We take Composites to Market

GKN WestlandAerospace

GKN Westland Aerospace, Inc.

GKN WestlandAerospace

GKN Westland Aerospace, Inc.,a division of GKN plc, is an engineering LED first tier supplier to the global aerospace industry.

GKN plc

GKN Aerospace

GKN WestlandAerospace

GKN WestlandAerospace

(Connecticut)

GKN Automotiveand Agritechnical

Products

GKN WestlandHelicopters

GKN Industrial Services

GKN CentralEnterprise

DevelopmentUnit (CEDU)

GKN has manufacturing facilities inEast Cowes on the Isle of Wight,Avonmouth, Luton, Portsmouth andYeovil all in the United Kingdom;Munich, Germany; Wallingford,Connecticut; Tallassee, Alabama;and San Diego and Los Angeles,California, in the USA.

Coordinate Measuring Machine is used to assureconformance of parts to the electronic master.

Turbo Fan Exit Case.

If the question relates to high-perfor-mance composites, GKN Westland

Aerospace, Inc., has the solution.

GKN Westland Aerospace, Inc. (GKNWA),today is recognized as one of the worldleaders in reinforced carbon composites.Our engineers and manufacturing expertshave the experience in both commercialand military applications for aerospace andindustrial components.

We help customers create cost-effec-tive alternatives to titanium and aluminum,offering the performance, complexity,laminate quality and dimensional accuracyrequired.

By working directly with customers,we jointly identify components best madewith composites.Together, we select thebest manufacturing method — pre-impreg-nated molding (prepreg), compressionmolding, resin transfer molding, or,perhaps, our proprietary Advanced ResinTransfer Molding (AdvRTMTM).

Our greatest strength is the back-ground and depth of experience of ourteam, offering customers the opportunity toleverage on proven success, eliminatingrisks previously associated with composites.Our experienced advanced engineeringdepartment specializes in composite designand analysis, using CATIA and Unigraphicssystems as well as more typical tools forcomposites analysis.

In the past, manufacture of high-perfor-mance composites was esoteric, sensitiveand complex. Today, at GKNWA, it isunderstood, routine, accomplished.

We are proud to have taken compos-ites technology to the next level. And,we are enthusiastic about the opportunityto demonstrate how GKNWA can helpyour companyadvance itsproductionand assemblyneeds for the future.

Turbo Fan Exit Case.One piece AdvRTM molding.Ten of these complex units combineto replace a traditional titaniumassembly.

COMPLETE COMPOSITES SOLUTIONS

Stabilizer Kick Rib

COMPOSITES FOR A NEW CLASS OF PARTSmore than 140 separate components forthe wings and fuselage of this aircraft.

What is AdvRTM?

The AdvRTM process builds the preformsto specific engineering requirements, withcontinuous in-process verification, allow-ing the finished preforms to be managed

without disorienta-tion of the fibersduring loading,mold closure andresin injection.

AdvRTM’sability to manufac-ture net-shape preforms is basedon the use of spe-cial fiber binderscreated to main-tain the integrity of the preformthroughout the

process.The process also uses differentbinders, each specific and chemically identical with the resin being processed,

critical to assuring the uniformity andquality of the matrix.

AdvRTM is not a replacement forprepreg molding. Rather, it allows intro-duction of composites into new applica-tions — engine components, includingplatforms, frames, cases, and blades,and complex airframe structures such asbeams, fittings, bulkheads and spars.

If your application can be describedas "5-axis, NC machined titanium," thenAdvRTM probably can reduce your costsand provide significant weight savings.

Now, composites are a low risk and viable option, where only metalscould be considered in the past.

GKNWA is continuing to invest in development of more advanced tooling methodologies,new resins and fabrics, and related composites manufacturing processes.

With AdvRTM, for the first time,complex geometric components

can be manufactured with composites,effectively competing with traditionalmetal designs and manufacturingapproaches.

We have manufactured and deliveredmore than 10,000 critical, rotating jetengine components.

In the AdvRTMprocess, advancedpolymer resins are injected into a matched moldencapsulating a continuous fiber,preformed reinforce-ment.The results arehigh performanceprecision moldedparts controllingboth contour andlaminate thickness.

The quality of the laminate is theinherent advantage of AdvRTM. Porosity,fiber distortion and fiber wrinkling are no longer a problem. Repeatabilityand delivery of the first piece moldedfrom a new tool, are routine.

Cost effectiveness also has taken onan added dimension with AdvRTMbecause multiple part numbers can becombined into a single composite component. In addition,AdvRTM offerscost avoidance for our customers in their subsequent assembly operations.

The key to these savings is the unique ability to closely control tolerances, eliminating fit-up and shimming during our customers’ finalassembly operations.

The Boeing Company said it savesapproximately $250,000 on each F-22Advanced Tactical Fighter — because ofGKNWA’s AdvRTM.We manufacture

Fuselage Frames

Why Composites?Compared with equivalent metalstructure, composites have:

• less weight;

• improved fatigue strength; and,

• greater corrosion resistance.

With the appropriate process,composites also can reduce manufacturing costs.

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Aileron Inbound Spar

Spar

The F119 Engine — one examplewhich incorporates a myriad ofcomposite details produced byGKN Westland Aerospace.

Engine Air Inlet Lip

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Why AdvRTMTM?With development of Advanced ResinTransfer Molding (AdvRTM), compositesnow are for primary load bearing struc-ture in airframes and propulsion systems.The inherent attributes are:

• incorporate significantly greater complexity into a single part;

• replace aluminum or titanium in highperformance jet engine or structuralapplications;

• consolidation of parts;

• quality and repeatability (97% yield onproduction programs); and,

• control of both sides of a laminate.

These characteristics define the bestapplications for the process. If require-ments of an application do not materiallybenefit from these attributes, anotherprocess may be more cost effective.

Finish Trimming—one example of the size, complexity and quality now achievable.

GKN’s specialized Instrument Analysis Laboratoryhelps us to optimize cure parameters and processcontrols and assure product quality.

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Flexible Molding Cell. Computer management of cell scheduling,tool handling, thermal cycle and resin injection.

In today’s aerospace world, only thoseprocesses capable of manufacturing

parts free of rejections the first time, andevery time, are considered as suitable for production. Our internal qualityrequirements conform to those of ourcustomers, meeting cost and scheduletargets, to assure GKNWA's productsanswer all needs and specifications.

Statistical process control is the keyto assuring reliability and quality.

Advanced process control equipment,integrated into the company's computernetwork, manages and monitors everystage of production, providing document-ed assurance that all standards are constantly being met.

GKNWA’s manufacturing systems haveenabled the company to become a qualifiedsupplier to major aerospace manufacturers.We are under contract and are deliveringparts to such major companies as TheBoeing Company, Lockheed Martin, Pratt &Whitney, General Electric and others.We are delivering primary and damage criticalstructure for aerospace applications.

Our manufacturing employees arecertified for key quality inspections,emphasizing quality at every level of the AdvRTMTM process.When an individ-ual worker is certified, the QualityAssurance Team will audit the work,making random inspections to guaranteeeach step remains in constant compli-ance with specifications.

At GKNWA, quality is everyone’sresponsibility.

AdvRTM provides the confidence of a superior technology and experienced engineering and manufacturing resources.Now you can accelerate introduction of composites in your product and realize the benefits of composites today.

Certified ISO9001 and AS9000

QUALITY STARTS WITH THE PROCESS

Quality evaluation may involve advanced ultrasonic inspection.

A N I N V I TAT I O NWe invite you to meet with us so,together, we can identify compo-nents best made with composites.Our engineers can help maximizethe benefits of composites,working to meet your objectivesof improved cost, higher quality,and reliable scheduling.

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GKN Process CapabilitiesFeature Design Guide Actual Cpk Data Yield

Molded Profile .020 1.3 99.99%

Molded Profile Point Repeatability .010 1.0 99.73%

Molded Thickness ±.005 1.0 99.73%

Molded to Molded Position .010 0.8 98.4%

Weight ±0.8% 1.3 99.99%

Machined to Molded Position ±.010 1.4 99.997%

Machined to Machined Features ±.005 1.3 99.99%

15 Sterling DriveWallingford, CT 06492

203-949-5000203-949-5009 FAX

GKN Westland Aerospace, Inc.

GKN WestlandAerospace

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