• Global Aviation Services: A superior interior

29

• Royal Air Force celebrates centenary

30

• Jet Airways takes Boeing 737 MAX • Boeing and Safran to design, build and service auxiliary power units

31

• Airbus and Bombardier celebrate C Series

33

• First ACJ320neo enters final assembly • Qatar Airways brings the Airbus A350 to Edinburgh

35

• Cargo in the spotlight at Farnborough • Delta to become launch operator of Bombardier’s Atmosphère cabin

36

• GE introduces AiRXOS to develop unmanned traffic management • Start-up Kittyhawk secures $5 million

37

• Honda sells aircraft to Japan • Airbus Helicopters delivers H145s to Rega

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aviation news page 29


contents

39

• Boeing HorizonX Ventures invests in UAV start-up Matternet • Lockheed Martin to build F-16 Block 70 aircraft for Bahrain

41

• Boeing and Embraer to establish strategic aerospace partnership

42

• Airbus Helicopters and Safran improve endurance of H125 and H130 • Consolidated Precision Products to acquire Selmet

43

• Airbus opens fourth A320 production line • Spirit AeroSystems opens new facility in Malaysia

45

• C Series adopted into Airbus family

47

• First BelugaXL rolls out of paint shop • Norway conducts first electric flight

48

• BAE Systems: Aviation innovation

64

• Lockheed Martin: Redesigning flight

84

• Porcher Industries: Airbus Helicopters H-160: A new chapter in helicopter design

axiom resin & innegra fiber page 10

Cover picture courtesy of Steve Cooke www.frontlineaviation.co.uk

BAE systems: aviation innovation Page 48

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  5


farnborough first W

hen asked to name a world famous airshow, most people would think of Farnborough first. If you’re going to the 2018 Farnborough International Airshow, here’s a glimpse of what you will be able to do and see there. If not, this is what you will be missing, not to mention all the networking opportunities! Farnborough has seen its share of firsts over the years, and this year is no exception. Visitors to the 2018 Farnborough International Airshow will experience for the first time the new £30 million Exhibition and Conference Centre, which was opened in March this year. At the heart of the new venue is a 12,500sqm exhibition hall, large enough to accommodate three football pitches. Surrounding the exhibition hall are ten conference and events areas, bringing the total amount of flexible space to 20,000sqm. The Exhibition and Conference Centre will be an important element of this year’s airshow, but it’s also a crucial factor in attracting other events to Farnborough to provide the venue with a variety of other income streams. This year’s show is also a first for the

new chief executive of Farnborough International Ltd, the organisers of the Airshow and operator of the Exhibition and Conference Centre. Gareth Rodgers, the former CEO of Southampton Football Club, was appointed in January this year, shortly before the Exhibition and Conference Centre was opened. “The new Conference and Exhibition Centre is a hugely impressive venue,” he said at the opening. “Farnborough International’s reputation for delivering major events is growing nationally and internationally, which is great news for our home town; we carry its name with pride and, with the opening of this Centre, are set to increase our direct and indirect contribution to the local economy.” The Farnborough International Airshow is the preeminent trade event of its type, and this year is set to attract

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the biggest global attendance ever. There are several ways to make the most of this exposure to thousands of potential customers.

Farnborough features

With more than 1500 exhibitors, 100,000sqm of exhibition space, a static aircraft and flying display and up to 100,000 visitors over the trade days alone, before it opens to the general public, organising the Farnborough International Airshow takes some planning. The organisers constantly look at ways to offer visitors and exhibitors more reasons to attend and enhance their experience. A number of key initiatives this year look like taking it in the right direction. A large area next to the delegations lounge in Hall 3 has been transformed


farnborough international airshow

“At the heart of the new venue is a 12,500sqm exhibition hall, large enough to accommodate three football pitches. Surrounding the exhibition hall are ten conference and events areas, bringing the total amount of flexible space to 20,000sqm”

into an ‘Air Force Command Centre’ where visitors will see a ‘real-life’ scenario played by actors from CrisisCast, a leader in producing specialist live events. The Live Product Demo Area has been designed to allow exhibitors to demonstrate their defence and security products to potential industry customers and military delegations in a unique selling platform combining cinematic footage, live demonstrations and role-play actors. Military delegations, invited guests and exhibition visitors will be taken on guided tours, every 30 minutes, in small groups to view the live product demonstrations. Another key addition to the show will be the introduction of FINN Sessions by the Farnborough International News Network, which is running a series of talks, panel discussions and seminars in which high-profile keynote speakers will challenge current perceptions and provide ideas for the future. Set across two theatres in Hall 3 and Hall 4, these sessions will provide a forum to share and discuss the major topics and trends affecting the aerospace industry. The Innovation Theatre in Hall 3 will focus on new technologies and innovations in flight while the Insight Theatre in Hall 4 will look at major topics affecting the aerospace agenda today, from the future of supersonic travel and space tourism, to new markets and growth strategies. The Innovation Zone brings together the best in advanced engineering universities, research and technology organisations (RTOs) and the agencies that support them, to showcase their latest technological advances and develop new partnerships with businesses, government and academia from around the world.

Displays

Nowhere can anyone see a more diverse range of aircraft on display, from vintage planes to fast jets and aerobatics to large commercial airliners, demonstrating the latest in innovation and technology. This year’s trade flying display, showcasing the most advanced aircraft in both commercial and military design, is sponsored exclusively by Embraer. To fit in with Farnborough’s business

role, the flying display takes place in the afternoon, leaving the morning and lunch period free for business meetings. The display provides a presentation in which participants can demonstrate the capabilities of their products, enhanced by a commentary broadcast across the exhibition site. The natural amphitheatre at the Farnborough Aerodrome also allows aircraft to be exhibited to maximum effect in the extensive static aircraft park. Running in parallel to the exhibition, the static display gives visitors the opportunity to view the aircraft close up.

Business Aircraft Park

The Farnborough International Airshow Business Aircraft Park (BAP) is an area devoted to business aircraft manufacturers, their products and services. This has been a feature of the show since 2008, and is represented this July by Airbus, Bombardier, Dassault, Embraer, Gulfstream, Piaggio, Pilatus and Textron. The Business Aircraft Park is now an integral part of the overall show and contributes significantly to the billions of dollars of business that is done across the trade week. Located within the main aircraft display area, the BAP is easily accessible from the centre of the main exhibition and will continue to accommodate requests for demonstration flights to potential and existing customers. As well enabling the wider aviation community to get a rare, up-close glimpse of these elegant aircraft, the Airshow hosts a delegation programme, which introduces manufacturers to potential customers for whom the convenience of business aviation is as valuable as privacy.

Cargo Village

The cargo sector is growing rapidly, presenting opportunities but also raising challenges. Increased demand leads to bigger loads and longer flights, requiring aircraft that are more fuel-efficient. Sponsored by industry heavyweights CargoLogicAir, Volga Dnepr and Air Bridge Cargo, the Cargo Village is a strategically important feature for companies investing in the innovation that will create the next-generation of

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cargo aircraft. Originally launched at the 2016 show, the Cargo Village is generating great excitement this year, not least because of the chance to get up close to the static aircraft on display. Dominating the area will be a CargoLogicAir 747-8 Freighter and an Antonov An-124, with a demonstration programme showing how they operate on the ground and a flying display that will also see them in the air. The Cargo Village will also feature a Boeing Global Services exhibit. For the first time this year, a dedicated two-day conference curated by IATA is planned for the Tuesday and Wednesday of the Airshow. This will bring highprofile industry experts together to discuss a range of topics and issues, from the future for cargo through to the exponential demand for express and e-commerce freight. A major area for discussion is to be the role of UAVs. As drones continue to grow in popularity, the conference will discuss how a future with UAVs might look, and what needs to be done to

make the most of the opportunities this presents, such as delivery to inaccessible areas.

Aerospace 4.0

The first industrial revolution started in the late 1700s. We’ve seen off the second and third in the last 250 years and we are now entering the fourth, the digital transformation that is set to revolutionise manufacturing industries through automation, data exchange and processes. The fourth industrial revolution will be at the heart of the Farnborough International Airshow. Brand new for FIA 2018, Aerospace 4.0 is a dedicated exhibition, sponsored by Deloitte and focused on the digital technologies transforming aerospace manufacturing. Big data, 3D printing, augmented reality. What will deliver the best value for your organisation over a reasonable timeframe? Experts from these new industries will be on hand to discuss their potential. This new feature will feature companies exhibiting

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technologies including: • Cloud computing • Internet of Things • Location detection technologies • Augmented reality • Big data analytics • Smart sensors • Autonomous robots • Simulation • System integration • Cyber security • Additive manufacturing

Meet the Buyer Programme

The FIA works hard to develop business relations throughout the aerospace supply chain. One of the most popular features contributing to this aspect of the event is the Meet the Buyer programme, which provides the ultimate networking opportunity for suppliers – a face-to-face 15 minute meeting with international buyers from sectors including aerospace, defence, space, security, MRO, airlines and cargo. Sponsored by American Express, Meet the Buyer puts suppliers in a room with


farnborough international airshow Boeing to showcase the Future of Aerospace at Farnborough 2018

B

oeing’s exhibit at the 2018 Farnborough International Airshow, from 16 – 20 July, will feature the future of air and space travel. From hypersonic travel to the future of autonomous flight, to manned space flight, Boeing will present the innovations that will revolutionize the way humans travel around the world and into space. Boeing will also highlight its portfolio of commercial and defence products and its broader services business. Visitors can immerse themselves in a large 360-degree theatre and board next-generation aircraft through virtual and mixed reality devices. The interactive exhibit showcases Boeing’s latest family of aircraft and services, and gives visitors a first look at what the company is developing in its second century of aerospace innovation.

Flying and static displays

On the airfield, the 737 MAX 7, which is scheduled to enter service in 2019, will make its air show debut with flying displays from 16 – 19 July. 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’s flying display will also include a Biman Bangladesh 787-8 featuring the breakthrough capabilities and innovations that have made the 787 extremely popular with operators and passengers. Other Boeing commercial airplanes on display at the show include an Air Italy 737 MAX 8, a Qatar Airways 777-300ER, CargoLogicAir and Qatar Airways 747-8 freighters, and a Royal Air Maroc 767 converted freighter. Boeing is also participating in the Cargo Village to showcase its family of freighters and lifecycle commitment through Boeing Global Services. Senior Boeing leaders at the show will include Dennis Muilenburg, chairman, president and CEO, Greg Smith, chief financial officer and executive vice president of enterprise performance & strategy and the heads of the company’s three business units: • Boeing Commercial Airplanes president and CEO Kevin McAllister; • Boeing Defense, Space & Security president and CEO Leanne Caret; • Boeing Global Services president and CEO Stan Deal. Other senior Boeing executives will also attend the show.

“Brand new for FIA 2018, Aerospace 4.0 is a dedicated exhibition, sponsored by Deloitte and focused on the digital technologies transforming aerospace manufacturing”

global decision makers in pre-arranged appointments they may not have been able to arrange anywhere else. At the 2016 show, over 1,600 meetings took place and more than £11 million worth of business was generated. Open to exhibitors and trade visitors, the 2018 Meet the Buyer Programme will run on the mornings of Tuesday 17th and Wednesday 18th July in Hall 1. The town of Farnborough dates back to Saxon times and is mentioned in the Domesday book as having a population of 132 people. Little is recorded about it since, until much more recently. Farnborough is the site of the first powered flight in Britain by American showman, Samuel Cody in 1908. It was also home to the historic Royal Aircraft Establishment where Sir Frank Whittle conducted much of his research into jet aircraft. The world-famous Farnborough International Airshow has been held at the airfield since 1948 and over the decades has showcased many pioneering

triumphs in aerospace. In the many workshops and hangars that sprang up in the area, some of the greatest achievements of the jet-age were tested and developed, including designs for the Concorde, high altitude space suits, night vision aids and heads-up cockpit displays. The latest achievements are all on show at Farnborough again this year, and while there is much to do and more to see than ever before, there is no doubt that networking is the major attraction for the average trade visitor. There are four exhibition halls packed full of organisations showcasing their businesses. With 1500 exhibiting companies and 73,000 trade visitors, there are plenty of people to meet in every segment of the industry. FIA 2016 generated $124 billion in orders and this year could be higher. We hope the sun shines for our readers and that you are all able to generate some profitable leads.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  9


axiom resin & innegra fiber a planet craving inflight connectivity

R

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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10

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

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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  13


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


A successful career at Airbus was the perfect preparation for Zeydan Öncü to found his own company, which he now aims to develop into a fully integrated onestop-shop for cabin interiors and equipment for fixed and rotary wing aircraft.   Aviation Manufacturer Magazine www.aviationmanufacturer.com

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GLOBAL AVIATION SERVICES A SUPERIOR INTERIOR

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F

ounded in 2006, Global Aviation Services Interior is the brainchild of engineer and businessman Zeydan Öncü. Combining the vision and attention to detail of the engineer with the flair and imagination of the entrepreneur, GAS has 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 produces of a range of its own cabin interior fittings in its EASA Part 21 certified facilities in Germany, the UK and the UAE, and has also expanded into the training of pilots, crew, engineers and technicians through its Global Aviation Academy. In 2007 GAS became the first company of its kind to take space at Abu Dhabi International Airport for the provision of MRO services, refurbishment and engineering services. The facility is also used for refurbishment of a wide range of cabin equipment and parts, including design and production of galleys, crew rest compartments, bars, seat parts, military aircraft interiors, composite parts and material supplies.

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GLOBAL AVIATION SERVICES A SUPERIOR INTERIOR

“The life cycle of an engineer 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” He added knowledge and skills during his early career with DaimlerChrysler Aerospace (DASA) in Hamburg, which subsequently became EADS and later Airbus, progressing into 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.

Business awards

Just ten years later, in October 2017, Öncü’s success was recognised with a vision and innovation award and an honour award, in addition to his being named Businessman of the Year, 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. So how does an engineer with a solid background and a safe career with Airbus become an award-winning entrepreneur supplying government agencies 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 is now also comfortable with German, French and English.

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 400-500 engineers and related managers. “I was responsible for the delivery of the A400M centre fuselage in respect 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.”

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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 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.” 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 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. After opening the facilities in the UAE and earning a Part 145 AMO (approved maintenance organisation) certificate, the first job there was to retrofit a Dash 8 Q300 from

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20

passenger configuration to VIP for the Crown Prince of UAE, and a Dash 8 Q400 for the President of UAE. “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 GAS 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 government-owned Turkmenistan Airlines for eight helicopter conversions. “The first one was an EMS conversion (emergency 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.”


GLOBAL AVIATION SERVICES A SUPERIOR INTERIOR

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. One of GAS’ current projects is the conversion of an Airbus A300-600 for the Iranian Red Crescent from a passenger aircraft into a flying hospital, including two onboard pharmacies and an abundance of high technology features. It’s the biggest aircraft conversion ever undertaken, anywhere. Another project is the conversion of two C-130 Hercules cargo planes for the Air Force – one for medical use and the other for VIPs. “The C-130J already has a lot of fixtures and fittings for various attachments, and that makes our life easier,” says Öncü. “We also have all the details of the aircraft and its parts in 3D on our CAD/CAM system. This project is in the development phase. The technology is one of our strengths.”

“We divide the job into different work packages, and we appoint a 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”

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Technology and methodology

In a very short space of time, GAS 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 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. GAS 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.”

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GLOBAL AVIATION SERVICES A SUPERIOR INTERIOR

“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”

GAS ensures that the technology and the skills of the engineers are employed to best effect with a meticulous approach 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 interdisciplinary 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.

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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 hangars to accommodate both rotor and fixed wing aircraft, and our management is here, too.” 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

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24

individual components for specific aircraft – purpose built, one-off solutions. These are high quality fittings. That is why we are 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


GLOBAL AVIATION SERVICES A SUPERIOR INTERIOR

“We have trained 28 pilots and 17 technicians based on EASA 147 certification, so far. 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!” 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

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 next step is to start an Academy in Turkey. GAS is also expanding its production and service facilities with the construction of a new hangar near Berlin, which will have its own runway. This will be a manufacturing and MRO, retrofit and conversion centre, and is expected to open in September 2018. The next major project after that is a joint venture in Saudi Arabia. “We were contacted by a very important sheik in Riyadh who is equipping military vehicles,” says Öncü. “We have agreed to do a joint venture there for the retrofit and conversion of helicopters for the army. So far we have 51 helicopters lined up for it. Because of the war with Yemen there are a lot of aircraft grounded, needing refurbishment, maintenance and adaptation engineering.”

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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 O

Royal Air Force celebrates centenary in London

n 10 July this year, 100 days after its official 100th birthday, the Royal Air Force celebrated its centenary with a spectacular fly-past of up to 100 aircraft over Buckingham Palace in London. In addition, over 1,000 RAF servicemen and women performed a ceremonial parade, with almost 300 personnel lining the route representing the diverse roles played within the RAF through the generations. The parade was commanded by Group Captain AnneMarie Houghton, a Sentry navigator from Headquarters Air Command, who has the distinction of being the first female navigator in the Royal Air Force after she graduated from training in 1991. The fly-past featured up to 100 aircraft with nearly 200 aircrew from 25 different RAF Squadrons, operating from 14 military stations and two civilian airfields. The aircraft assembled in holding patterns off the coast of East Anglia before merging near Ipswich and flying down the A12 corridor to London. One of the highlights was the flight of three F-35 Lightning II fighters, the RAF’s next generation fast jet, making their first public appearance since landing at RAF Marham in Norfolk in June. Among the veteran aircraft involved was one of only two airworthy Lancaster Bombers in the world, and the World War Two Hurricane and the Spitfire - the iconic Battle of Britain fighter. Twenty two Typhoons, the backbone of Britain’s recent air attack and quick reaction capabilities, spelt out the figures 100 as they flew over the palace. The Tornado GR4, the RAF’s longest-serving strike and reconnaissance fast jet, also featured, along with Hercules transport planes and Chinook helicopters. The display was introduced by nine helicopters, and as you might expect, the nine members of the Royal Air Force Aerobatic Team, the Red Arrows,

Picture courtesy of Steve Cooke www.frontlineaviation.co.uk

rounded it off. One of the world’s premier aerobatic display teams, the Red Arrows represent the speed, agility and precision of the Royal Air Force. As the public face of the service, they assist in recruiting to the Armed Forces and act as ambassadors for the United Kingdom at home and overseas, promoting the best of British. Flying distinctive Hawk jets, with their trademark Diamond Nine shape and combination of close formations and precision flying, the Red Arrows have been displaying since 1965. All their display pilots have flown operationally, in frontline aircraft such as the Typhoon, helping the Royal Air Force to secure the skies. Based at RAF Scampton in Lincolnshire, the Red Arrows had flown almost 4,900 displays in 57 countries by the beginning of 2018 – the Squadron’s

54th season. The RAF was founded on 1st April 1918 by merging the Royal Flying Corps and the Royal Naval Air Service during the First World War. Since 1 April 2018 the RAF100 campaign has been in full swing with one hundred days of special events, activities and other initiatives at local, regional, national and international levels, with more scheduled throughout the year. Some of the events that have already taken place as part of the RAF100 celebrations include the Baton Relay, which has covered thousands of miles all over the world, and the RAF100 Aircraft Tour which has already been to Cardiff, Wales and is currently in London. It will continue its venture with visits to Newcastle in Northern Ireland, Birmingham, Glasgow and Manchester.

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Jet Airways takes delivery of india’s first Boeing 737 MAX

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et Airways has become the first airline in India to operate the new Boeing 737 MAX. The delivery marks the first of 150 737 MAX airplanes ordered by the Mumbai-based airline, following two separate orders for 75 jets placed in 2015 and earlier this year.

“We are proud to become the first airline in India to introduce this brand new airplane to our customers” “The new 737 MAX is a critical element to our future growth strategy and we are proud to become the first airline in India to introduce this brand new airplane to our customers,” said Naresh Goyal, Chairman of Jet Airways. “The 737 has been

the backbone of our dynamic fleet for many years and we are excited to leverage the superior capabilities of the new 737 MAX. The improved economics and efficiency as well as the passenger pleasing features of the MAX will enable us to strengthen our position as India’s premier airline.” Jet Airways is India’s second-largest airline with a fleet of nearly 120 aircraft serving more than 60 destinations across 15 countries in Asia, Europe, North America and elsewhere. The 737 MAX is the fastest-selling airplane in Boeing history, accumulating more than 4,500 orders from 99 customers worldwide. The family of aircraft is powered by CFM International LEAP-1B engines, and includes design updates such as Boeing’s Advanced Technology winglet that will result in less drag and optimize performance, especially on longerrange missions. Together, these improvements reduce fuel use and CO2 emissions by at least 14 percent compared to today’s Next-Generation 737s – and by 20 percent more than the single-aisle airplanes they replace.

Boeing and Safran to design, build and service auxiliary power units

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oeing and Safran are joining forces to design, build and service auxiliary power units to create better value for customers and the industry at large. An APU is an onboard engine used primarily to start the main engines and power aircraft systems on the ground and, if necessary, in flight. Both companies will have a 50 per cent stake in the partnership, which will be

based in the United States. The transaction is subject to customary conditions including regulatory and

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antitrust clearance, but is expected to close in the second-half of 2018. Safran currently supplies a

wide range of components to Boeing commercial and defense programs, including as a partner to produce CFM’s LEAP-1B engine for the 737 MAX (through CFM International, a 50/50 JV between Safran Aircraft Engines and GE). Boeing and Safran also are partners in MATIS, a joint venture in Morocco producing wiring products for several airframe and engine companies.


news Airbus and Bombardier celebrate C Series Partnership

Tom Enders, CEO Airbus (left) with Alain Bellemare, CEO and President of Bombardier

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hile the United States was celebrating Independence Day, a group of people in Quebec, Canada were throwing their own party on the 4th of July this year. After receiving all the required regulatory approvals, Airbus, Bombardier and Investissement Québec closed the C Series transaction on 1 July 2018. To mark the occasion a celebration was held on 4 July for all employees at the C Series and Bombardier commercial aircraft facility in Mirabel, Quebec, in the presence of the companies´ CEOs. Airbus acquired a majority stake in the C Series Aircraft Limited Partnership (CSALP) in a transaction originally announced in October 2017. The partnership’s head office, primary assembly line and related functions will be based in Mirabel. The C Series is positioned to capture a significant percentage of the estimated 6,000 aircraft needed in the 100-150 seat market segment over the next 20 years. The partners are expecting increased

demand to support a second C Series final assembly line in Mobile, Alabama, dedicated to supplying US-based customers – thus circumventing tariffs

the UK later in July. News reports from the event hinted that development of the new assembly line in Mobile would be fast-tracked,

“Airbus chief executive Tom Enders told the press that he expected ‘more exciting news’ to come in time for the Farnborough Air Show later in July” imposed by US authorities after Boeing complained about alleged subsidies to Bombardier from the Canadian government. Airbus already assembles aircraft from its own A320 family in Mobile. In a question and answer session after the Mirabel event, Airbus chief executive Tom Enders told the press that he expected “more exciting news” to in time for the Farnborough Air Show in

with construction to begin by the end of 2018 and deliveries to customers starting in mid-2020. It took three years to deliver the first A320 from Mobile - Airbus broke ground on its current assembly line in April 2013, held an opening ceremony in September 2015 and delivered the first jet in April 2016 - but this time it will be adding to an existing facility, not developing a greenfield site.

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news

First ACJ320neo enters final assembly

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he first ACJ320neo has entered final assembly in Hamburg, marking the start of a new era in Airbus corporate jets. Featuring the largest cabin in its class, the ACJ320neo is due to be delivered to Acropolis Aviation of the UK in the final quarter of 2018, together with a second aircraft for Comlux of Switzerland. More than 300 A320neo family airliners are already flying with carriers around the world, but deliveries of corporate jet versions are only just beginning. Like the airliner versions, the ACJ320neo features new-generation engines and sharklets, which save around 15 per cent in fuel and deliver a leap forward in range.

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“The hallmark of the ACJ320neo family is a wider and taller cabin than that of traditional business jets” The resulting ACJ320neo can fly 25 passengers 6,000 nautical miles /11,100 km in 13 hours - enabling routes such as London to Beijing or Cape Town

and Moscow to Los Angeles - while the ACJ319neo can fly eight passengers 6,700 nm/12,500 km or 15 hours. The hallmark of the ACJ320neo family is a wider and taller cabin than that of traditional business jets, while having a similar ramp-footprint and operating costs and better residual value. ACJ320neo family differences from airliner variants include a cargo-hold that is reinforced to carry additional centre tanks (ACTs) for intercontinental range, built-in airstairs for airport autonomy, and a lower cabin-altitude for passenger comfort. Orders for the ACJ320neo family now total nine aircraft, comprising three ACJ319neo and six ACJ320neo aircraft.

Qatar Airways brings the Airbus A350 to Edinburgh

atar Airways has upgraded its capacity to the Scottish capital, Edinburgh to the Airbus A350-900, the first A350 service to Scotland, in order to meet increasing demand from passengers. The daily service between

Doha and Edinburgh was previously operated by a Boeing 787 Dreamliner aircraft. “We are excited to welcome the A350 to Edinburgh as the only one in operation in Scotland,” said Gordon Dewar, chief

executive of Edinburgh Airport. “The increase in capacity is a sign of the increasing demand for the Doha route which has been one of our top performers since its introduction in 2014.

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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

Cargo in the spotlight at Farnborough

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argo is taking centre-stage at this year’s Farnborough International Airshow with a 1,000sqm village centred around a static display of ‘giants of the sky’, including 747s and an Antonov. The Cargo Village was introduced at the 2016 Farnborough International Airshow, but this year’s show will also feature a dedicated cargo conference programme for the first time, where industry experts and thought-leaders can discuss the issues, opportunities and challenges facing the sector, including an analysis of the future for air cargo, through to the impact of

“We’ve created a hub for the cargo industry at the Farnborough International Airshow”

exponential demand for express and e-commerce freight. “We’ve created a hub for the cargo industry at the Farnborough International Airshow,” says Amanda Stainer, commercial director for Farnborough International. “The Cargo Village brings people, companies and aircraft together. The conference programme means a conversation will happen simultaneously and I think the discussions during the conference will be influential.” The Cargo Village is sponsored by Cargo Logic Air, Volga Dnepr and Air Bridge Cargo.

Delta to become launch operator of Bombardier’s Atmosphère cabin

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elta Air Lines has signed a firm purchase agreement for 20 CRJ900 aircraft, becoming the launch operator of the new Atmosphère cabin for CRJ Series regional jets. Key features of the new interior include a larger entrance, more passenger space, LED lights and in-seat electric power, a spacious lavatory large enough to accommodate a wheelchair, and ‘wheels-

first’ storage bins providing 50% more capacity than before. Bombardier will show the new cabin (in Delta livery) for the first time at the Farnborough Air Show in July. Delta will take delivery of the world’s first Atmosphère cabin CRJ900 aircraft in late 2018. The order is valued at approximately US$961 million.

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GE introduces AiRXOS to develop unmanned traffic management

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E has founded a new company, AiRXOS, to accelerate the integration of air and ground space for manned and unmanned vehicles. AiRXOS will help government agencies, regional aviation authorities and private sector operators manage and meet the increasing demand for sophisticated and safe unmanned aircraft systems (UAS) operations. “These transformative, collaborative efforts between states, industry and government will be the foundation for realizing the power of UAS advanced operations,” says Kenneth Stewart, general manager, AiRXOS. “GE already has been using drones and drone technology for some time; what AiRXOS offers

is the infrastructure and advanced operations necessary to unlock the emerging markets of autonomous flight.” To keep pace with innovation, NASA’s Technical Capability Level (TCL) testing and the expansion of the Low Altitude Authorization and Notification Capability service program (LAANC) continue to move the industry forward. AiRXOS is a TCL partner and has recently applied for a LAANC application in support of bringing a broad range of UAS operations safely to scale. AiRXOS is a venture between GE Business Innovations and GE Aviation, and is a wholly-owned subsidiary of GE.

“AiRXOS offers the infrastructure and advanced operations necessary to unlock the emerging markets of autonomous flight”

Drone start-up Kittyhawk secures $5 million funding

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alifornia-based Kittyhawk, a startup technology company offering what it calls a ‘unified approach’ to the safe operation of commercial unmanned aircraft systems (UAS), has secured $5 million in funding from

investors including Bonfire Ventures, Boeing HorizonX Ventures, Freestyle Capital, and a return investment from The Flying Object. Kittyhawk’s technology will support development of a UAS traffic management system that enables piloted

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and autonomous air vehicles to safely coexist. Kittyhawk is partnering with Boeing subsidiary Jeppesen to expand unmanned operations by participating in the US Federal Aviation Administration’s (FAA)

Low Altitude Authorization and Notification Capability (LAANC). LAANC is a collaborative effort to create processes that integrate unmanned aircraft, cargo delivery and beyond visual line of sight operations safely into the airspace.


news Honda sells aircraft to Japan

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onda Aircraft Company, a wholly owned subsidiary of American Honda Motor Co, has expanded its sales to Japan with the appointment of Marubeni Aerospace as HondaJet Japan. HondaJet Japan will provide sales, service and maintenance of aircraft in the region. The application for JCAB type certification was submitted in May 2018 and the first aircraft is expected to be delivered in the first half of 2019. “It has been a longstanding dream to advance human mobility skyward since Honda Motor Co, was established,” said Honda Motor Co President & CEO Takahiro Hachigo. “When we started aircraft research there were many challenges to overcome. Today,

“Honda is marketing the HondaJet Elite to customers in Japan, which it claims is the fastest, furthest and highest-flying plane in its category”

with our own advanced technology and the creation of the HondaJet, we have been able to provide innovation to the light jet market and create new value in business aviation. I am proud that HondaJet has expanded sales to Honda’s home here in Japan.” Honda is marketing its new, upgraded model, the HondaJet Elite, to customers in Japan, which it claims is the fastest, furthest and highest-flying plane in its category, seating up to seven passengers. The HondaJet Elite has inherited the aeronautical breakthroughs developed by Honda Aircraft, including the overthe-wing engine mount (OTWEM) configuration, composite fuselage and natural laminar flow (NLF) fuselage nose and wing.

Airbus Helicopters delivers first H145s to Rega A

irbus Helicopters has delivered the first two of six H145 helicopters to Swiss Air-Rescue Rega, to replace Rega’s existing fleet of EC145 helicopters, which will be phased out by mid-2019. Rega has used six EC145s for 15 years, providing airborne medical assistance to around 60,000 patients, and is now opting for the H145, the successor to the EC145. “The H145 represents a continuation of our success story and ensures that we can continue to provide our patients with reliable and professional help in the years to come,” said Ernst Kohler, CEO of Rega.

“The H145 is the market leader for police and rescue missions”

The H145 is the market leader for police and rescue missions with a combined fleet of over 200 helicopters worldwide. A spacious cabin and a maximum take-off weight of 3.7 tons mean the H145 is also well suited for special intensive care transports. The helicopters are equipped with the Helionix digital avionics suite, providing user-friendly flight data management and a high-performance 4-axis autopilot, which reduces pilot workload during missions. Its low acoustic footprint makes the H145 the quietest helicopter in its class.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  37


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

Boeing HorizonX Ventures invests in UAV start-up Matternet

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oeing has announced an investment in Matternet, a California-based start-up pioneering safe, on-demand unmanned aerial vehicle (UAV) delivery operations in urban environments. Matternet became the world’s first company to receive authorization to launch UAV operations over densely populated areas in Switzerland in 2017. Leveraging its Matternet Station, M2 drone and Cloud platform, the company has achieved safe flights over densely populated areas and partnered with Swiss Post for on-demand deliveries of medical samples to hospitals in Switzerland. “Matternet’s technology and proven track record make the development of a safe, global autonomous air mobility

“Matternet’s technology and proven track record make the development of a safe, global autonomous air mobility system a near-term reality” system a near-term reality,” said Brian Schettler, managing director of Boeing HorizonX Ventures. “Our investment

will allow Matternet to scale its operations while strengthening Boeing’s position as a leader in next-generation transportation solutions.” In May 2018, Matternet was selected to participate in a joint US Department of Transportation and Federal Aviation Administration program aimed at accelerating integration of unmanned aircraft into national airspace. As part of the program, Matternet will work with hospitals, universities and transportation agencies in California and North Carolina to facilitate on-demand delivery of medical supplies and samples. Boeing HorizonX Ventures led the $16 million, Series A investment in Matternet, with participation also by Swiss Post, Sony Innovation Fund and Levitate Capital.

Lockheed Martin to build F-16 Block 70 aircraft for Bahrain

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ockheed Martin has been awarded a $1.2 billion contract from the US government to produce 16 new F-16 Block 70 aircraft for the Royal Bahraini Air Force. The Kingdom of Bahrain is the first customer to procure the F-16 Block 70, the most advanced F-16 production configuration. This will also be the first F-16 production program to be performed in

Greenville, South Carolina, where it is expected to create between 150 and 200 new jobs. The F-16 Block 70 features advanced avionics, an active electronically scanned array radar, a modernized cockpit, advanced weapons, an advanced engine and an extended structural service life of 12,000 hours.

  Aviation Manufacturer Magazine www.aviationmanufacturer.com  39


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

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Interior Propulsion


news

Boeing and Embraer to establish strategic aerospace partnership

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oeing and Embraer have agreed to form a joint venture that would align the commercial aircraft and services business of Embraer with Boeing’s commercial development, production, marketing and lifecycle services operations. Boeing will own 80 per cent of the joint venture 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 chairman, president and chief executive officer. 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. The proposed partnership is expected to be accretive to Boeing’s earnings per share beginning in 2020 and to generate estimated annual pre-tax cost synergies of approximately $150 million by year three. 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. “The agreement with Boeing will create the most important strategic partnership in the aerospace industry, strengthening both companies’ leadership in the global market,” said Paulo

Cesar de Souza e Silva, Embraer chief executive officer and president. “The business combination with Boeing is expected to create a virtuous cycle for the Brazilian aerospace industry, increasing its sales potential, production, creating jobs and income, investments and exports, and in doing so, adding more value to customers, shareholders and employees.” The JV will become one of Boeing’s centres of excellence for

“The agreement with Boeing will create the most important strategic partnership in the aerospace industry” 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 everything runs smoothly, the transaction is expected to close by the end of 2019. The news of this joint venture closely follows the establishment of the alliance between Airbus and Bombardier in the C Series Aircraft Limited Partnership (CSALP).

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Airbus Helicopters and Safran improve endurance of H125 and H130

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irbus H125 and H130 helicopter customers will get a boost in their operations thanks to a significant reduction in direct maintenance costs for the Safran Arriel 2D engine, which equips both single engined aircraft. The two main improvements provided by Safran are the extension of the time between overhaul (TBO) by 25 per cent to 5,000 hours for new and in-service helicopters, and the new three year/2,000 hours warranty conditions, replacing the previous two year/1,000 hours warranty for all H125 and H130 helicopters delivered in 2018. “Extensive endurance tests conducted on the Arriel 2D and analysis of engine fleet data have enabled us to further validate the engine’s strength and simplicity,” said Nicolas Billecocq, Safran Helicopter Engines’ vice president of the light helicopter engines program. “Thanks to these new improvements, the Arriel 2D will feature one of the lowest direct maintenance costs of its class.” Axel Aloccio, head of the light helicopter programme at

Airbus Helicopters, called the TBO and warranty extensions “very concrete improvements for H125 and H130 operators around the world.”

“Thanks to these new improvements, the Arriel 2D will feature one of the lowest direct maintenance costs of its class” The H125 and H130 lead the single-engine helicopter market, accounting for almost 70% of deliveries in the last five years. More than 1,000 Arriel 2D-equipped H125 and H130 helicopters are in service worldwide.

Consolidated Precision Products to acquire Selmet

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onsolidated Precision Products Corp, a manufacturer of highlyengineered components and subassemblies for the commercial aerospace and defence markets, has reached a definitive agreement to acquire Selmet, Inc. Terms of the transaction were not disclosed. Founded in 1983, Selmet manufactures complex, titanium castings and machined components for the aerospace and defence industries in a stateof-the-art casting foundry in

“This highly complementary acquisition will round out our product offering to include titanium castings”

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Albany, Oregon. Selmet’s current management team will remain upon closing of the transaction to help drive continued growth. “This highly complementary acquisition will round out our product offering to include titanium castings, enabling us to meet the strong demand from customers seeking advanced titanium content for nextgeneration platforms,” said James Stewart, chief executive officer of CPP. “We are pleased to welcome the talented Selmet team to the CPP family.”


news

Airbus opens fourth A320 production line in Hamburg

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irbus has inaugurated the fourth A320 family production line in Hamburg, Germany. Making use of digital technologies and a more flexible industrial setup, the new line is a key enabler for ramping up the singleaisle programme to 60 aircraft per month by mid-2019. “The inauguration of our latest, most modern A320 production line opens a new chapter in efficient, digital aircraft manufacturing,” said Guillaume Faury, president of Airbus Commercial Aircraft. “With these new technologies we are building our aircraft more efficiently, a key enabler for higher production rates. I would like to thank the teams who pushed this newest Airbus production standard from concept to reality.”

The A320 family aircraft are manufactured globally, at Airbus sites in Europe, China and the US. In addition to the new production line, Airbus also inaugurated a larger

“With these new technologies we are building our aircraft more efficiently” and modernised Hamburg A320 family delivery centre with more customer areas, more efficient delivery processes and increased hospitality services.

Spirit AeroSystems opens new facility in Malaysia S

pirit AeroSystems has expanded its manufacturing operations in Subang, Malaysia, with the official opening of the site’s new logistics warehouse. The 50,000-square-foot facility will accommodate increasing volumes of assembly work on aerostructure components for commercial airliners. “The new warehouse supports our strategy of growing the Spirit Malaysia business and increasing the capacity and capability of the site and its employees,”

said Scott McLarty, vice president / general manager, UK and Malaysia. “This site is at the epicentre of growth in aerospace, and we expect our presence here to keep pace with the needs of

OEMs, airlines and the flying public.” Officially opened by Spirit President and CEO Tom Gentile, the expansion will free up other manufacturing space and improve the site’s

capacity to rapidly build complex aerostructures for high-rate production programs at competitive cost. The warehouse is adjacent to other buildings on Spirit’s campus in the Malaysia International Aerospace Centre near Kuala Lumpur. The building and its supporting infrastructure have been designed with future expansion in mind, giving the company flexibility to eventually add another 75,000 square feet of warehousing space.

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news

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Bombardier C Series adopted into Airbus family

t has not taken long for Airbus to welcome Bombardier’s C Series jets into the family. The deal in which Airbus acquired a majority stake in the C Series Aircraft Limited Partnership (CSALP) closed on 1 July, but Airbus has now announced that the aircraft are being rebranded as Airbus A220. Bombardier’s 120 seater CS100 will now be called A220-100 and the 130140 seat CS300 will become the A220300. Straight out of the paint shop, the first A220-300 to wear the Airbus livery landed at the Henri-Ziegler Delivery Centre, near Toulouse, on 10 July in front of a gathering of Airbus employees

“Today, we are thrilled to welcome the A220 to the Airbus family and are honoured to see it wearing its new Airbus colours for the first time”

and members of the global news media. “Everyone at Airbus has been looking forward to this historic moment,” said Guillaume Faury, Airbus President, Commercial Aircraft. “Today, we are thrilled to welcome the A220 to the Airbus family and are honoured to see it wearing its new Airbus colours for the first time.” Faury paid tribute to everyone at Bombardier and in the supply chain who were responsible for bringing the C Series aircraft to the market. “The A220 now enters a new phase in its career with all Airbus’ resources behind it to further its commercial success worldwide.”

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news First BelugaXL rolls out of Airbus paint shop T

he first BelugaXL has rolled out of the Airbus paint shop in Toulouse, France, sporting a special livery to make it resemble a beluga whale. The livery was one of six choices submitted to Airbus employees in a poll where 20,000 people participated. With 40 per cent in favour, the smiley livery won. The BelugaXL will now undertake ground tests before its first flight, planned in summer 2018. The decision to build the BelugaXL was taken in November 2014 to address the transport and ramp-up capacity requirements for Airbus beyond 2019. Built as a replacement for the current Beluga A300-600ST, the BelugaXL is derived from the larger and more powerful A330-200, which is six metres longer, one metre wider, and boasts a payload lifting capacity that is six tonnes greater than its predecessor. Crucially, a BelugaXL will be able to carry two wings for the new widebody A350 XWB, instead of a single wing currently accommodated on the BelugaST. The first of five BelugaXLs will fly in summer 2018 and enter into service in 2019.

“A BelugaXL will be able to carry two wings for the new widebody A350 XWB”

Norway conducts first electric flight A

vinor, Norway’s staterun aviation company, conducted its first electric flight at Oslo Airport on Monday 18 June, with a view to commencing commercial passenger flights by 2025. The two seater Alpha Electro G2 plane, built by Pipistrel in Slovenia, flew for just a few minutes, carrying Avinor CEO Dag Falk-Petersen and

Norway’s Minister of Transport, Ketil SolvikOlsen. “The government

has commissioned Avinor to develop a program to facilitate the introduction

of electric aircraft in commercial aviation. It was a great experience to get involved in this flight and see that we are in the process of developing future aviation,” said the Minister. By 2025, Avinor will offer exemption from landing fees for small electric aircraft. Norway plans to make all domestic flights electric by 2040.

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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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BAE systems aviation innovation

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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 redesigning flight   Aviation Manufacturer Magazine www.aviationmanufacturer.com

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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  65


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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 will participate in the Paris Air Show this 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

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Aircraft Structure • Cleaners • Corrosion Inhibiting Compounds (CIC) • Metalworking Fluids • Multi-Purpose Sealants • Non-Destructive Testing (NDT) Products • Pretreatment Technologies

Increase your quality, yield, throughput, capacity utilization, and cycle time, AND decrease your energy use with Chemetall! Our award-winning and innovative technologies hold multiple global, regional, and industry approvals. Contact us today! www.Chemetall.com

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


News & Features Editor:

Martin Ashcroft martin@aviationmanufacturer.com Editor:

Vanessa Ward vanessa@aviationmanufacturer.com Sales:

sales@aviationmanufacturer.com General email contact:

info@aviationmanufacturer.com Design and Artwork:

artwork@aviationmanufacturer.com Managing Director:

Simon Ward

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Worldwide Business Media Limited London EC1V 2NX United Kingdom www.aviationmanufacturer.com Tel: +44(0)203 5751249

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Aviation Manufacturer Magazine is published by Worldwide Business Media Limited, London, EC1V 2NX United Kingdom. Registered No. 6809417 England/ Wales. VAT No. 972 7492 76. All rights reserved. Reproduction in whole or any part without written permission is strictly prohibited. Liability: while every care has been taken in the preperation of this magazine, the publishers cannot be held responsible for the accuracy of the information herein, or any consequence arising from it. All paper used in this production comes from well managed sources.

Aviation Manufacturer Magazine  

Issue 9. Cover Story: Farnborough International Airshow

Aviation Manufacturer Magazine  

Issue 9. Cover Story: Farnborough International Airshow