GKN Aerospace Technology

Philip GraingerSenior Technical Director and

Chief Technologist

Introduction

No shortage of passengers –steady population growth

Plenty of need for more commercial aircraft

Commercial market is in boom

Approx 8,000 aircraft forecast to 2015

Source: Rolls-Royce (Oct 2006)

Environmental IssuesAdvisory Council for Aeronautical Research in Europe (ACARE) has set targets, endorsed by all major aerospace companies, to be met by 2020

Reduce fuel consumption and CO2 emissions by 50 per cent

Reduce external noise by 50 per cent

To reduce the emission of nitrous oxides by 80 per cent

To make substantial progress to reduce the environmental impact of the manufacture, maintenance and disposal of aircraft and related products

Targets not stringent enough – 30%

But prepared to pay to make a better aircraft

Source: Rolls-Royce (Oct 2006)

A CARBON BASED LIFE

Why???

Weight, weight and weightCompared to aluminium structure Carbon can save between 20% to 30%

LifeCarbon fibre components are relatively insensitive to fatigue damage

Design FreedomBecause CFRP is a moulded product extravagant high performance shapes are possible for the same cost as traditional solutions

Future Trends

Lighter engines delivering the same power provide:

A lower weight propulsion system installation

Lighter wing attachments leading to a lighter wing

A more efficient aircraftLess fuel burn and lower emissions

Engines of the future will incorporate:

Lower speed, larger diameter fans and perhaps open rotors

Higher bypass ratios

Better fuel efficiencies

Lower CO2, NOX and noise emissions than engines of today

Future Trends

Lightweight structures are an equally important part of the equation

They will be self sensing for damage through life

They will be highly automated in manufacture to compete on cost and drive up quality

End of life disposal will become ever more important

A400M Carbon Spar

Stiffeners co-cured with skins

Fasteners used to attach ribs to skin

Tape-layed and diaphragm formed

assemblies

Expanding Composite Usage

Main composite parts

Boeing B787250 passengers

EIS 2010

Main composite parts

Airbus A380550 Passengers

EIS2008

0%

10%

20%

30%

40%

50%

60%

1970 1975 1980 1985 1990 1995 2000 2005 2010 2015

Com

posi

tes

ratio

in s

truc

tura

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faft

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AIRBUS BOEING Military

A300

A320A340-600

A380

B747-400

B777

A400M

B787

A350F-35(JSF)

F-22

F/A-18E

A330

A310

AV-8B

F/A-18A

F-16 B767

B737-300

Aerospace Application Aerospace Application –– Expanding Composite UsageExpanding Composite Usage

A320X

Carbon Fibre Demand

Worldwide CF Demand vs SuppliabilityWorldwide CF Demand vs Suppliability

PROPRIETARY

20,000

25,000

30,000

35,000

40,000

2004 2005 2006 2007 2008 2009 2010

Unit: Ton

Total Demand

Supply total

Supply not forecast to meet demand until 2008; by 2010 supply equals demand

Carbon fibre not confined to aircraft applications

Industrial applications

Sports applications

GKN Aerospace Composite Differentiators

World leading expert on Resin Transfer moulded assemblies

JSF Front Fan Frame

F22 spars

World first with out of autoclave processesA380 Fixed Trailing edge Panels

GE GenX fan case

First Tape layed and formed Primary Spars for Large Aircraft

A400M Wing Spars

Technology to Product

EnginesFan Blades

Fan Cases

Wing Structures

Anti Ice Systems

VITAL (EnVIronmenTALly Friendly Aero Engines)

Development and manufacture of engine composite fan blades.

Lay-up trials commenced June 2007.

First blades manufactured at Cowes

Programme is on track for manufacture of 45 test blades by December 2007.

Birdstrike test by RR Q1 2008.

Trials began on production tooling in June 2007

Fan Blade Opportunities

Wide body aircraft blades. (e.g.A350)- £50M turnover

Single Aisle blades. (A320/Boeing 737) - £120M turnover

Bonding fixturing

Automated manufacture

General Electric GenX Fan Case

Contracted for the Boeing 787

Uses Resin Film Infusion

Automated lay-up

Turnover £80M

Second Engine to Test

First Engine to Test

JSF Resin Transfer Moulded Fan Frame

F-135 Fan Frame

Highly complex structure

Manufactured in one shot

No machining prior to engine parts assembly

Contract Value of £200M

Integrated Wing

Automated manufacture of closed box type structures

Demonstrator components now fully defined

Staged manufacture now in progress, leading to a wing box demonstrator.

Closed cell wing box

Out side surface

In side waffle surface

Out side surface

In side waffle surface

Waffle skin structure

ALCAS (Advanced Low Cost Aircraft Structures)

Out-of-autoclave manufacture of large scale spar component.

Trials at 3.0m scale successful.

Trials at 7.0m scale underway.

Full scale 11.5m component scheduled for completion and delivery by April 2008.

7.0m tool - First DDF trial June 2007

Next Generation Composite Wing

Underpinning technologies for next generation 150 seateraircraft.

Deposition of carbon pre-pregsat higher rate.

Advances in composite tooling, especially when combined with Out-of-autoclave self heated tools with embedded thermometers and local cure detection.

Higher Rate ATL

Wing Structure Opportunities

A400M Spars program born out of Framework 4 and 5 work

£10M turnover

Success on a wide body program (A350)£200M turnover

Whole wing technology for Single Aisle£500M turnover

Ice Protection

Spraymat™ - plasma sprayed metal on composite materialsSelected for Boeing 787 wing ice protection system

Design drivers: WeightNon-metallic structureNo engine bleed airField replaceable

Design concept (composite heater mat structure behind a thin aluminum erosion shield, on the movable slats)

Potential Business on Single Aisle £50M

Single Aisle Solution

Spar Bracket Assembly showing alternative

mounting of the TWB to the Fixed Wing Forward Spar

TWB

Airframe Electrical Connections

Slat Deployment Mechanism

Demountable Composite Solution (c/w integrated heater elements)

‘Breakaway’ at Telescopic Tube Termination (not shown)

Mounting Flange to Fixed Wing Rib

JSF F-135 Engine Inlet Ice Protection

StartDefineDevelop contract with Pratt & Whitney

JSF F-135 engine inlet struts, vane and hub require electro-thermal ice protection

Metal plasma spray on dry composite cloth

Wrap/drape to shape

Process via resin transfer moulding with the engine case already won

Business for JSF £250M

Summary

Technology Programs in GKN Aerospace have been directed towards and led to significant new business

Work in Framework 4 and 5 directly led to Composite spars product for A400m

Work in Framework 5 led to winglet design and build for APB

RTM Fan frame development led to JSF

Fan blades could be a great product

Anti ice, already on 787, has enormous potential

All programs are focussed on product and partnerships that will generate significant future revenues

Osborne Tour

The Osborne site has been home to ditching tank and aircraft ditching facilities in the past

Re-entry launch vehicle nose cones and structures have been tested there for the last 100 years

Today it is home to Production facilities

Composite Research Centre

Advanced Composite Facility