Workshop EWADE-Finale

Alenia Aeronautica Technologies applied in R&D Napoli 25 Maggio 2011

N. Cauceglia - CTO

• Mission, Centers of Excellence & Network • Main Programs • Market Drivers & Challenges • Research & Innovation Network and main Research Project • Laboratories & Test Facilities • Relationships with Academic Institutions • B787 overview and Composite experience

MISSION/ ROLE CORE TECHNOLOGIES TEST FACILITIES

Air Vehicle Engineering Flight Test Centre

General Systems Demonstrators

Avionic & Weapon Integr . Rigs

UAS Sys. Integr . Simulator

System Low Observability Skylight Simulator

Integrator System Processes Anecoic Chamber PROCESS TECHNOLOGIES TECHNOLOGIES TECHNOLOGIES PROCESS PROCESS PROCESS Structural Processes Independent Composite/Metal Structural, systems and material Prime Innov. Concepts/ Materials laboratories

Manufacturing Processes

Torino Caselle Venegono / Alenia Aermacchi Total Headcount Final assembly Trainer aircraft Ground and flight test ∼∼∼1900 in Italy : ∼∼∼12.000 Logistic support ∼∼∼500 Design ∼∼∼3600 Venezia System integration and flight Overhaul and maintenance simulators Venezia/ SuperJet International Torino /Alenia SIA Marketing, Logistic Support and special versions regional aircraft Engineering systems

Foggia Nola Carbon fiber and composite material Machining Rome technologies assembly Large sheet metal Headquarter fabrication Large panel assembly ∼∼∼4800 Pomigliano ∼∼∼1500 Design Grottaglie-Monteiasi Metal bonding B787 carbon fiber fuselage production large structure Decimomannu sub-assemblies Flight Test center Structural laboratories

Alenia main subsidiaries, main consortia, JVs and program suppliers

SAPHIRE

Military Programs Commercial Programs

BAE Systems Airbus Eurofighter A380 Tornado A340 A330 Boeing A321 767 Tanker Boeing Dassault 787 Neuron 767 EADS 777 Eurofighter Bombardier Tornado CSeries L-3 Communications Dassault C-27J (JCA Program) Falcon 2000 EX Lockheed Martin Falcon 900 EX F35-JSF EADS C-130J ATR42/72 Embraer Sukhoi AMX Sukhoi Superjet family

Defense and Military Airlifters Regional Aircraft Mission Systems Aerostructures Trainer Aircraft Surveillance Aircraft UAV

T e c h n o l o g y R o a d m a p

Transport Aerostructures Trainer UAV

• Low Cost Communication • Low Cost Countries • Technology as offset Globalization

• Russia & Asia Growth New Comers • Brazil Growth

• Less Military Expenses Economic Crisis & Oil • Airline crisis Price growth • Growing Operative Costs • Fast Technology Evolution • Huge R&D Investment R&D Cost • Strategic alliances required

Public/Private Funding

• MULTICULTURAL ENVIRONMENT • NEW PARTNERSHIPS IN NEW COUNTRIES • STRONG LY COMPETITIVE CIVIL A/C MARKET • INTELLECTUAL PROPERTY AS A STRATEGIC ASSET

ONLY ONE ANSWER :

– MORE RESEARCH

– MORE INNOVATION

– MORE DEVELOPMENT

Regional, National & European Institutions R&D 474M€* Main National & European R&D/Revenue~18%* Universities & Research Centers

Main International & National Industrial Stakeholders

LOMBARDIA • Distretto aeronautico PIEMONTE lombardo - Embedded • Torino Wireless tactical training system • Distretto aerospaziale piemontese - Integrazione di sistemi complessi PUGLIA • DHITECH • DAP - Distretto aerospaziale pugliese - Advanced process engineering, LAZIO production and repair • Distretto dell’Aerospazio e Difesa - Systems developmeent, infrastructure, laboratories

CAMPANIA • IMAST • DAC - Distretto aerospaziale District recognized by MIUR campano - Airframe integration District being established (structure, systemi) PON Research & Competitivity

EDA ETAP Industrial Steering Working Groups Commitee Euromart Engine Equipment ATM (Aircraft) Industrial Management Groups

Civil & Military Funders

ETAP GSS MIDCAS ETAP TDP 4.5

European Projects

1600 M€ Vehicle ITD 800 EU + 800 Stakeholder

Eco -design Smart Fixed-Wing Green Regional Green For Airframe and Systems Aircraft Aircraft Rotorcraft Leaders: Dassault Aviation Leaders: Airbus Leaders: Alenia Leaders: Eurocopter & Fraunhofer Institute & SAAB & EADS CASA & AgustaWestland

Sustainable and 174 M€ 87 EU M€+ 87 Stakeholder Green Engines ITD Leaders: Rolls -Royce & Safran Clean Sky Technology Evaluator

Systems for Green for all vehicles vehicles vehicles all all all forforfor

Transverse Transverse Transverse Transverse Operations Leaders: Liebherr & Thales ITD: Integrated Technology Demonstrator © 2011 Alenia Aeronautica I N T E R N A L 13 Green Regional Aircraft – Participants

AIR GREEN Cluster with following members: Piaggio , Italy, single -voice Cluster's representative Polo delle S&T, Univ. Naples, Italy Centro Sviluppo Materiali (CSM), Italy IMAST, Italy (technological district) FoxBit, Italy Sicamb, Italy Politech . Turin, Italy Univ. Bologna/Forlì, Italy Univ. Pisa, Italy

ATR A sizeable amount of activities are CIRA PLUS Cluster reserved to Call for Proposals open with following members : to European Institutions and CIRA, Italy, single voice Cluster's representative Industry: we expect to reach about Dema, Italy Aerosoft, Italy 53 additional partners INCAS, Romania Elsis, Lithuania For end of this year, we foresee about 85 HELLENIC AEROSPACE INDUSTRY participants involved in GRA!!

ONERA

Advanced aerodynamics (Low Noise Innovative structures (Low Weight Configuration) Configuration) Lower Fuel Consumption multifunctional composites Better climb performance advanced metallic materials Lower Airframe noise from high lift devices Structure health monitoring and landing gear

Innovative systems (All Electrical Aircraft) Bleed less architectures Limited hydraulics Energy management New aircraft configurations (NC) Advanced turboprops Open rotors Evaluation of new avionics Advanced turbofan architecture in MTM domain for Fuel & noise reduction Upgraded capabilities for MTM Lower Maintenance costs

• Present ATM system is characterized by : – Fragmentation of airspace, – Obsolescence of present ground and on-board systems – Low usage of airspace resources

• SESAR objectives : – To triple the airspace capacity – To reduce ATM costs by 50%

– To increase safety by a factor 10 EUROPEAN EUROCONTROL THE INDUSTRY – To reduce environmental impact of single flight COMMISSION = public-private by 10% partnership 700 mio€ 700 mio€ 700 mio€ 2 founding members 3rd ‘founding’ • In three Phases : member – Definition (2004-2008) : to define new operative concepts and new R&D requirements (activity completed ) – Development (2008-2013) : research & development of new systems & standards by a common organization , the SESAR Joint Undertaking (in progress ) – Deployment (2014 -2020): introduction in service of new systems, procedures & standards (definition phase )

Extended Enterprise - Collaboration Digital data Multidisciplinary optimisation

Concurrence

Life Cycle Virtual prototyping

Product Lifecycle Standard methodologies Management Knowledge And process Management

Virtual & Physical Prototyping & Simulation in Programs and Research Virtual Product Virtual Testing Virtual Manufacturing Virtual Utilization

Concept Performance & Validation Industrialization Operation

In Service Strategic Concept Assessment Development Manufacture & Disposal

O2 Concentration

Virtual Product Navigation Multi-disciplinary Process, Data & Full Scale Testing © 2011 Alenia Aeronautica Integration Knowledge Management I N T E R N A L 18 Alenia Aeronautica and the new Frontier of Simulation & Testing Alenia Aeronautica Labs & Test Centers

• Ideas are not enough • State of the art labs in relevant areas • Skylight simulator • Anechoic Screened chamber • HIRF • Structural Test lab • The Flight Test Center

STRUCTURAL LABORATORY

MATERIAL & PROCESS LABORATORY

B787 Horizontal - Stabilizer Mechanical Lab Chemical Lab Material Test Machines

SYSTEM & ACOUSTIC LABORATORY

Microscopy & Failure Analysis Lab

Acoustic Lab Electric/Electronic Lab Fluid-dynamic lab

SSJ 100 Future Narrow 787 (51%) Bodies Fuselage “one piece New composite-metal barrel fuselage” hybrid solutions Cocured horizontal Eurofigther Prototype TYPHOON (40%) stabilizer (15%) Extended composite Wing panel cobonded spars application

Neuron - Advanced AMX (3%) ATR 42/72 UAV Advanced design technologies Tailplane cocured (19%) multi spar box and tools Tailplane extended cobonding JSF F-35 Wingbox composite- titanium integral design

B767 (3%) Moving surfaces composite application

JTI - Green Regional Platform EU - ALCAS Low weight : Innovative assembly tools for • Multifunctional materials wing CFRP structures • Adaptive materials National projects • Nanomaterials National projects • Titanium Welding • RFI Window Frame • Enhanced acoustic • Integral Fuselage frames performance structures EU - AWIATOR – “one-piece frame-shear tie” A340 Platform WINGLET Cocured multispar box (Closed mold cure)

EU - FACE cabin comfort design

2006 2007 2008 2010

Since 2005 Alenia Aeronautica has launched educational programs in close collaboration with local Scientific Faculties and Polytechnics

Examples of these educational programs are the following :

• Advanced Training EN gineers Aeronautics (ATENA – 2005 -2007 – dedicated to Greek students – advanced aeronautic education by Turin Polytechnic’ Professors mixed with training on the job at Alenia premises)

• Master Of Science in Aeronautics for the International Community (MOSAIC 2008 - 2010 – dedicated to Turkish, Lithuanian, Bulgarian, Greek, Romanian students – continuation of ATENA scheme)

• AEROTECH (1 st edition 2006-2007 – dedicated to post-graduated engineers – in partnership with ATR Toulouse (France), Cira, SAM Consortium, Magnaghi, Officine Aeronavali, OMASUD, Piaggio Aereo Industries, Sintart,Tecnam, Vulcanair and with Dipartimento di Progettazione Aeronautica (DPA), Università degli Studi di Napoli Federico II, Consorzio Eubeo (Consorzio Universitario per l'Innovazione), Regione Campania, Unione Industriali di Napoli

• INDUSTRIAL PhD Program (2010-on – dedicated to Italian post-graduated students)

MOSAIC : Post Graduated Master Of Science in Aeronautics for the International Community

Aircraft System Development 3 months Training job the on Mixed Courses/Training on the Job 6 months

Product oriented Research oriented Applied Thesis Research Thesis 9 months Specific Areas Areas Areas Areas Areas Areas Areas Specific Specific Specific Specific Specific Specific Advanced Technologies Advanced Technol. Develop. Thesis Areas: • Aircraft System Engineering • Advanced Materials & Manufacturing • Virtual Reality, Simulation and Training • Logistic support and maintenance © 2011 Alenia Aeronautica I N T E R N A L 24 Benefits for Universities

• For Professors : • initial possibility to provide lectures and seminars and in future be part of the consortium for the International Master hosting courses etc. • For students and Professors : • opportunity to visit Italian Universities/Research centres/ Industries, gain knowledge, establish new links, be part in network (concerted action) participate in common research projects (for instance within European Framework Programs) …. • For students: • high level education also suitable for those willing to continue academic career (ex. PhD) • Student education tailored also on industrial needs • (Master different orientations)

Breakthrough passenger cabin Overhead Enhanced Advanced crew rests flight deck wing design

Advanced Large cargo engines and capacity nacelles Composite Innovative primary systems structure technologies

Common Core More Electric Systems Open Systems Architecture Architecture

Advanced Flight Controls

e-Enabled Integrated Systems Health Management

Efficiency Contribution

Systems

Engines

Materials

Aerodynamics

Other Steel 5% Carbon laminate 10% Carbon sandwich Titanium Composites Other composites 15% 50% Aluminum Titanium Aluminum Titanium/steel/aluminum 20% © 2011 Alenia Aeronautica I N T E R N A L 28 Aerostructure Technology

Boeing 787 - The First “Plastic” Airplane For the first time in aviation history, composites will be applied to every primary structure of an airliner Composites : lighter, no fatigue or corrosion

Complete, large sections cocured together (One Piece Barrel) gives fewer joints, fewer parts, simple assembly, lower weight

Alenia Aeronautica is Boeing 787

Benchmark for future airliner development: RiskRisk--sharingsharing partner • 20% lower Direct Operating Costs • Savings from aerodynamics, materials •• About 15% ofofairframe and systems , engines and their •• Proprietary processes synergies •• New plantsin Italy and USA © 2011 Alenia Aeronautica I N T E R N A L 29 Structure Design and Technologies 787 Program Experience

787 Alenia Work Packages

Skin Lay Up Trim & Drill

BOEING 787-8 HORIZONTAL STABILIZER (Alenia Patented Technology based)

TECHNOLOGY SCALE-UP : FROM FEASIBILITY SPECIMEN (1983) TO AMX STABILIZER & VERTICAL FIN (1986) TO ATR 42/72 STABILIZER (1995), TO 787 STABILIZER DEMONSTRATOR (2006)

ATR HS

© 2011 Alenia Aeronautica I N T E R N A L 32 © 2011 Alenia Aeronautica I N T E R N A L 33 This document and all information contained in the pages 1-25; 28-34 is the sole property of ALENIA AERONAUTICA SPA. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of ALENIA AERONAUTICA SPA. This document and its content shall not be used for any purpose other than that for which it is supplied .