The new technology catalogue
Great ideas for better aircraft and better manufacturing from companies in the aerospace supply chain The new technology catalogue
Welcome
The Midlands is home to one of the largest aerospace industry clusters in the world. The times ahead are challenging. We’re seeing an unparalleled growth in the number of aircraft being manufactured, experiencing uncertain economic conditions and facing intense global competition. At the heart of any solid plan to get ahead and grow are great ideas. Right across the supply chain. That’s why the MAA is proud to be celebrating ten years of enabling aerospace businesses, mostly our smaller companies, to access over £8m of funding and develop more than 40 new technologies for new and next generation aircraft.
It’s sometimes assumed that lower-tier aerospace companies should focus solely on efficiency initiatives and have less to David Danger, Chair Peter Smith, Vice Chair contribute when it comes to innovation and new technology. The truth is, these companies catalogue. There’ll be more stories like this to come often have great ideas but lack the resources to develop as we explore new ways of working together in the them. With the right support, innovative thinking can be Midlands to maximise the development of new developed and take off. You’ll read inspiring examples technologies for the world’s aerospace industry into the of how the MAA has enabled this to happen in this future.
Companies across the Midlands aerospace supply chain are in constant competition to be positioned on tomorrow’s aircraft programmes. Developing new capabilities, processes and technologies is vital to stand out. To enable more of our companies to do this, the MAA’s unique philosophy of support addresses all the key things these companies need, and tackles all the barriers which could get in the way, at once. We’re passionate about helping supply chain companies create their own intellectual property and especially to turn their fantastic technical knowhow into knowledge they can exploit commercially by helping solve challenges the big aircraft and engine makers face. If there’s one thing I’ve learned, over the ten years the MAA has been supporting brilliant companies like those you’ll see featured in this catalogue, it’s just how deep the well of new ideas is within the aerospace supply chain and especially within small manufacturers. It’s a privilege to be part of helping transform these concepts into real competitive advantage.
Take G&O Springs, for example, a high-performing spring manufacturer which was one of the early companies to receive support through our ATEP programme a decade ago. The company now possesses IP for spring Andrew Mair, Chief Executive design critical for better performing actuation systems, has secured new customers that recognise its expertise – and sales have more than doubled.
Over the following pages, you’ll discover the innovative way we work with aerospace companies at all levels to develop new product technologies and better manufacturing processes. I hope their success stories will inspire you to work with them on your new aerospace projects and to talk to our team if you have fresh ideas of your own which you’re considering developing.
3 3 Midlands Aerospace Alliance The new technology catalogue
Companies get real results Support at the highest level
Many of the technologies we’ve supported supply chain The MAA approach means a high rate of project Top companies within the aerospace sector get GKN companies to mature will be used on current and next acceptance actively involved with our work. We value the time they generation aircraft programmes or help manufacture them provide for inputting into strategic development and “NATEP has been a very exciting activity,” says Jim better. They also help the companies that developed Idea funded supporting supply chain organisations. Godman, Global Head of Engineering Integration at them improve productivity, reduce costs and create GKN Aerospace. “We’ve been very successful but it’s For example, over 75 leading aerospace companies, more jobs by winning more work with existing and new only the start of the journey. We need to continue.” including Airbus, Boeing, Rolls-Royce, GKN and BAE customers around the world. Systems, have advised supply chain companies as part Meggitt of one of the technology development programmes 42% we designed, NATEP. Toby Hutton, Manager of Friction and Structural “It really helped that my MAA Materials at Meggitt, was involved with an ATEP 58% Technology Manager understood Rolls-Royce project, researching ways to increase brake life on aircraft, as part of the funding programme that was my technology. This helped get my “We need to develop a lot of technology across a wide a precursor to NATEP. He then joined the MAA’s idea down into a convincing and range of fields,” says Robin Hill, Head of Electronics at Technology Group to advise on NATEP in the Midlands Rolls-Royce. “Obviously we can’t possibly do it all in and found it rewarding. successful application.” house.” “The MAA’s approach is excellent at drawing in SMEs He says the programme’s reach into the supply chain and sometimes larger organisations that might have through regional aerospace alliances is crucial. He not considered aerospace before,” he says. “The Aerospace suppliers grow in confidence Companies’ competitiveness is enhanced values the Technology Managers who take on the expertise that the MAA supplies gives these firms detailed management of projects and work with confidence and a vehicle through which to drive their 63% Low companies like Rolls-Royce to ensure the requirements R&D. NATEP has brought impactful benefits to the 57% Average of end-customers are satisfied. aerospace sector in the UK as well as the wider UK TRL = 6.3 He would “absolutely” support further NATEP projects economy.” and is interested right now in “how we can continue to stimulate the supply chain.” Airbus 25% 18% Average TRL = 3.9 20 Rolls-Royce Confident to collaborate Confident to collaborate market Competition in the company’s with other firms on with primes/upper tier High 12 technology development aerospace companies Low Competitiveness position enhancement High Before After TRL = Technology Readiness Level Finmeccanica Other customers 63 7 at all tiers /Leonardo Source: Evaluation of NATEP technology development programme by Regeneris Consulting 7 GKN Aerospace
Companies achieve or make good progress towards their goals 4 3 GE Aviation Develop or test an idea Raytheon No progress 2 Raise company profile Some progress but lots more to do Access grant funding AIM Aviation Eurocontrol Lots of progress but not quite finished Safran Ipeco Access specialist expertise Boeing ITP Mission accomplished Build market intelligence Bombardier Thales Cobham Wesco Aircraft Access equipment
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Dozens of aerospace companies have been end-users for projects, from Airbus that supported 20 NATEP projects to 63 that supported one project.
Source: Evaluation of NATEP by Regeneris Consulting Source: NATEP
4 5 Midlands Aerospace Alliance The new technology catalogue
We help ideas take off Technology experts enable success
We have industry experts working at every level. Our board and three working groups are made up of a fantastic network of over fifty senior aerospace figures. The MAA Technology Group steers the MAA’s work on technology development, gives valuable advice on individual projects and takes pride in seeing the results!
Our team of Technology Managers mentor companies at every stage. They are always on the lookout for problems that need solving and great ideas that may be eligible for financial and expert support. They also help businesses Aerospace Primes fine-tune their proposals and apply for funding. Then they work with companies to develop the new technologies (OEMs) and new manufacturing processes that will enable them to advance. Technology Managers always work with companies in a collaborative way. Not only do businesses benefit from their Project end users, technology group experts project management expertise, for example, but the Technology Managers also encourage fruitful partnerships between companies, universities and research organisations and help them get the attention of potential customers. Tier 1 Multi-technology systems companies Bridget Day Stan Payne Project end users, technology group experts Bridget leads the team. She Stan is the MAA’s go-to expert combines thirty years’ experience for technology roadmapping and working as an aerospace engineer helps companies to recognise and Tier 2 with ten as a Technology Manager develop their innovation strategy at the MAA to help the companies and find clear paths to commercial Component makers she mentors gain confidence exploitation of their technologies. Companies doing projects and receiving funding and flourish. She’s currently He particularly enjoys using his exploring additive manufacturing and digital factory business acumen to help companies achieve their enhancements. wider objectives through this process. Tier 3 Parts makers Guided technology Malcolm Diplock Eric Bray Companies doing projects and receiving funding development from the bottom up Malcolm enjoys seeing projects Eric appreciates the uniqueness through from concept to of each of the companies he completion, especially when the supports as well as the variety lead partner goes on to establish of technologies and challenges We know just how Funding projects an ongoing relationship with an with which he’s involved. He likes More NATEP many great ideas there aerospace prime end-user, as it can helping companies move forward NATEP Projects with technology centres are at every level within (ATEP goes national) (e.g. additive manufacturing) the aerospace industry. create new opportunities for them. into the next stage of their journey. ATEP 2 Work with big firms to inject They’re not all at the top. (Midlands) bottom-up innovation ATEP 1 Great ideas come from the Dr Pamela Farries Peter Knight (Midlands) Help small companies ground too where even the develop R&D culture smallest project could make a big Pamela gets great satisfaction Peter has spent most of his career from discovering overlooked working in R&D and joined the Projects with global difference. Many of these ideas aerospace clusters are about better parts, components technologies, sometimes from MAA after serving as a member 2005 2010 2015 The future or software. Many are about better different sectors, and bringing of the MAA Technology Group in Projects in this ways to make things. And many are them to aerospace. At the moment, his previous job. Peter brings his catalogue just about making things simpler, more she’s excited by research into experience and enthusiasm for efficient and finding new ways to achieve better energy storage, potentially developing technology to smaller We and all the companies supported are grateful to BEIS, AMSCI, quality, cost and delivery targets. for electric aircraft and hybrid flight. organisations. He values the way the MAA cares for the Finance Birmingham, AWM and ERDF who have provided the We’re proud many manufacturers’ ideas long-term viability of the aerospace supply chain and is Government funding to match industry investment into the technology projects in this catalogue. Many thanks as well to our take off. With the right backing, lower-tier committed to supporting this task. sister regional aerospace alliances and national organisation ADS companies can be really innovative, add more with which we worked as part of the UK’s industry-Government value, stay globally competitive and move up in Aerospace Growth Partnership. the industry.
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MAA projects deliver locally and globally Low cost gearbox electronics exchangers for springs and finishing casting alloys High strength High strength Naturally, most of the technology projects we’ve supported are based in the Midlands. We support NASA Credits: metal bonding New materials Blisk machining long life tooling using composites Nano coatings for Lightweight piping
companies outside the Midlands too, if they are partnering with a Midlands company or don’t have a Composite actuator High temperature heat High temperature
regional aerospace alliance where they are located. Plasma cleaning of FADEC
The results will make their way across the globe on new and next generation aircraft.
Companies across our region participate in engine for SMEs Software for Software manufacture aircraft wings aircraft Dry drilling of Engine control Engine control systems design blade coatings Non-hazardous Non-hazardous Innovative UAV Innovative UAV software timing software MAA new technology power modules piezo transducers High temperature High temperature Ultrasonic assisted Blade core die block Blade core Innovative electronic Innovative electronic projects Derbyshire composite machining Manufacturing intelligence NASA’s STARC-ABL Turboelectric Aircraft Concept. Aircraft Turboelectric STARC-ABL NASA’s Notts Lincolnshire
Staffordshire technology pipe fittings manufacture manufacture Surface cooler development for engine test of bleed valves Engine ring parts Small UAV engine Small UAV Lightweight engine Shropshire Advanced telemetry Additive manufacture Additive manufacture Combustion chamber
Leicestershire
Worcestershire Northants Warwickshire Herefordshire for tyres
The Midlands New design methods
MAA promotes future exports with 1 in 5 end users outside the UK MAA supports smaller companies Composite for interiors 3D weaving of 8% Bio composites brake materials composite structures Innovative ceramic 20% 10% heating system pre-preg
49% 80% 33% composites 3D moulded Aircraft is for illustrative purposes only and does not imply Aircraft on this concept aircraft. any of these technologies are using graphene Novel miniature Novel miniature electronic circuits electronic actuators for seats Use of graphene in lightning protection software Conductive adhesives calibration Environmentally friendly Environmentally aids inspection New technologies delivered Augmented reality Augmented reality Innovative slip gauge Inventory optimisation UK Outside UK Large Medium Small Micro
Source: NATEP participants 8 9 Midlands Aerospace Alliance The new technology catalogue
Project Catalogue Process Optimisation for Aerospace Alloys Lead Partner Pattonair Customer
Page Electronics Manufacturing/Processing Software/Modelling Composites Actuators/Sensors Additive Layer Engines Materials Instrumentation/Metrology Coolers/Heat Exchangers Arrowsmith ANT Industries Technoset l Engineering Process Optimisation for Aerospace Alloys 11 ITP SA Visual Inventory Optimisation System 12 l Customer Lightweight Pipe End-Fittings 12 l l Manufacturing l Technology Centre Inhibiting Delamination in CFRP Composites 13 Machining and consultancy Additive Aero Valve Optimisations (AAVO) 13 l l Xenon Pulse Technology in Fibre Placements 14 l Subcontractor Hands-Free Inspection Interface 15 l When MAA members ANT Industries, Arrowsmith and relaxation. For Managing director Shaun Rowley ROCA: RapiTime Object Code Analyser 15 l Engineering and Technoset faced manufacturing this lead to a more generic understanding of how to Configurable Double-Sided Cooled Integrated Power Module 16 l challenges on precision aerospace make-to-print parts, produce a whole family of similar parts, and the securing l l Plasma Cleaning in MCM Advanced Manufacture 16 they realised that NATEP could be an opportunity to of a long-term contract for rings on a new engine series. l SPARCS Rotary Engine 17 help differentiate themselves from their competitors. “It’s always a challenge for an SME to find the time for l l l Machine Connectivity and Manufacturing Intelligence 17 By embracing a culture of R&D to produce innovative R&D. When you can sit with a team of experts, you get Novel Miniature Actuator (NMA) 18 l solutions, the partners demonstrated how they can new ideas that challenge what you do. For us, that was add value for their customers. Under this project Proof of Systems Assurance and Certification 19 l a bonus.” they formed a consortium with the Manufacturing Graphene Composites Evaluated in Lightning Strike (GraCELS) 19 l l Technology Centre (MTC) in Coventry to tackle two Arrowsmith asked MTC to help solve manufacturing Piezoelectrically - Enabled Aero Controls 20 l specific problems; the machining of large diameter, problems associated with the thread-rolling of ultra- 3D Moulded Circuits 20 l l l very thin section aero engine rings for end user ITP SA, hard aerospace alloys. By again carrying out off-line l Chrome free Ipcote 21 and thread rolling in ultra-hard materials for end user research into the thread rolling process, machinery Enterprise Bio-Interiors Project 21 l Pattonair. and tooling, MTC were able to help Arrowsmith write Dry Drilling of Aluminium Alloys 22 l l a set of manufacturing standards that would enable ANT Industries machine many parts for aero engines l them to consistently produce conforming parts. Finite Measurement 23 including large diameter, complex section engine rings, l l Combustion Chamber Process Innovation 23 where the wall thickness can be as little as 1-2 mm. This Managing Director Jason Aldridge feels it is important Graphene-Enhanced Adhesive Technology through that the UK aerospace supply chain demonstrates its 24 l presents major challenges due to material relaxation Functionalization (GrEAT Fun) and distortion meaning that it is difficult, and in some commitment to finding advanced solutions at every l l High Temperature Heat Exchanger 24 cases impossible, to produce parts within drawing stage of manufacturing. “As a result of this project, we l l Composite Pipe Bending 25 tolerances, resulting in the need for concessions. With will be manufacturing components that previously could Heat Transfer Surface Development 25 l l l assistance from ANT Industries, MTC carried out ‘off- not be made, and we’ll be using precision controlled Cooled Core Die Blocks 26 l line’ research into machining, tooling and fixturing production techniques that keep quality high and costs Small Rotary Engine Technologies 27 l strategies, and how these affect component stability down”. Ultrasonic Assisted Machining of Aerospace Composites (USAMAC) 27 l l Affordable Diffusion Bonding 28 l l Forging Tools using Nano Engineering (FORTUNE) 28 l l Composite Actuation Gearbox Housing 29 l Integrally Bladed Rotor (IBR) – Barrel Milling Cutter 29 l Software Defined Telemetry 30 l l Surface Cooler Development 31 l l
A2OX Aluminium Alloy 31 l Aircraft Tyres Finite Element Modelling 32 l Aerospring Spring Characterisation 32 l l Biocomposites for Aerospace Interiors 33 l Endurance Braking 33 l Integrally Bladed Rotor (IBR) – Abrasive Flow Machining 34 l Contact: Jason Aldridge – [email protected]
10 11 11 Midlands Aerospace Alliance The new technology catalogue Visual Inventory Optimisation System Inhibiting Delamination in CFRP Composites Lead Partner Lead Partner
CANDA Systems Consult Avila RLC Engineering Group Composite Innovations M Wright & Sons GKN Aerospace Software coding Software spec and test Customer Composite tooling 3D composites Customer
Maintaining stock levels of aerospace incorporating best practices in Carbon fibre reinforced plastic been produced, including T-section components and materials at the inventory management such as (CFRP) composite structures beams, which have been subjected optimum levels can be a problem, trend analysis, alerting, forecasting, which use conventional two- to a range of mechanical tests with especially when this involves high financial planning, and automated dimensional woven fabric layers excellent results. End user GKN part counts, many expensive replenishment. The grant enabled can fail through de-lamination Aerospace is looking at how this parts, multiple sites, legacy parts, a prototype version of the VIOS at the inter-ply boundaries when different customer programmes software to be demonstrated to subjected to impact or cyclic technology can be incorporated into and contractual commitments, prospective customers and, assisted loads. Typically the introduction its composite aerospace components. with varying call-off rates and by valuable feedback from users, of through-thickness fibres which bind the plies together M Wright project leader, Simon Marshall, comments; replenishment lead times. a full commercial version of the results in reduced mechanical properties due to crimping “The development of 3D weave architectures allows software has now been produced of the in-plane reinforcing fibres. MAA member Consult Avila and the manufacture of composite structures with increased with production partner ValueChain its partner CANDA Systems have In this 2 year project, M Wright & Sons together Technology. resistance to interlaminar failure due to impact or cyclic tackled this problem by developing with moulding partner Composite Innovations have loading. In addition, near crimp-free architecture creates a new visual management software Consult Avila chief executive Jose developed a 3D weaving capability which results in laminates with excellent in-plane mechanical properties. tool (VIOS) to optimise inventory, Guzman-Bello comments: “Our ‘near-zero’ crimping of the reinforcing fibres, leading with guidance from end-user RLC Engineering Group. approach is designed to change the way of working and to 3D preform structures which exhibit increased This allows engineers the flexibility to design structures VIOS provides users with data visualisation screens create a new way of thinking. Inventory is a symptom resistance to delamination whilst maintaining good in- with high damage resistance without compromising in- allowing dynamic inventory planning and control, and not the disease.” plane mechanical properties. Various test shapes have plane mechanical properties”.
Contact: Dudley Wood – [email protected] Contact: Simon Marshall – [email protected]
Lightweight Pipe End-Fittings Additive Aero Valve Optimisations (AAVO) Lead Partner Lead Partner Sigma Precision 3T RPD Aerospace Company Ashton & Moore GE Aviation Additive layer manufacture Components Customer Meggitt Aerospace Design, machine, test Finishing Design and manufacture Customer
The objective of this 12-month project, led by MAA and processes. Sigma’s Director of Technology & Suppliers of aerospace components specification, it became possible to member Sigma Precision Components, was to reduce Improvement, Mike Andreae, reported: “The results and systems are under constant integrate silencing measures into the aircraft weight by designing and manufacturing a show the new end-fittings are at least 50% lighter than pressure to reduce the cost and valve design, reducing the complexity new range of lightweight pipe end-fittings, taking full current designs and, in some cases, more efficient due to weight of components, whilst of the bleed air system. The integration advantage of the benefits offered by the metal additive improved flow characteristics.” improving performance. In this of components and functions into single layer manufacturing (ALM) process. Working with partner project, Meggitt Control Systems parts reduces technical, commercial and 3T RPD, it soon became clear to project leader Sigma set out to develop a fully-optimised supply chain challenges. The result was that its design team would need additional training in jet engine compressor bleed a lighter, quieter, more reliable and more order to take full advantage of the exciting possibilities valve by taking advantage of the efficient valve with a reduced cost of offered by ALM technology. design freedoms of additive layer manufacture. manufacture (ALM). The NATEP grant enabled the partners to redesign Project leader Scott Lathrope comments: and build a selection of typical complex end-fittings Bleed valves vent the compressor during low power “For Meggitt, the critical output of this project is the – including T and Y pieces, instrumentation fittings, operation to prevent engine stall. Venting of the design-for-process lessons when ALM is utilized in flanged fittings and elbows – which were subjected to compressor contributes significantly to the engine noise. system development. The result is a process for a rigorous analysis and testing to validate both materials By beginning the valve design with the basic functional broader approach to product design.”
Contact: Mike Andreae – [email protected] Contact: Scott Lathrope – [email protected]
12 13 Midlands Aerospace Alliance The new technology catalogue Xenon Pulse Technology in Fibre Hands-Free Inspection Interface Lead Partner Placements Cranfield Aerospace Customer Coventry University Muretex Lead Partner Human factors System development Major Aerospace Tier 1 Hexcel Heraeus Noblelight Rolls-Royce Customer Composite Material Xenon Technology Customer In this project led by the use of traditional Muretex, the partners paper and electronic work have investigated the instructions Cambridge-based Heraeus Noblelight used NATEP According to Heraeus Technical Director Jeremy use of an optical head- funding to help it demonstrate the use of xenon Woffendin, “This new technology is generating strong Based on the experience mounted display system flash technology as a highly controllable heat source commercial interest from the aerospace sector, with gained with the NATEP to provide ‘hands-free’ in automated fibre placement (AFP) when laying additional opportunities in other market sectors. demonstrations, Muretex aerospace inspection up composite materials for aerospace applications. We’re now working with key equipment OEMs to fully has launched its Augmentor® service which offers Together with partner Hexcel Composites, project integrate our system into their products.” He added: and assembly instructions without reference to printed bespoke solutions aimed at augmenting human leader Heraeus has taken the idea from a basic “NATEP helped us to develop the system in a timely materials. The NATEP grant enabled the partners to capabilities through the use of technology. Founding laboratory test bench demonstrator to a fully working fashion and lowered the financial risk; it has enabled us develop the infrastructure and processes necessary Director, Jon Platts comments: “The project enabled us system fitted to a Coriolis composite fibre placement to create new jobs at Heraeus whilst securing jobs for to serve up work instructions in a readily assimilated to rapidly build the kernel of the system against realistic machine at the National Composites Centre, Bristol, the existing workforce, and put the UK firmly in the lead manner, reducing operator workload and improving use-cases and whilst the grant funding is extremely under the watchful eye of end user, Rolls-Royce. for this technology”. efficiency, accuracy and traceability. Trials at Coventry welcome, the gravitas of a NATEP funded project was This patented technology, which offers significant University were commissioned to demonstrate the equally valuable and allowed us to access key end- advantages over competing laser and infrared-based benefits of using a head-mounted display system over users.” systems has been branded as humm3 and is now winning orders from equipment OEMs. Contact: Jon Platts – [email protected]
ROCA: RapiTime Object Code Analyser Lead Partner Rolls-Royce Customer University of York Rapita Systems Certification consultancy Software development Airbus Defence and Space Customer
How long does it take for safety- from NATEP, aerospace software critical aerospace software to run, verification specialists Rapita, working in particularly in ‘worst-case’ scenarios? collaboration with the University of York, This is a question that all suppliers has produced a demonstration version of of aero engine control software its Rapita Object Code Analyser (ROCA) such as Rolls-Royce must be able to for RapiTime, which eliminates the need answer with certainty as part of the to instrument source code. ROCA can certification process. reduce the effort and cost needed to Until now, timing measurements have perform timing verification by 25%. been obtained by ‘instrumenting’ Rapita CEO, Dr Guillem Bernat the code using Rapita Verification Suite (RVS), which involves an extra comments: “NATEP gave our project a tooling step, and has an impact on execution time. A platform that brought it to the attention By Coriolis Components theoretical solution to avoid this step was put forward of two end users, Rolls-Royce and Airbus Defence and in a PhD thesis in 2011, but implementing it required Space. Both companies were involved in our research investment and hardware support, not to mention a and their input was invaluable to ensure we developed a Contact: Jeremy Woffendin – [email protected] good measure of innovative thinking. With funding demonstrator that met their exact needs”.
Contact: Ian Broster – [email protected] 14 15 14 Midlands Aerospace Alliance The new technology catalogue Configurable Double-Sided Cooled SPARCS Rotary Engine Integrated Power Module Lead Partner Vortex Exhaust Advanced Innovative Aero Composites Lead Partner Technology Engineering Innovations Exhaust design, manufacture Design, build, test Customer Pre-Met Copper retaining clips Semelab Rolls-Royce Design, manufacture, test Customer design and manufacture In this 18-month project led by Lichfield-based Advanced Innovative Engineering (AIE), the partners For the Leicestershire-based reliability, performance, and ease have developed a high-performance compact propulsion semiconductor specialist of integration, whilst reducing system for a new generation of commercial unmanned Semelab, part of the TT cost, size and weight. aerial vehicles (UAVs) designed by end user, Aero Electronics Group, R&D Composites Innovations. The project involved the Semelab Engineering Director underpins its corporate culture design and manufacture of a small rotary engine which Julian Thomas commented that as it seeks to keep ahead of incorporates AIE’s patented SPARCS rotor cooling although the company is no the market and maintain its system and a new exhaust system from Vortex Exhaust stranger to match-funded R&D, status as an expert in its field. Technology. The result is an extremely lightweight the MAA’s approach brought engine which features better thermal control, gas sealing Under this 18 month NATEP miniaturised devices. AIE’s Nathan Bailey comments: unexpected business benefits. and exhaust cleanliness than competing engines. project, Semelab and project “This new engine hits a sweet spot in the market partner Pre-Met designed and “One of the good things was The 5hp, 40cc engine is designed to power a small because it competes with both higher power electric manufactured a new configurable and highly thermally the workshops they arranged, particularly sessions on rhomboid-wing UAV, itself highly innovative. The UAV’s which have endurance limitations, and less efficient electronic power module for end user, Rolls- intellectual property (IP) and road-mapping. These types compactness of the engine meant that many of the efficient small conventional internal combustion engines Royce. This module uses a unique architecture to of business level workshops are very useful, especially for commercially available ancillaries were too large, which generate unwanted vibrations for sensitive provide significant improvements in heat dissipation, SMEs.” requiring AIE to design and manufacture its own payloads”.
Contact: Julian Thomas – [email protected] Contact: Nathan Bailey – [email protected]
Plasma Cleaning in MCM Advanced Machine Connectivity and Manufacturing Manufacture Intelligence Lead Partner Lead Partner Welwyn Components Accelonix Rolls-Royce ATS Arrowsmith Plasma cleaning Power & Hybrid Hitex (UK) System design Customer Embedded technology Engineering MCM manufacture and integration Customer
Northumberland-based Welwyn cleaning in safety critical applications has The objective of this project from wireless communications and embedded Components, a division of TT historically been discouraged because Applied Tech Systems (ATS) and partner windows data processing and Android Electronics, is on a journey of of fears of surface damage. This project Hitex was to bring the ‘digital factory’ wifi display platforms. So-called credit increased automation within its investigated the effects of plasma cleaning within reach of SMEs. While larger card technology enables them to install production line for Multi-Chip companies are embracing the fully on an MCM that is used to control aero low-cost data gathering on manufacturing Modules (MCM), a form of integrated digital revolution with fully integrated engines and flight management systems, machinery which will communicate via hybrid electronics. One key aspect in software connecting every part of a flagship component for Rolls Royce wifi with a server, offering the possibility ensuring the necessary high levels of the manufacturing operation, smaller engines. reliability for these often safety critical companies usually have limited resources of integration into the manufacturing products is cleanliness, particularly TT Electronics Engineering Director, Julian and end up with a miscellany of digital and manual intelligence network. End user Jason Aldridge of prior to die placement and wire bonding. Thomas, comments: “Working with partners Rolls-Royce systems, often driven by legacy software and with poor Arrowsmith Engineering has been a major advocate for The aim of this project was to investigate whether and Accelonix, Welwyn Components were able to show interconnectivity. this enabling technology. “The widening gap in digital categorically through this NATEP project that plasma automation of the production line could include in- The project partners have developed a cost-effective maturity between higher and lower tiers in the aerospace line plasma cleaning of the substrate. Although an cleaning presents a viable solution which can safely be machine connectivity module (MCM) to monitor manufacturing supply chain needs to be closed if our established process in other industries, the use of plasma incorporated into the automated MCM line.” manufacturing processes, using retrofitted sensors, industry is to compete globally”.
Contact: Julian Thomas – [email protected] Contact: Greg Ella – [email protected]
16 17 Midlands Aerospace Alliance The new technology catalogue Novel Miniature Actuator (NMA) Proof of Systems Assurance and Certification Lead Partner
Abstract Solutions D-RisQ Lead Partner System design and GE Aerospace SysML programming Customer Modelworks ‘engine’ Midland Aerospace CNR Services BE Aerospace Manufacture International Customer As the avionics industry moves towards phase, with a high level of confidence. Design, assembly, test the development of ever more complex Based on D-RisQ’s underpinning systems, validation of software against Formal Methods technology, the Engineering design specialist and MAA member requirements for aircraft certification new tool incorporating the SysML CNR Services International led this NATEP project purposes becomes a major challenge. modelling language as a ‘front end’ to design, build and demonstrate a new actuator for Current techniques focus on manual first and business class aircraft seats. CNR Managing review at the outset of the project and takes system requirements expressed Director Chris Reckless said success in testing the then, towards the end of the project, in English, converts them to a ‘Novel Miniature Actuator’ to aerospace specifications testing reveals any inadequacies of the system against formalised representation expressed in SysML and then the requirements. This process is inevitably error prone points to a potential game-changer in its class. “The uses the Formal Methods technique to validate that the and costly, especially when errors are discovered late in new device is smaller, lighter, cheaper and uses less requirements have been fully and accurately captured. power than its current counterpart. Once this gets a project. This problem led software specialists D-RisQ D-RisQ’s Business Director Nick Tudor comments: productionised, the weight reduction alone will run and Abstract Solutions to propose a NATEP project “Whilst the methods used are generic, the intention is into millions of dollars savings a year. It’s a massive in which a new tool would be developed that can win for the operators.” automatically verify that requirements for a system have that this tool can be qualified for use on safety critical been fully and accurately captured early in the design aerospace applications conforming to DO178C Level A.” Together with partner Midland Aerospace, which made one of the key components of this radically Contact: Nick Tudor – [email protected] different actuator, CNR proved to its end user, BE Aerospace, that it was possible to ‘swim against the stream’ and re-think the design concept completely Graphene Composites Evaluated in rather than keep refining an existing concept. Lightning Strike (GraCELS) Lead Partner SHD Composites Airbus UK Resin and prepeg Haydale Composite Customer Solutions Functionalised graphene Cobham Technical BAE Systems Services and project management Customer Lightning strike testing
Use of composites in aircraft the incorporation of graphene/2D applications such as fuselage, nano-particles into the composite leading edges and wing surfaces resin. The key to success lies in the By Hideyuki KAMON from Takarazuka is complicated by the fact that efficacy of dispersion of the nano- the materials are very poor fillers throughout the resin, and electrical conductors, especially here Haydale’s patented plasma Contact: Chris Reckless – [email protected] in the laminate through-thickness functionalisation technique has allowed direction, and so perform badly in lightning-strike composite panels to be developed events. To provide protection against lightning strike with significantly improved through-thickness electrical conductivity. Sample panels have been subjected to designers need to specify the incorporation of additional ‘laboratory lighting strike’ by lighting testing specialists materials such as copper mesh; this, however, adds cost at Cobham Technical Services. Project Leader Peter and weight to the aircraft. Hansen is enthusiastic about the possibilities for this In this 18-month NATEP project, composites specialist technology. “Whilst we still need to undertake further Haydale Composite Solutions, together with partners research, we have achieved some very encouraging SHD Composites and Cobham Technical Services, results which have generated significant interest within have come up with a novel solution which involves the aerospace sector.”
Contact: Peter Hansen – [email protected] 18 19 18 Midlands Aerospace Alliance The new technology catalogue Piezoelectrically - Enabled Aero Controls Chrome-free Ipcote Lead Partner Lead Partner Ashton & Moore Messier Dowty Spray system Customer Linwave Ionix Advanced Indestructable Rolls-Royce Paint Company Technology Technologies Customer Signal processing Design, build, test Clean Burner Systems Coating development Rolls-Royce Precision heating Customer Although piezoelectric device is designed for operation The Ipcote product with the benefit of offering lower transducers have been around at temperatures up to 350˚C manufactured by Indestructible for many years, until recently for 25,000 hours. Much of curing temperatures. Building Paint Company (IPC) is the temperature limitations of the work has centred around on the previous research the aim approved by a large section of the material have precluded encapsulation of the piezo of this 18 month ATEP project the aeronautical industry as an their use in instrumentation on material to make it rugged even was to reformulate Ipcote to be gas turbine engines. All that is about to change with a erosion and corrosion-resistant when immersed in fuel. chrome-free. Partner Ashton & new ‘high temperature’ piezoelectric material developed coating for turbine blades, Moore was able to determine by Ionix Advanced Technologies from original research There has been strong interest from end user, Rolls- undercarriages and parts for high how the chemical replacements undertaken by the University of Leeds. Working Royce, and project leader Tim Comyn of Ionix temperature applications. Whilst with partner Linwave Technology, Ionix have initially believes there is also a strong market pull for the high it is a replacement for cadmium affected the spray application. concentrated on the development of a piezoelectric temperature piezo-electric devices in non-aero markets. plated products, IPC recognised Clean Burner Systems developed that because the product was based on chromic acid, displacement transducer which would replace a linear “We are commencing broad commercial release of a highly focussed heating element normally used for it was subject to fresh legislative threats. IPC have a variable differential transformer (LVDT) position sensing technology based on this transducer in a range of curing tarmac, that in this project can be used to apply device currently used on gas turbine engines. The new sectors including petrochemical and nuclear.” representative on the European REACH committee. the chrome-free Ipcote product in situ on a runway if A previous feasibility study, also funded by ATEP, Contact: Tim Comyn – [email protected] working with with CERAM (now Lucideon) researched necessary. Thus a new chrome-free coating material the chemicals involved. This indicated that manganese and application/curing process was developed and redox agents could be a potential chrome replacement, successfully applied to test parts. 3D Moulded Circuits Lead Partner Enterprise Bio-Interiors Project Moulded Circuits Laser Optical MBDA UK Lead Partner Plated polymers and Engineering Customer composites Holographic diffractive optics SHD Composites AIM Aviation Product and Ipeco Composites Manufacture and test Customer This NATEP project gave Laser The research developed process design Optical Engineering (LOE) and two different, but complementary approaches partner Moulded Circuits a helping For Lincolnshire-based prepreg than current materials. However, project hand to develop a laser processing to allow for different types manufacturer SHD Composites, a new leader Nick Smith emphasises that there system capable of marking high of substrate and also the material set to revolutionise aircraft are other benefits likely to be at least variation in feature sizes resolution circuity onto engineering interiors has been developed using which might favour one as interesting to the aerospace industry, polymer parts. With guidance and an unlikely biomass waste product. particular approach. Using concerning the health and safety of encouragement from end user, Under this 18-month NATEP project, both additive (deposition) production workers and the environment. MBDA, the team have developed SHD and partner AIM Aviation have and subtractive (ablation) “The new material is much safer to handle a laser writing system capable of developed a new composite material producing copper tracks or circuits on 3D polymer techniques, the team have been able to successfully in which the phenolic resin that is as manufacture does not involve any and composite structures. This allows such structures apply 3D circuitry to trial structures provided by MBDA. traditionally used has been replaced hazardous volatile organic compounds to become electrically functional components within LOE’s Managing Director, John Tyrer, comments: “This by a furfuryl alcohol resin derived from waste by- (VOCs) and the hot melt manufacturing is less energy- a system, replacing the traditional circuit board. The partnership is well placed to take advantage of what we see as a large and expanding market for ‘intelligent products of sugar cane processing. intensive and solvent-free, leading to reduced technology will give designers scope to combine part structures’ and embedded functionality across a wide emissions.” SHD has acquired a new factory which will functionality to reduce component count and weight, This new material has demonstrated great fire-resistance range of sectors.” be used to manufacture the new prepreg material after it and allow much greater freedom to produce truly properties compliant with aerospace standards and innovative designs. mechanical properties which are as good as, or better is certified.
Contact: Daniel Lloyd – [email protected] Contact: Nick Smith – [email protected]
20 21 Midlands Aerospace Alliance The new technology catalogue Dry Drilling of Aluminium Alloys Finite Measurement Lead Partner Lead Partner Powerkut Winbro Group Coventry University Measurement hardware, Kyocera Unimerco Teer Coatings, MIBA Robotics, electronics, software Technologies Airbus UK testing Customer Tooling Coating Group Customer Tool design Coatings development Since the early 1900s, gauge blocks, sometimes referred to as slip gauges, have been widely used throughout MAA members Teer Coatings and Kyocera Unimerco Technology Manager at the MAA, acted as technology the manufacturing industry as reference standards for Tooling have been working together with the University broker, introducing Kyocera to supplier of advanced calibration of instruments and measuring equipment. of Manchester to explore tools for in-situ, liquid coatings, Teer Coatings, part of the Miba Coating Coventry-based Powerkut, which provides a gauge block lubricant-free drilling on aluminium alloy aircraft Group. Airbus quickly came on board as end user, and a calibration service, realised that the labour intensive and structures. Tooling supplier Kyocera Unimerco had NATEP project was born. highly specialised calibration procedure had changed observed that dry, in-situ drilling of aluminium alloys, Combining drill re-design and the application of little in the last 50 years or so. This did not seem with no significant loss of drill tool performance, advanced hard, solid lubricant coatings, the project compatible with current trends in manufacturing, as would simplify and reduce the cost of aircraft wing team have been able to demonstrate that dry drilling exemplified by Industry 4.0. manufacture while also improving the workplace is not only feasible, but a practical reality which fulfils The objective of this 24 month project involving partners environment. For aircraft manufacturers like Airbus, the performance and commercial requirements. Dr Powerkut and Coventry University was to automate using cooling/lubricating fluids during drilling adds to Managing Director, Paul Bexon, comments; ”This NATEP Hailin Sun, R&D technology centre manager for Teer the gauge block calibration operation. Removing the complexity of manufacture, and the management project helped Powerkut to develop its relationship Coatings commented: “This project has been more manual handling of the blocks eliminates the need of traditional lubricants in an open factory environment than a collaboration, it’s brought about a new business for thermal stabilisation, and automating the probing with Coventry University, and provided an opportunity imposes additional complexity and cost. The idea relationship, which is important as we see a great deal operations allows human interpretation to be replaced plus financial support to pursue some ideas on moving of dry-drilling was shared with the MAA at the of potential for this technology, not just in aerospace”. by highly repeatable machine measurement. Powerkut’s calibration technology forward.” Farnborough Airshow, and Peter Knight, NATEP Contact: Paul Bexon – [email protected]
Combustion Chamber Process Innovation Lead Partner Nasmyth Hucknall Aerospace prime Sheet Metal Technologies Customer Laser expertise Process development
For complex structures and Working closely with partner Hucknall precision welding company, Sheet Metal, Nasmyth carried out Nasmyth Technologies, difficulties in research into the three processes - manufacturing a make-to-print legacy welding, graphite bonding and thermal combustion chamber component in a barrier coating of a perforated surface highly competitive market presented – all of which were having a negative a difficult choice; this was to either impact on combustion chamber decline the work, accept a high throughput. New alternative processes attrition rate arising in particular from were successfully developed for each of these areas, three troublesome processes, or to invest in finding which were presented to the customer. For Nasmyth solutions, working with the customer to seek design changes where necessary. Nasmyth decided that, Project Leader Mac Fletcher, the project had added whilst the business case might not be very attractive, benefits: “This project has helped show our customer there was a strong case for helping the customer, which that Nasmyth is more than a make-to-print company, and was committed to continued support of the engine. can add value through innovation. We firmly believe this Fortunately help in the way of a grant from the NATEP underpins the development of a mutually beneficial long Contact: Hailin Sun – [email protected] programme was on hand. term relationship”.
Contact: Nicky Forster – [email protected]
22 23 22 Midlands Aerospace Alliance The new technology catalogue Graphene-Enhanced Adhesive Technology Composite Pipe Bending Lead Partner through Functionalization (GrEAT Fun) Rolls-Royce Customer eMould (UK) Sigma Precision Components Lead Partner Tooling development Pipe manufacture, bend and test SHD Composite Materials GE Aviation Systems Bentley Motors Adhesive manufacture Customer Customer Haydale Composite Solutions Carbon fibre reinforced thermoplastic pre-made Sigma composite straight pipe Resin masterbatch development Element Hitchin Aerospace Prime pipes offer potential weight reductions into the desired form under computer Adhesive testing Customer for aircraft because they are durable, control. To achieve this, it was necessary strong and light. The problem with to design and manufacture special tools Whilst most adhesives make conductivity to produce conductive airframe and aero-engine pipes, which are heated and cooled during a good electrical insulators, there adhesives. The approach has the however, is that they are seldom if ever precisely controlled, automated forming are some situations, like ensuring added benefit that the addition straight and more usually have bends cycle. earth bonding continuity between of graphene can also enhance the in complicated 3D geometries. Traditional manufacture The bent pipes have been subjected to a range of aerospace composite structures, mechanical properties of the joint. of thermoset composite parts, which involves laying the tests and have been shown to meet performance where having a conductive fibres in a mould replicating the final shape required, Project Leader Haydale’s requirements. Sigma’s Director of Technology & adhesive would be beneficial. As is problematic for pipes which can have many different experience with a patented Improvement, Mike Andreae, said that interest from aircraft designers are continually shapes. graphene processing technique end users Rolls-Royce and Bentley Motors was strong. increasing the composite part called functionalisation has shown Leicestershire-based Sigma Precision Components, “Composite pipe is a disruptive technology which count to reduce weight, challenges that structural adhesive resin a leading supplier of metallic pipes, considered the offers up to 50 per cent weight reduction compared such as electrically conductive structural adhesives systems can be developed with significantly improved traditional thermoset method neither a sensible nor cost- to stainless steel and 15 per cent reduction compared are becoming more important. There are examples electrical conductivity. Project Leader Peter Hansen of effective approach for composite pipes. Sigma proposed to titanium. While only a proportion of aerospace of conductive adhesives on the market that use silver Haydale comments: “Our research into a number of a novel alternative which NATEP has been able to help applications would be eligible for a composite pipe or other metallic fillers to increase conductivity but different resin formulation systems has provided us with turn into a reality. In this 12-month project, Sigma and solution due to thermoplastic temperature constraints, these are often of high density, expensive and the filler encouraging results. Although we still have work to do to partner eMould (UK) have developed a process to bend this is still a very large potential global market.” loading levels compromise the adhesion strength. In this reach the desired electrical conductivity levels, we have NATEP project, partners Haydale Composite Solutions, demonstrated anti-static adhesive pastes and films which Contact: Michael Andreae – [email protected] SHD Composite Materials and Element Hitchin have are also attracting interest from our end user for other investigated utilizing graphene’s extraordinary electrical applications”.
Contact: Peter Hansen – [email protected] Heat Transfer Surface Development Lead Partner Dunlop Equipment Metal foam Meggitt Control Serck Aviation Manufacture Systems University of Birmingham Customer High Temperature Heat Exchanger Testing
Lead Partner Arden Precision Machining Advanced Chemical Etching HS Marston Aerospace Rolls-Royce Process chemistry Manufacture Customer PAB Coventry Sheet metalwork In this project Wolverhampton-based H S Marston heat exchangers by Serck Aviation and Dunlop Equipment (now both Aerospace worked with a Telford SME, Advanced approximately 300˚C. Meggitt) worked with the University of Birmingham Chemical Etching (ACE) to develop high temperature For ACE this project and two local SMEs - Solihull’s Arden Precision heat exchangers made from new alloys for aero engine has led to a new (now Nasmyth) and PAB Coventry - to develop a applications. Both tubular and plate fin heat exchangers business area and manufacturing process to join metal foam to small were manufactured in a material new to this market, new the development of a tubes, which maximises the working surface within a processes were developed for forming, brazing, welding. new laboratory for the small volume. The need to have a perfect joint for heat By manufacturing to existing designs a direct comparison hydrofluoric acid-free transfer is particularly challenging. The technology could be tested. The new material and process etching of titanium involved a novel nickel-based metal foam (Retimet) developed extended the operating temperature of the and nickel alloys. which has proved to be a more effective heat transfer and tested on a specially designed, fully instrumented medium in a range of environments inside and outside water/air heat exchanger test facility at Birmingham aerospace. A number of prototypes were manufactured University.
24 25 Midlands Aerospace Alliance The new technology catalogue Cooled Core Die Blocks Small Rotary Engine Technologies Lead Partner TechTeam Development Lead Partner Assemble and test A&M EDM Design, manufacture, UAV Manufacturer Customer Material Solutions evaluate ALM manufacture Gardner BTC Invest Tech ASNU Corporation Europe Design, build, test, evaluate Customer Injection design, and support manufacture, test
For Smethwick-based precision fuel, even at low temperatures. This An 18-month NATEP project led by machinists, A&M EDM, NATEP came at project, which involved partners Gardner BTC featured the use of an opportune moment in the growth of TechTeam and ASNU, resulted in additive manufacturing (AM) to help the company. For many years A&M has the design, building and testing of a improve the yield from one of the manufactured parts of rotary engines 11 kW rotary engine with excellent cold starting on heavy fuels, and an many complex manufacturing steps in for other companies, and has built impressive continuous wide-open- making modern gas turbine blades. up considerable experience in the throttle performance. Starting from a Turbine blades for aero engines are manufacturing intricacies associated ‘clean sheet’ also meant that, in addition to the engine, usually manufactured by investment with this type of engine. However, the recruitment the team needed to design and build a dynamometer casting (or lost wax processing) and a of design staff with significant rotary engine design cell test facility, plus most of the engine ancillaries. experience, plus the chance to secure a grant, gave temporary embedded ceramic core is A&M’s Managing Director, Mark Wingfield is optimistic A&M management an opportunity to move from a make- used to preserve the spaces which will that the project heralds a new business line for the to-print subcontractor to an engine OEM. eventually become complex internal air company: “This NATEP grant has given us and our cooling galleries. For end user Invest Working with a leading European UAV manufacturer, partners the incentive and encouragement to turn a Tech, manufacture of these ceramic A&M identified a gap in the market for a small rotary business proposition into a business reality, and we see cores presented a problem because the engine with rapid starting when running on kerosene good growth potential within the UAV market”. narrow and convoluted ‘fingers’ of the Contact: Tim Shires – [email protected] ceramic core were prone to fracture due to thermal stresses arising from heating and cooling.
Together with 3D printing partner Ultrasonic Assisted Machining of Aerospace Material Solutions, Gardner has redesigned the ceramic core Composites (USAMAC) manufacturing dies to introduce Kyocera Unimerco Lead Partner optimised thermal control within the Tooling die block during injection. The cooling Tooling development Teer Coatings, Miba BAE Systems channels were designed and positioned Coating Group Customer to make far more complicated internal pathways than Coating development with the aid of computer thermal analyses to give Warwick Manufacturing have previously been achieved through conventional greater control over the injection process and minimise Group machining, giving our end user significantly better Testing and validation residual stresses in the injected core. Gardner’s Keith thermal control of their process.” Fulford comments: “By using AM, it has been possible This project tackled the drilling of of the art knowledge, the consortium composite structures, in particular laminates combined advances in high performance Contact: Keith Fulford – [email protected] of carbon reinforced composites and high multi-layer coatings, innovative drill design performance titanium alloys, which are together with the latest in ultrasonically extremely challenging for tooling. Project assisted machining technology, to improve leaders, Teer Coatings, together with drilling performance and extend drill tooling partner Kyocera Unimerco, teamed life when machining composite/titanium up with Warwick Manufacturing Group (WMG) to take alloy material stacks. Teer’s R&D Manager, Hailin Sun, advantage of WMG’s expertise in a new innovation comments: “The unique combined expertise brought involving active tooling. together under this NATEP partnership has allowed The benefits of Ultrasonic Assisted Drilling (UAD) in us to make significant advances in composite/titanium reducing cutting forces and tool wear rates, while alloy drilling technology. Our collaboration continues preserving workpiece surface quality, are only just being as we explore this area further, and our end user, BAE recognised. Building on previous research and state Systems, remains very engaged and supportive”.
Contact: Hailin Sun – [email protected] 26 27 26 Midlands Aerospace Alliance The new technology catalogue Affordable Diffusion Bonding Composite Actuation Gearbox Housing Lead Partner Unipart Manufacturing Lead Partner Customer Advanced Rojac Tooling Goodrich Actuation Ajax Tocco Composites Group Technologies Systems Machine design University of Material technology Tooling design Customer Wolverhampton Rolls-Royce Marine Modelling, process Customer The objective of the project led by Wolverhampton- Line Gearbox, H S Marston parameters Test and development BAE Systems based Goodrich Actuation Systems (now UTC was endurance Customer Aerospace Systems) was to determine whether it would tested on a be possible to manufacture a viable, cost effective back-to-back Diffusion bonding is an established technology in conventional diffusion composite gearbox that would be interchangeable gearbox test the production of heat exchangers and fuel cells, but bonding process, and, with a current aluminium die-casting gear box, but rig at Goodrich the equipment required is slow and expensive, and by using local heating; offering substantial weight savings. Secondary benefits and met the there are size limitations to assemblies that can be good bonds could be over the aluminium housing were a lower thermal design criteria. built. In this project, researchers at the University of achieved in less than expansion when exposed to temperature extremes, Moving from Wolverhampton teamed up with induction heating a minute. With ATEP and the elimination of corrosion. The composite unit aluminium to a composite housing offered a 60% specialists, Ajax Tocco, heat exchanger specialist H S programme support the manufactured by Rojac, which replicated the A320 Flap weight reduction. Marston, and end users Unipart, Rolls-Royce Marine and team developed a lower BAE Systems. Research carried out at the University of capital equipment cost Wolverhampton proved that it was possible to eliminate process and a test rig demonstrator for the new bonding Integrally Bladed Rotor (IBR) – Barrel the large expensive pressure vessels, necessary in the process. Milling Cutter Development Lead Partner Forging Tools using Nano Engineering Technicut ITP Engines UK GEO Kingsbury Tooling design and Milling m/c and ITP SA Management, design, fixtures, Customer (FORTUNE) development inspection, analysis controller support Lead Partner Anopol Coating technology Teer Coatings Rolls-Royce Advanced Manufacturing Coating process Customer Research Centre University of Birmingham CAM software lead, machining Nano techniques Subcontractor In the FORTUNE project, thermal stability and high machining This innovative NATEP project seeks to make For this project, IBR manufacturer and TCL, Anopol Limited and capability for steel. The coatings improvements to a long-established manufacturing project leader ITP Engines UK joined Birmingham University appear to show almost universal process for one particularly challenging group of engine forces with cutting tool manufacturer collaborated with Rolls-Royce working characteristics under components. The current manufacturing process for Technicut, and milling machine supplier Inchinnan, to investigate operating conditions of low and the blades on compressor Integrally Bladed Rotors Geo Kingsbury. Working closely with highly wear resistant high temperature, low and high (IBRs) typically completes milling of the blades in two the University of Sheffield Advanced multicomponent or multilayer machining speed, machining of operations, using a larger diameter tool for the aerofoil - Manufacturing Research Centre and hard coatings, based on CrN ordinary materials and difficult to thereby reducing the number of passes - and the smaller leading CAM software vendors, the but incorporating other metals; machine materials, and machining diameter tool for the fillet. Barrel milling cutters have a partners have been able to demonstrate these have been developed under lubricated and under using closed field unbalanced ‘dual profile’, theoretically allowing both operations to a viable solution to IBR milling using magnetron sputter ion plating technology. They are minimum lubricant quantity or even be performed with a single tool, hence saving machining a barrel cutter. Although there are still some hurdles exploited in coated machining and forming tools for dry conditions. These coatings can be used for both time. There is also the added benefit of eliminating to overcome, ITP’s Engineering Director, Dan Price, a wide range of materials in various applications and cutting and forming tools, for conventional macro- any machining ‘mismatch’ which can arise from a two is optimistic. “We are constantly looking for faster, environments. These coatings are characterized by machining tools as well as for micro-machining tools, tool approach. Whilst this type of tool is not new, its more efficient ways to make engine parts; this NATEP desirable properties including good adhesion, high either as a single coating or in combination with an application to IBRs has not previously been successful, project has enabled us to bring together the right team hardness, high toughness, high wear resistance, high advanced, self-lubricating topcoat. principally because the available CAM software does not of experts and trial something which we have been adequately support this type of movement. considering for some time, with encouraging results”. Contact: Hailin Sun – [email protected] Contact: Kevin Ngoe – [email protected] 28 29 Midlands Aerospace Alliance The new technology catalogue Software Defined Telemetry Surface Cooler Development
Lead Partner Lead Partner Advanced Chemical Etching Etched components H S Marston Rolls-Royce Plc G2 Communications TBG Solutions Rolls-Royce Design and test Customer System design, build, test Customer Wireless technology University of Wolverhampton CFD modelling
This NATEP project tackled the challenge of reliably This 2 year project with end user Rolls-Royce was led by extracting instrumentation data from the rotating core H S Marston Aerospace and involved partners University during gas turbine engine testing. Currently, engine of Wolverhampton and Advanced Chemical Etching manufacturers such as Rolls-Royce make significant (ACE). The aim of the project was to develop advanced use of wireless radio data transmission systems surface coolers, a technology of particular interest to (telemetry), but the harsh test environment makes turbo fan jet engine manufacturers that was not currently reliable data collection very difficult; time-consuming available in the UK. The project centred around the use set-up times, data drop-outs and signal corruption of a chemical etching process to produce single layer, are relatively common issues, leading to the need open fin structures to facilitate oil cooling within the to repeat tests. Existing hardware also has a limited engine by-pass duct. This technique was designed to bandwidth constraining the number of channels which give a competitive advantage for the UK. Testing was can be simultaneously transmitted. carried out on a segment of a by-pass duct subjected to high air flow rates, and the results were used validate In this 18 month project, TBG Solutions has teamed CFD models of different surface cooler configurations. up with G2 Communications to develop an innovative intelligent wireless telemetry system based on Software Defined Radio (SDR). By using SDR it has been possible to design a self-optimising system which operates over a range of radio frequencies to provide a highly reliability data transmission link, A2OX Aluminium Alloy whilst minimising the power requirements from the London & Scandinavian Lead Partner on-board battery. TBG’s Neil Roddis is optimistic Metallurgical Co about the possibilities for the system: “Although this Alloy melters Aeromet International Aero Engine Controls project targeted the engine test cell application, there Investment casting Customer are many other potential applications outside of the Grainger & Worrall aerospace sector where reliable and efficient wireless Precision sand casting communications are needed for sensor networks.” University of Birmingham Modelling Contact: Neil Roddis – [email protected] This project built upon This new material offered end the success of a previous user Aero Engine Controls (now collaborative research project at Rolls-Royce) a step change in the University of Birmingham, fatigue strength for its engine which resulted in a patented components. The University of formulation of an innovative Birmingham modelled the casting aluminium alloy called A2OX. process which contributed to Aeromet International, experts additional benefits including in investment casting, and Grainger & Worrall, experts higher casting yields, with in precision sand casting, reduced processing time and worked together using materials produced by London energy usage. The picture shows a successfully produced & Scandinavian Metals to scale up the previous work. complex fuel pump housing in the new material.
30 31 30 Midlands Aerospace Alliance The new technology catalogue Aircraft Tyres Finite Element Modelling Biocomposites for Aerospace Interiors Lead Partner AIM Altitude Lead Partner University of Airbus Component manufacture Birmingham Dunlop Aircraft Tyres Tyre design Customer and test NetComposites Modelling Prepreg development, AIM Cabin Interiors Customer project management Composites Evolution This project was born out of a need by Dunlop Product management Aircraft Tyres (DAT) to be able to accurately model new designs of aircraft radial tyres. Working closely When lightweight fibre-reinforced polymer free of volatile organic compounds, and with the University of Birmingham and Airbus, DAT composite materials are used in fire- sustainably-derived from waste agricultural developed a finite element modelling capability sensitive applications such as aircraft biomass. Furthermore, PFA resins provide for tyres such that the behaviour and performance interiors, the most common state of these benefits without any compromises of new tyre designs could be predicted. The the art solution is to use phenolic resin in terms of basic mechanical performance, work programme evaluated current tools used in systems. However, during manufacture fire performance or cost compared to automotive tyre design and developed a process these materials pose some health risks to phenolics. They also provide opportunities to integrate CAD and FE packages together with a operators which need careful management, for improved out-of-mould surface finish. tyre material database. Results from the modelling and moulded parts need extra operations were validated against test data and were provided Joe Carruthers, Managing Director of to achieve a good surface finish. to Airbus in a format which fed directly into their NetComposites sees a bright future for this landing gear system simulation. In this NATEP project, NetComposites new greener material: “The fire resistance teamed up with AIM Altitude and Composites Evolution tests in particular for PFA-based material exceeded all to develop a pre-impregnated (prepreg) composite expectations. This may allow reinforcements to be used material using a 100% bio-based polyfurfuryl alcohol which up to now have not been considered feasible for (PFA) resin system. Compared to phenolic resins, PFA aircraft interiors such as flax, perhaps paving the way for Aerospring Spring Characterisation resins offer significant advantages; they are non-toxic, a 100% bio-composite material.”
Reliable Spring Contact: Elliot Fleet – [email protected] Manufacturing Co Lead Partner BAE Systems Spring manufacture Customer G&O Springs Alloy Wire Spring manufacture International Goodrich Technical Endurance Braking Materials supply Centre Customer Institute of Spring James Kent Lead Partner BAE Systems Technology Ceramic Materials Customer Testing Meggitt Aircraft Braking Systems CERAM Manufacture Embraer Redditch-based G&O Springs were aware that there was Chemistry and Testing Customer little if any empirical test data for springs manufactured from special aerospace alloys such as Inconel 718 or The objective of this project mechanical features to make it a titanium. In the absence of information such as cycle life, led by Meggitt Aircraft Braking modular design. A large number relaxation over time and load at temperature, designs Systems was to develop a of materials were tested within tended inevitably to be very conservative, with large braking system with a modular the project as well as the modular design margins resulting in larger spring housings. design, enabling it to be design. An improved brake G&O were confident that providing this missing data refurbished in modules, thus performance and longevity was could lead to significant mass savings. In this 2 year providing increased reliability achieved. Together with partners project led by G&O Springs, they were joined by fellow and improved service life. The James Kent Ceramic Materials and spring manufacturer, Reliable Spring Manufacturing who improvements came from CERAM (now Lucideon), the project produced a number of springs using a range of materials the formulation of the carbon supplied by Alloy Wire International, for testing by thereby allowing end users such as BAE Systems material with specially designed team also developed advanced the Institute of Spring Technology (IST). Tests included and Goodrich to develop smaller lighter aerospace ceramic material developed by James Kent, an SME anti-oxidant coatings providing greater resistance to the fatigue data, relaxation data and load-deflection components. G&O springs led design workshops working in the dental industry mostly. The work involved agents that cause catalytic oxidation damage to existing curves over a range of temperatures. The results were for engineers from their customers and established incorporating and testing a number of new brake design brakes from runway de-icer fluids. incorporated into IST spring design programmes, themselves as knowledgeable suppliers. Contact: Toby Hutton – [email protected]
32 33 Integrally Bladed Rotor (IBR) – Abrasive Flow Machining
Brunel University Lead Partner Mathematical modelling ITP Engines UK Management, design, Rolls-Royce Customer Extrude Hone inspection and analysis Fixtures and testing
ITP’s blisk manufacturing centre of excellence in Lincoln, together with partners Extrude Hone and Brunel University, have been getting to grips with the science behind a 50 year old process that is used extensively after the machining of metallic parts to improve surface finish. This 2 year NATEP project has turned the spotlight on abrasive flow machining. Despite being deceptively simple in concept, the process has always been largely empirical because the underlying physics and chemistry are extremely complex and not fully understood. During the project Brunel University has constructed a mathematical model of the abrasive flow machining process using the COMSOL Multiphysics® modelling software and the team have validated this through a series of tests on material coupons and blisk segments carried out by Extrude Hone and ITP. These tests have allowed researchers at Brunel to refine their model to a point where excellent agreement between predicted and actual wear rates and profiles has been achieved. Whilst modelling has allowed ITP engineers to optimise the abrasive flow finishing of some parts, they have bigger goals in mind, and the key to success is predictability. ITP’s Engineering Director, Dan Price, is enthusiastic about the new possibilities: “Being able to predict accurately exactly how much material will be removed, and where from, means that ITP are coming to see abrasive flow machining not so much a finishing process as a machining process. The new thinking is to leave more stock on blisk aerofoils during milling, and then bring parts to size using abrasive flow machining. This will lead to a reduction in 5-axis milling time.”
Contact: Dan Price – [email protected]
Catalogue content and design by Andrew, Bridget and Peter at Midlands Aerospace Alliance in conjunction with Milan Creative and Karen Blake Branding + Design
34 Midlands Aerospace Alliance
The MAA is one of five regional aerospace alliances in the UK and is one of the biggest in the world with more than 300 member organisations, more than half of which make ‘flying parts’ which go onto the aircraft while the rest make equipment for design, testing, manufacturing or supply other specialist services.
Major Midlands aerospace companies including Meggitt, Moog Aircraft Group, Rolls-Royce and UTC Aerospace Systems sit on the MAA Board of Directors as do representative supply chain companies and regional partners.
Midlands Aerospace Alliance Tel: +44 (0) 24 7643 0250 Business Innovation Centre Binley Business Park [email protected] Coventry CV3 2TX www.midlandsaerospace.org.uk 36