THE ADVANCED AEROSPACE MANUFACTURING AND ENGINEERING PARTNER CONTENTS

OVERVIEW Group History 2

Denel Aerostructures 3

Group Structures 4

Denel Aerostructures Values 7

COMPANY HISTORY International Customer Base 10

Current Programmes 12

Past Programmes 14

Nadcap Accredited 17

WORLD CLASS ENGINEERING CAPABILITIES Engineering Capabilities 18

Core Capabilities 20

Current Engineering Projects 24

Past Engineering Projects 28

WORLD CLASS MANUFACTURING CAPABILITIES Core Capabilities 34

Manufacturing Engineering 36

Machining 38

Sheet Metal 40

Special Processes 41

Composites 44

Assembly 45 02 THE CREDIBLE STATE- OWNED SOUTH AFRICAN STRATEGIC PARTNER FOR INNOVATIVE DEFENCE, SECURITY AND RELATED TECHNOLOGY

GROUP THE DENEL GROUP SOLUTIONS HISTORY CONSISTS OF:

DENEL AEROSTRUCTURES South African National Defence 'S Denel Aerostructures (DAe) is part of Force’s (SANDF) requirements the Denel Group, South Africa’s largest As the leading aerospace A leader in advanced systems as prime contractor and, where LARGEST manufacturer of defence equipment. company in Africa, a power- engineering technology, Denel we have competitive advantage, Denel operates in the military aerospace house in aerospace design and Dynamics’ core business covers also international customers as a MANUFACTURER and landward defence environment. advanced manufacturing, Denel tactical missiles, precision-guided systems integrator and subsystem OF DEFENCE Denel was officially incorporated as Aerostructures is associated with weapons, unmanned aerial vehicle and product supplier. DLS is a a private company in 1992. Denel the best original equipment systems (UAVS), integrated air consolidated, program based EQUIPMENT is a state-owned company with its manufacturers (OEMs) in the defence and related technology systems house for the development, sole share-holder the South African global industry and recognised solutions. The business is situated production, maintenance and in Irene, near and employs Government, reporting to the Department by Airbus as one of the most upgrades of infantry systems, approximately 800 people (64% of Public Enterprises. reliable suppliers on the A400M artillery gun systems and combat of its employees are technically programme. turrets as well as small arms. The highly qualified and world-class KEY DOMESTIC SUPPLIER company is based in Lyttelton, experts in their specialised fields). DENEL AVIATION south of Pretoria. The company’s Denel Dynamics has successfully Denel is a major defence contractor in A well-established Maintenance developed, produced, integrated strength lies in the unique fine its domestic market and a key supplier to Repair and Overhaul (MRO) and supported electronic and balance of technologies and the South African National Defence Force facility, Denel Aviation had been mechanical engineering systems engineering capabilities allowing (SANDF), both as original equipment providing support services to the since 1963, establishing a sound it to take complex systems or manufacturer (OEM) and for the over- (SAAF) technology base and infrastructure products through its whole life cycle, haul, maintenance, repair, refurbishment and the South African aviation along the way. from conceptualisation, systems and upgrade of equipment in the industry for more than 40 design, development, testing and SANDF’s arsenal. qualification to industrialisation years. Denel Technical Academy DENEL PMP falls under Denel Aviation and and production, product support is a well-established training PMP has been involved in the and eventual decommissioning. REPUTABLE INTERNATIONAL institute, accredited by several manufacture of ammunition since This strength is enhanced by an SUPPLIER training authorities and the 1931, and develops and man- entrenched culture of learning South African Civil Aviation ufactures small-to-medium calibre which is fostered in the company. Over the years Denel has built a Authority. Denel Technical ammunition, brass and copper reputation as a reliable supplier to its Academy consists of three training strip, high qualitypercussion caps many international clients. It supplies sectors: Apprenticeship Department of all types, mining drill-bits as well DENEL OVERBERG systems and consumables to end-users (Aviation and Engineering as power cartridges and cutting TEST RANGE charges. as well as sub-systems and components Industry), Youth Foundation Pro Denel Overberg Test Range is a to its industrial client base. -gramme, Advanced and Type well established test facility located Training (Aviation Industry). on the southernmost tip of Africa specialising in the in-flight testing Denel Land Systems is a landward and evaluation of missiles and defence system solutions business aviation systems for the local and with its primary focus on the international aerospace industries. 2 3 DENEL GROUP'S STRUCTURE

A RESPECTED SOUTH AFRICAN GOVERNMENT SOUTH AFRICAN Minister of Public Enterprises Minister of Defence and Military Veterans Other Ministers PROVIDER OF

South African INNOVATIVE Airways

Chief: SA Dept. of Trade & Industry DEFENCE, SECURITY Aviation South African National Defence Science & Technology Express Sector Defence (Secretary (Procurement) Economic Development Force of Defence) National Treasury AND RELATED Mango TECHNOLOGIES

Turbomeca Africa Associated (Pty) Ltd Companies Cassidian BUSINESS ENTITIES Optronics (Pty) Ltd Denel Strategic Equity Partners Rheinmetall Denel Munition (Pty) Ltd Denel Denel Dynamics Aviation

Denel Denel Land Denel PMP Overberg Test Systems Range

4 5 THE ADVANCED AEROSPACE MANUFACTURING AND ENGINEERING PARTNER

WHAT DENEL AEROSTRUCTURES STANDS FOR VISION Denel Aerostructures is the reliable African link in the global aerostructures supply chain: • Providing on time, on quality service and value for our customers. • Building a prosperous company for employees and our owners.

MISSION

Denel Aerostructures shall design and Denel Aerostructures aims to surpass produce complex metal and composite customers' expectations with on-time aerostructures, supplying to Original delivery, innovation and on-quality Equipment Manufacturers and other standards with a full range of engineering aerostructure suppliers. Denel Aerostructures (DAe) is part of the capabilities - design, development, test state-owned Denel Group, a respected and certification. As a strategic partner South African provider of innovative in global programmes, the company defence, security and related technologies. intends to build on its longstanding As the leading aerospace company reputation for innovation, quality and in Africa, a powerhouse in aerospace specialised solutions in aerospace design industries. As a strategic industrial and design and advanced manufacturing, and manufacturing. Our mastery of tech- economic asset for South Africa and we are associated with the best original nology and depth of skills are forged a primary contributor to the growth of PERFORMANCE INTEGRITY equipment manufacturers (OEMs) in the through decades of experience in the the aerospace sector and high–tech DENEL AEROSTRUCTURES We embrace We are honest, truthful global industry and recognised by Airbus aerospace sector. manufacturing on the continent – Denel VALUES operational excellence. and ethical. as one of the most reliable suppliers on Aerostructures is ideally positioned to the A400M programme. Denel Aerostructures is at the core of be a strategic aerospace design and the country’s largest aerospace hub, manufacturing partner. CARING Our strategic customers include Airbus, the Aerotropolis. We are located next INNOVATION We care for our ACCOUNTABILITY AgustaWestland, Boeing, Gulfstream, to OR Tambo International airport in We create sustainable people, customers, We take responsibility BAE Systems, SAAB and a US Business Johannesburg - Africa’s largest and innovative solutions. communites, nations for our actions. and the environment. Jet OEM. Denel Aerostructures invests busiest airport. With the Ekurhuleni extensively to establish modernised, Aerotropolis attracting aerospace and world-class facilities for high-end advanced manufacturing companies, machining, composites, manufacturing, DAe is well-positioned and close to a assembly and special processes. growing number of supply and partner

6 7 COMPANY HISTORY 1968 1983 1964 1990 1970 1980

Atlas Aircraft Corporation established Aermacchi MB-326 Impala Allouette / MRO Oryx / Super Puma conversion Cheetah / Design Authority Rooivalk / OEM 2007 2005 2000 1995 1996 1992

Denel (Pty) Ltd established Ace / All composite turbo prop trainer Gulfstream G150 SAAB Gripen Airbus A400M Denel Saab Aerostructures (Pty) Ltd established 2011 2011 2011 2011 2009 2012

A400M MSN 001 first flight Denel Aerostructures SOC Ltd A400M Interim Type Certification Completion of Gripen Programme Completion of A109 Programme New contract with US Business Jet established

8 9 INTERNATIONAL CUSTOMER BASE

Developing complex aerostructure components and assemblies, Denel Aerostructures is a leading supplier with extensive and growing experience from its international partnerships. Denel Aerostructures has the capability and technology to develop all types of defence and commercial airframe structures and the ability to support our customers all the way from concept designs through high volume serial production of aerostructures, to in-service support.

10 11 CURRENT PROGRAMMES

Airbus A400M US Business Jet Ribs, Swords, Spars (RSS)

Wing-to-Fuselage Fairing (WWF)

Winglet

Top Shells (TS)

PRODUCTS DELIVERY DATE OF DELIVERY/YEAR QUANTITY DELIVERED SIGNIFICANT MILESTONE TO DATE PRODUCTS DELIVERY DATE OF DELIVERY/YEAR QUANTITY DELIVERED SIGNIFICANT MILESTONE TO DATE Wing-to- Contract signature Jan 2005, MSN001 December 2006, bird strike, lightning Current 16 per 12 Fuselage & hail tests completed in April 2011, MSN006 new baseline December 2010, year ramping up Fairing MSN007 1st production model December 2011. New negotiated contract signed to 24 in two years Winglet First article delivery 29 January 2014 80 New Programme September 2012. time.

Top Shell Contract signature Aug 2005, MSN001 May 2006, MSN006 new baseline Feb Current 16 per 19 2009, MSN007 1st production model December 2010. New negotiated contract year ramping up signed July 2012. to 24 in two years time. Ribs, Spars Original contract signed Aug. 2006, transfer stopped in April 2010, transfer To ramp up to 24 New Programme and Swords re-initialised in February 2012, first test parts production complete. per year.

Vertical Stabiliser Gulfstream G150

Horizontal Stabiliser

PRODUCTS DELIVERY DATE OF DELIVERY/YEAR QUANTITY DELIVERED SIGNIFICANT MILESTONE TO DATE Rooivalk Concept design started in 1985. 3 per year 12+ ADM, EDM and XDM PRODUCTS DELIVERY DATE OF DELIVERY/YEAR QUANTITY DELIVERED XDM 1st Flight; 11 February 1990. SIGNIFICANT MILESTONE TO DATE ADM 1st Flight; 22 May 1992 1st with a glass cockpit. Empennage First Unit (unit 90) delivered in June 1997. Max 48 per year 110 EDM 1st Flight; 18 November 1996. 1st Production unit 1st Flight; Nov 1998.

12 13 PAST PROGRAMMES

SAAB Gripen BAE Systems Hawk

Main Landing Gear Unit

Flaps Rear Fuselage Tail Plane Airbrake Pylons

PRODUCTS DELIVERY DATE OF DELIVERY/YEAR QUANTITY DELIVERED PRODUCTS DELIVERY DATE OF DELIVERY/YEAR QUANTITY DELIVERED SIGNIFICANT MILESTONE TO DATE SIGNIFICANT MILESTONE TO DATE Main Umbrella agreement signed March 2000, SAAB has praised the build quality Max. 15 per year 145 Tailplane Programme commenced May 2000. Tailplanes built with the final delivery made in 12 per year 151 Landing of DAe’s MLGUs. August 2009. Gear Unit Flaps Programme commenced July 2002. Flap sets built with the final delivery made in 12 per year 46 Pylons Umbrella agreement signed March 2000, NATO Export baseline designed, Max 96 per year. 343 April 2009. developed and manufactured at DAe; first production started in mid 2003 and delivery early 2004. Airbrakes Programme commenced September 2003. Airbrakes built with the final delivery 12 per year 83 made in September 2008. Rear Umbrella agreement signed March 2000, March 2011 delivery of 100th. Max. 15 per year 115 Fuselage

14 15 FIRST COMPANY IN AFRICA AgustaWestland A109 Main Rotor Head TO BE NADCAP ACCREDITED

Tail Rotor Head

Engine & Rotor Mast Cowlings

QUALITY Accredited for: Tail-Boom ACCREDITATIONS • Non-Destructive Testing Main Rotor Blades Rear Fuselage • Chemical Processes • Heat Treatment Nose Cone Centre Fuselage Doors • Composites

PRODUCTS DELIVERY DATE OF QUANTITY DELIVERED SIGNIFICANT MILESTONE TO DATE A109 Product Supply Agreement signed July 2000, 30 AC delivered to SAAF (5 AW built, 25 DAe built). 30

ACCREDITED BY CERTIFIED BY

Boeing

APPROVED BY PRODUCTS DELIVERY DATE OF QUANTITY DELIVERED TO DATE SIGNIFICANT MILESTONE Boeing Period 2004 to 2011 - Total number of orders received from Boeing – approximately 3300. Detailed part with varying rates. Total number of details delivered 45148

737 details Programme commenced 2004 and completed in 2011. DAe contracted to produce 75 Detailed part with varying rates. and sub- different parts and sub-assemblies for the 737 Aircraft. assemblies

747 details Programme commenced 2004 and completed in 2011. DAe contracted to produce 148 Detailed part with varying rates. and sub- different parts and sub-assemblies for the 747 Aircraft. assemblies

767 details Programme commenced 2004 and completed in 2011. DAe contracted to produce 53 Detailed part with varying rates. and sub- different parts and sub-assemblies for the 767 Aircraft. assemblies

777 details Programme commenced 2004 and completed in 2011. DAe contracted to produce 113 Detailed part with varying rates. and sub- different parts and sub-assemblies for the 777 Aircraft. assemblies

16 17 WORLD-CLASS- ENGINEERING - CAPABILITIES

Denel Aerostructures portfolio of engineering capabilities include full spectrum Conceptual Design, Definition, Development, Testing and Certification

18 19 CONFIGURATION MANAGEMENT

Configuration Management processes are aligned to SUPPORT CMII, ISO10007 and OEM customer requirements. Primes (Windchill) is used for EBOM management, QMUZIK ERP is used for MBOM management and eBrowzer (eB) is used for documentation management. PRODUCE DISPOSE The main Configuration Management activities include: CONFIGURATION MANAGEMENT • Development of configuration management plans LIFECYCLE • Identification of configuration items to be placed under change management • Change control of the configuration items VALIDATE DESIGN • Requirements and release management CORE CAPABILITIES - • Status accounting which tracks change information ENGINEERING • Audits to verify that configuration item changes match the documentation

PRODUCE Project Plan

RESOURCES CONFIGURATION MANAGEMENT INTERFACE PLANNING • Core team of 55 • Processes aligned to ISO 10007 & INPUTS OUTPUTS • Aerospace specific experience: customer requirements Total collective > 870 years • Processes aligned to CMII AUDIT IDENTIFICATION Project Products CM Changes Average ~ 19 years • Primes (Windchill) used for EBOM Change Requests Change Decisions • 18 graduates (7 post-graduate) management Verify Changes • 11 Technical diplomas • eBrowser (eB) used for documentation STATUS CHANGE Change Data • 19 Other (CMII, PM etc) management; • Average age 43 • Q-Muzik ERP used for MBOM RELEASE management

SOFTWARE DESIGN OFFICE ENABLERS Stakeholder Investment • MSC Nastran • Catia V5 Decision Gates ENGINEERING • Full conceptual design, definition and development Technical Reviews • MSC Patran • Catia V4 CAPABILITIES • MSC Marc • ESDU • Metallic and composite • Mathcad • Dytran structures • MATLAB • iSight • Digital mock-up (DMU) integration, e.g. Airbus A400M • CPD (Composite Part Design) • Airbus tools (ISSY, SAMTECH tools etc.) • In-house developed tools (DCU etc.)

STRUCTURAL TEST LABORATORY STRUCTURAL ANALYSIS

• Material testing to International • Classical & numerical methods Specifications • Linear and non-linear finite element • Coupon, element, detail, sub- component analysis and component level testing • Metallic and Composite Materials • Static and fatigue testing • Static & dynamic analysis • Ground vibration testing • Durability and damage tolerance analysis • Impact testing (Bird strike, hail, debris etc.) • Aero-elastic analysis (flutter & divergence) • Environmental conditioning • Loads analysis • Weights engineering

Airbus A400M Top Shell Forward

20 21 CORE CAPABILITIES - ENGINEERING

DESIGN OFFICE METALLIC AND COMPOSITE STRUCTURAL ANALYSIS STRUCTURAL TESTING STRUCTURE DAe’s portfolio of engineering cap- DAe has very strong capabilities in The DAe engineering team comprises abilities include full Conceptual Design, • Sheet metal parts airframe structural analysis. Our of experienced test engineers that work Definition and Development. • Machined components team of experienced engineers are closely together with our test laboratory, highly skilled in classical aircraft stress a facility that is constantly growing in • Composite design using CPD analysis methods and their effective capabilities and accreditation. This covers: (includes the creation of CD and implementation. In addition, they are • Initial sizing and layout CM models and DXF files) also highly experienced in the effective In addition to the test laboratory, DAe • Preliminary studies use of computer-aided analysis of also has access to a range of other test engineering systems through the use of facilities at sister companies, such as • Stress layouts Finite Elements for stressing and flow Denel Dynamics, where we perform • Final detail design DIGITAL MOCK-UP (DMU) INTEGRATION simulation for aerodynamic design. impact testing and component level • Creation of manufacturing drawings • Creation of highly detailed mock-ups to show testing. Our capabilities and experience include • Design studies, which incorporate all parts and components that make up the numerous examples of static as well as DAe has experience and skills in static corrosion, bird strike, environmental structure. dynamic analysis, and we are equally and fatigue testing as well as ground impacts and trade-off studies • This increases the visibility of the model comfortable with analysing metallic or vibration testing. Our capabilities • Design for low cost, ease of for various phases of development and composite structures. Our experience include environmental conditioning of manufacture and low weight manufacturing, for both DAe and its of dynamic analysis included sim- test specimens to specified moisture customers. ulations of impact as well as simulations absorption and temperature conditions. • Reduces development time and cost, by of phenomena such as flutter and divergence. optimising processes and methods. DAe's structural analysis department also has strong capabilities and experience in durability and damage PARTICULAR RISK ANALYSIS (PRA) SUPPORT tolerance analysis. This includes the LIAISON ENGINEERING analysis of ultra-high-cycle fatigue such • Blade Release as sonic fatigue which was performed The engineering team applies its experience and on the Airbus A400M project. • Sonic Fatigue skills in the support of production processes where • APU Thermal Risks required. DAe has the ability to estimate and • Water Tightness predict flight loads and experience • Lightning Strike This is applied on a variety of industrialised at performing mass and balance calculations and other weight • Rapid Decompression and Leak Pressures programmes such as: engineering functions to the • Bird Strike requirements of customers. • Hail Strike • Ribs, Swords and Spars on the A400M Vertical Stabilizer, for Airbus Military • Hard Body Impact • Winglets for a US Business Jet OEM • Propeller Ice Strike • Empennage on the Gulfstream G150 jet

22 23 CURRENT ENGINEERING AIRBUS A400M TOP SHELLS (TS) PROJECTS The Top Shells are metallic semi-monocoque structures that form an integral part of the A400M Centre Fuselage. These are located at the forward and aft parts of the Centre Wing Box cut-out. As a result of the location, the Top Shells also provide structural provision for various systems housed in the space between the Wing-to- Fuselage Fairing (WFF) and the Centre Fuselage. DAe is responsible for the complete design, manufacture and certification of the Top Shells with Airbus Germany as the customer. Airbus A400M Top Shell Aft Inner Airbus A400M Top Shell Aft

AIRBUS A400M VERTICAL TAIL PLANE AIRBUS A400M (VTP) RIBS, SWORDS WING TO FUSELAGE AND SPARS (RSS) FAIRING (WFF) The WFF comprises a metallic substructure covered by 80 composite panels. The WFF provides aerodynamic efficiency over the Wing Box and protects critical aircraft systems. DAe is responsible for complete design, manufacture and certification of the WFF with Airbus as the customer.

DAe was involved in the development of the Airbus A400M VTP Ribs, Swords and Spars. An engineering team comprising of design and stress engineers was stationed at the Airbus Finkenwerder site in Hamburg, Germany. The team was involved in the redesign and weight saving exercise that was required for the MSN6 aircraft and onwards. The Ribs, Swords and Spars are composite monolithic structures with co-bonded stiffeners. Production and transfer of design authority for these class 1 and flight critical structural parts are planned for 2013. The metallic substructure of the WFF The LH & RH Onglet showing the composite Panels highlighted on WFF showing the Composite Panels that cover the the Metallic substructure. metallic substructure.

24 25 CURRENT ENGINEERING PROJECTS

DEVELOPMENT DENEL The Rooivalk development has comprised of the following: ROOIVALK (OEM) The Rooivalk combat support helicopter • A complete new airframe and undercarriage. is the most comprehensive development • A propulsion system based on a modified Super Puma power train. programme yet undertaken by Denel, • A main transmission vibration isolation system. through Denel Aviation and Denel Aerostructures. DAe’s responsibilities • An integrated suite on a 1553 data bus. on this project included system concept • An integrated weapons system suite on a 1760 data bus. through detailed design, flight testing, • An integrated Health Usage and Monitoring System (HUMS). development, integration, system support and qualification. • A complete mission, ground support and training system. • Test flying and certification of this system.

ROOIVALK EXTERNAL LONG RANGE FUEL TANK DEVELOPMENT SEEKER 400 UAV Denel Aerostructures has a well- • Size - 3450mm long x 640 diameter. established global reputation in the • Mass – 51.5kg empty and 496kg full. field of weight saving. Denel Dynamics, • Fuel capacity – 550 litres. another company in the Denel Group, is responsible for the design and • Construction – metallic centre section comprising pressed development of the first prototype of the sheet metal pressed bulkheads, frames, external skin with machined Seeker 400 Unmanned Aerial Vehicle. aircraft attachment fitting and machined system During the weight optimisation phase. DAe was commissioned to redesign fittings for the fuel transfer pumps valves electrical plugs etc. the wing of the Seeker 400 production • The nose and tail section being manufactured from model to achieve vital savings. composite material. • Lightening protection was designed into the tank for all weather operation.

26 27 PAST ENGINEERING PROJECTS

SAAB GRIPEN ORYX RADOME DOOR The Gripen is a multi-role jet fighter DAe was involved in the development of a operated by the South African Air Force. large composite Radome door for the Oryx Engineering activities included the helicopter from the concept phase through development, design and testing of the to qualification. The development included Weapons Pylons, weapons integration, the composite Radome door and the local structural and flutter analysis and reinforcement of the existing interfaces and Ground Vibration Testing. Major airframe to withstand increased door loads. components such as the Main Landing Gear Unit, Rear Fuselage and the Weapons Pylons were produced by DAe.

AGUSTAWESTLAND A109LUH The A109LUH is a military light utility helicopter ACE built under license for South African Air Force. The development of the LUH was a joint An all composite turbo prop trainer venture with AgustaWestland and activities developed by Aerotech (a division of included the structural integration of the the CSIR Council for Scientific and avionics suite, design and integration of the Industrial Research) in conjunction chaff and flare dispensing system and cockpit with Denel. Built as a demonstrator it modifications. Major components such as was used to develop the technical and main rotor heads and main rotor blades were manufacturing technologies associated produced by DAe for AgustaWestland. with carbon fibre airframes.

28 29 PAST ENGINEERING PROJECTS

AERMACCHI MB-326 IMPALA The Cheetah was an upgrade from the The Impala was a light military jet built III fighter jet. Major under license for the South African Air Engineering activities focused on the Force. Engineering activities included development and flight testing of a fatigue monitoring, battle damage prototype reconnaissance variant which repairs and the redesign and testing of involved the redesign of the nose to a prototype composite dive brake. accommodate cameras and an suite. Other Cheetah engineering projects included the design, manufacture and flight testing of a wing with a revised for increased manoeuvrability, and the redesign and ATLAS C4M KUDU testing of the main of the wing for improved fatigue life. The Kudu was a light utility aircraft based on the Aermacchi AL-60B and was built under licence for the South African Air Force. The development of the Kudu was a joint venture with Aermacchi and activities included the conversion of the type from a tricycle gear to a taildragger configuration, modifications to the vertical stabilizer and redesign of the engine cowling for improved acoustics and cooling.

30 31 WORLD-CLASS MANUFACTURING CAPABILITIES

Denel Aerostructures has state-of-the-art technology and manufacturing facilities for composite and metallic aerostructures

32 33 DAe IS ASSOCIATED WITH THE BEST ORIGINAL EQUIPMENT MANUFACTURERS (OEM'S) IN THE GLOBAL INDUSTRY AND RECOGNISED BY AIRBUS AS ONE OF THE MOST RELIABLE SUPPLIERS ON

CORE CAPABILITIES - THE A400M PROGRAMME OPERATIONS

MANUFACTURING ENGINEERING SHEET METAL

• Process Engineering • Fluid Cell Press • Jig and Tool design • 5-axis CNC Router and Drilling • NC programming • Hand forming • Material Technology • Stretch forming • Press and roll forming

ASSEMBLY MACHINING

• Sub Assemblies: T&J sub • 5 Axis high speed machining assemblies, Main Rotor Head, PRODUCTION • 3 axis machining (including long Bearing and Bush Installation bed) • Main assemblies build in ICY Jigs • Jig Boring, grinding and - Airbus Wing to Fuselage Fairing conventional machining - Airbus Top shells • CMM Inspection - G150 Empennage • Semi-automated C-Frame Riveter • Leica Laser Inspection

COMPOSITES SPECIAL PROCESSES

• Utilise glass fibre, Kevlar, and pre-preg • Heat Treatment caters for both carbon materials, as well as metal bonding aluminium (DAe) and Steel (fixing of metallic parts to composite (Turbomeca Africa) treatments. structures) • Surface treatment caters for Chromic • Typical assemblies range from Cowlings, Acid Anodising & Chemical milling. Fairings, to A400M composite panels • Paint shop • The facility has Class 7 and 8 rated clean • NADCAP Accredited for: rooms • Non Destructive Testing • NADCAP Accredited • Chemical Processing • Autoclaves 8 - 13m • Heat Treatment • Composites

34 35 CORE CAPABILITIES - OPERATIONS

QUALITY MANUFACTURING MANUFACTURING JIG AND TOOL DESIGN Accredited for: ENGINEERING ENGINEERING Design all tools needed to MACHINING • Non Destructive Testing Manufacturing Engineering specialize produce a structural assembly. SHEET METAL • Chemical Processes in developing holistic manufacturing This includes all detail part SPECIAL PROCESSES • Heat Treatment method data packs for aerostructure tooling up to final assembly and COMPOSITES • Composites assemblies. This includes detail metallic inspection tooling software used ASSEMBLY machined, sheet metal and composite is Catia V5. parts.

PROCESS ENGINEERING NC PROGRAMMING Develop manufacturing data packs for NC programming develop machine detail sheet metal parts, high speed programs for the manufacture of aluminium machined parts, complex composite components on 3, 4 and 5 axis High Speed parts as well as the sub assemblies machines. and full structural assemblies. The data pack contains the quality as well as the • Catia V4 and V5 special process requirements which are • Visi Cad Cam detailed step by step. Q-muzik software is used. • VERICUT tool path verification software • ICAM for generating post processors

MATERIALS TECHNOLOGY Responsible for assessing qualification status of special processes against customer requirements and developing special process cards for surface and heat treatment processes. This includes Anodic, Cathodic, Paint and Heat treatment processes.

36 37 CORE CAPABILITIES - OPERATIONS

MANUFACTURING MACHINING MACHINING PLANT CAPABILITY ENGINEERING MACHINING CAPABILITY MACHINING SWARF AND WATER MANAGEMENT SHEET METAL SYSTEM SPECIAL PROCESSES 5 AXIS N.C. MILLING QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) NO. PRODUCT TYPE SIZE COMPOSITES Deckel Maho DMU 80 P 2 700 650 650 A ALUMINIUM Semi automated management of all ASSEMBLY Deckel Maho DMU 125 2 1100 800 800 swarf generated by the NC milling Starrag ZT 800 1 1600 1000 1320 1 NC Parts Up to 800 mm x 300mm operations within the main machining area. Additional to this capability, Zimmerman FZ37 1 4500 3000 1500 2 5 Axis DMU Up to 800mm x 800mm manage the cooling temperature Zimmerman FZ37 1 6500 3000 1500 3 3 Axis Parts (Long Beds) Up to 5m x 2,5m of the cutting fluid utilized in all 70kw High Speed Spindle 24000 RPM the equipment. 4 Large 5 Axis Parts Up to 6m x 2,5m A third Zimmerman machine will be commissioned January 2014 5 CMS 5 Axis Router 3m x 18m NC–MILLING MACHINES – 3 AND 5–AXIS 3 AXIS N.C. MILLING QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) B STEEL

Leadwell V40 10 1000 500 650 1 Complex Parts Eg. Main Rotor Heads Up to 800mm x 800mm Have the capability to mill most Leadwell LBV 3215 2 3000 1500 800 aerostructures component. C PROCURE Conventional machining – Leadwell LBV 5229 2 5000 3000 1000 Recent accomplishments include no special processes the machining of a Rib–D (prototype) 1 South African Supplier base Cliffsway, Dailiff, for the Airbus programme. CONVENTIONAL QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) MicroMax, Panonia MACHINES Milling Machines 5 Various sizes Lathes 1 With copy attachments Grinders: Internal 1 External 1 Surface 1 Jig 1 Centre less 1

JIG BORING QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) SIP 700 1 1500 800 1300 SIP 640 1 1000 800 1300 full NC

38 39 CORE CAPABILITIES - OPERATIONS

MANUFACTURING ENGINEERING MACHINING SPECIAL PROCESSES PLANT CAPABILITY SHEET METAL SPECIAL PROCESSES SURFACE TREATMENT COMPOSITES NO. PRODUCT TYPE SIZE ASSEMBLY Refurbished and upgraded Phase 1 of the surface treatment area in order to manage A MANUFACTURE larger parts through these facilities.

1 Large parts which make up the assemblies Up to 7m Qualified facility for the processing of Airbus A400M Top Shells (Chromic Anodising). SHEET METAL PLANT CAPABILITY 2 Stringers Up to 2m FLUID CELL PRESS (QUINTUS PRESS TYPE QFC 1.1 X 4 - 1000) 3 Stretch Forming & Profiling of Extrusion Up to 3m 4 Skins 1.1m x 4m max High pressure forming press. The press SURFACE TREATMENT CAPABILITY has the capability to do multiple sheet NOTE Fluid Cell Press parts which can be produced with tooling metal part forming cycles with a usable Metallic Manufacturing – Aluminium, Steel and Other tray of 1.1 x 4 meters. It has an estimated ALUMINIUM QTY LENGTH WIDTH (mm) DEPTH (mm) capacity of 200,000 parts per year on a (mm) one shift scenario. Chrome Anodizing 1 8000 1000 3000 Chrome Anodizing 1 10 000 750 2000 METALLIC MANUFACTURING Chrome Anodizing 1 5300 700 2000 FLUID CELL PRESS QTY DIMENSION Sulphuric Anodizing 1 6000 800 2000 Fluid Cell Press 1 1.1m X 4m (100 MPA) Pickling Processing 2 8000 1000 3000 Chromate Conversion 1 1900 1000 2000 STRETCH FORMING QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) Coating Vertical Stretch Form- 1 2400 2000 1500 Hard Anodizing 1 1000 400 800 ing Chemical Milling 1 450 800 600 Horizontal Stretch 1 3000 750 250 Sulphuric Etch 1 1000 1200 1200 Forming ROLLERS QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) STEEL, ,STAINLESS QTY LENGTH WIDTH (mm) DEPTH (mm) STEEL, TITANIUM (mm) Farnham Roller 1 5900 continuous Cadium Plating 1 2000 1000 1600 Lisse Roller 1 2300 continuous Phosphating (Zink) 1 2000 1000 1600 Titanium Pickling 1 400 400 600 ROUTER QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) Passivation Stainless Steel 1 1200 440 800 NC Router 1 4700 1200 Passivation Stainless Steel 1 600 600 600

FREEZER QTY LENGTH WIDTH (mm) HEIGHT (mm) (mm) MECHANICAL QTY LENGTH WIDTH (mm) DEPTH (mm) Various Freezer 1 6000 3000 2000 PROCESSES (mm) Glass Peening 1 1000 1500 800 40 41 CORE CAPABILITIES - OPERATIONS

MANUFACTURING ENGINEERING MACHINING SHEET METAL SPECIAL PROCESSES PAINT SHOP BOOTHS 1 2 3 4 5 COMPOSITES Length 7m 7m 7,8m 3m 1,5m ASSEMBLY Height 3,2m 2,8m 3,2m 3,2m 1,5m Width 4m 4m 4,3m 4,3m 1,0m SPECIAL PROCESSES PLANT CAPABILITY NON-DESTRUCTIVE TESTING Drying Tunnel Spray Curtains (Qty 4) ALUMINIUM HEAT TREATMENT Facility capable of the following Length 24m Length 2,8m testing: This semi–automated aluminium solution treatment furnace has the ability to • Magnetic Particle Inspection Height 2,3m Height 2m manage large panel parts. The furnace has dedicated cooling water support and • Die Penetrant Eddy Current Width 2,5m Width 0,5m has an operating temperature range of 500° to 550°C (Max = 600°C). • X-Ray - Real Time • Ultrasonic Testing Ovens (Qty 3)

FURNACE 41 FURNACE 17 Range 0-550°C Range 0-400°C Maximum 550°C Maximum 400°C Size 5.35m x 2m height x 1.1m width Size 4.6m x 1.65m height x 1m width

HEAT TREATMENT CAPABILITY Metallic Manufacturing – Aluminum, Steel and Other

ALUMINIUM QTY X-AXIS (mm) Y-AXIS (mm) Z-AXIS (mm) Solution Treatment 1 7000 3000 2000 Furnace Furnace ageing/ 1 7000 1500 2000 Stress relieving

STEEL – ONLY VIA TURBOMECA AFRICA (TMA) Various Ageing/Hardening, Stress Relieving, Annealing Furnaces Various Salt Baths

42 43 CORE CAPABILITIES - OPERATIONS

MANUFACTURING MANUFACTURING ENGINEERING ENGINEERING MACHINING MACHINING SHEET METAL SHEET METAL SPECIAL PROCESSES SPECIAL PROCESSES COMPOSITES COMPOSITES ASSEMBLY ASSEMBLY

NO. PRODUCT TYPE MATERIAL TYPE SIZE

A STRUCTURAL Up to 7m PLANT CAPABILITY COMPOSITES PLANT CAPABILITY AUTOCLAVE ASSEMBLY 1 Empennages Composite/Metallic

CMS ROUTER QTY 2 The composite facility currently has two autoclaves ASSEMBLY LINE 2 Tail units Composite/Metallic with a third to be commissioned October 2013. 3 Elevators/Tabs/Flaps Composite/Metallic The CMS has two independent spindle heads with a maximum speed of Operating pressure range up to 10 bar at 200ºC. Currently DAe assemble sub and main assemblies for the following OEM's: 22000rpm. The table envelope includes a maximum length of 4 Airbrakes Composite/Metallic 18m X 3.8m X 1.8m. AUTOCLAVE LENGTH • AIRBUS 5 Wing Tips Composite/Metallic 1 2,5m x 13m • Gulfstream 2 3m x 8m 6 Small to Medium aircraft Composite/Metallic structures 3 2,5m x 9m (on order) A Semi Automatic C Frame riveter was also installed with a reach of 2m. 7 Fairings/Cowlings Composite/Metallic

B MECHANICAL Between COMPOSITE CAPABILITY 0.5m & 3m

Clean Rooms QTY 2 1 Small complex critical Composite/Metallic assemblies 471m2 Class 7 464m2 Class 8

MAIN PRODUCTION EQUIPMENT QTY Surface treatment plant 1 Automatic ply cutters 2 NDT ultrasonic and X–ray 1 Metronor measuring equipment 1 Paint shop 1 Automated surface treatment plant 1 A&C Scanners 2

44 45 Denel Aerostructures (SOC) LTD. operates a dynamic world class supply chain, offering end-to-end managed solutions through: · Value realisation driven by an integrated customer-focused lean global supply chain network · Sales & operations planning and logistics solutions · Supplier collaboration and creation of strategic supply agreements Management of material flows from sources of supply through plants to customer

State Owned Company Thin Web Machining Our Customer Base Supply Chain

Denel Aerostructures Denel Aerostructures has portfolio of engineering state-of-the-art technology capabilities include full and manufacturing

Accredited for: spectrum Conceptual facilities for composite • Non Destructive Testing Design, Definition, and metallic • Chemical Processes • Heat Treatment Development, Testing and aerostructures • Composites Certification

Engineering and Design Nadcap accredited World Class Engineering World Class Manufacturing Capabilities Capabilities

Advanced Composite Facility Airbus A400M partner

46 47 NOTES CONTACT DETAILS Address: Astropark, Atlas Road, Bonaero Park, Gauteng GPS: S 26.14522 E 028.26659 Email: [email protected] Tel: 011 927 3319 Fax: 011 927 2632 Visit us: www.denelaero.co.za