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787 delivery date set for mid-first quarter 2011

Fri, 27 Aug 2010 09:03:59 GMT

Boeing says it now expects delivery of the first 787 in the middle of the first quarter 2011.

The delivery date revision follows an assessment of the availability of an engine needed for the final phases of flight test this fall.

While Boeing works closely with Rolls-Royce to expedite engine availability, flight testing across the test fleet continues as planned.

Boeing said last month that the cumulative impact of a series of issues, including supplier workmanship issues related to the horizontal stabiliser and instrumentation delays could push first delivery of the 787 a few weeks into 2011. The delay in engine availability has extended that estimate to mid-first quarter 2011.

www.boeing.com

QinetiQ files for three world records

Wed, 25 Aug 2010 09:03:59 GMT

QinetiQ has filed for three world records for Zephyr, its solar powered high-altitude long endurance (HALE) Unmanned Air System (UAS).

Subject to ratification with the Federation Aeronautique Internationale (FAI), Zephyr achieved the absolute duration record for an UAV, the duration record for a UAV in the U/1.c /50-500kg category and the absolute altitude record for a UAV being filed at 70,740ft.

Zephyr was launched on 9th July and stayed aloft for 14 nights (336 hrs/22 minutes) above the US Army's Yuma Proving Ground in Arizona, before being brought safely back to earth on the morning of 23 July having achieving all the objectives of the trial.

“We now await official FAI confirmation that we have met all necessary criteria,” stated Zephyr programme director, Jon Saltmarsh. “This is a tremendous achievement, earning Zephyr a well deserved place in the record books and setting a significant milestone in aviation history.”

Chris Kelleher, QinetiQ’s chief designer added: “We’re delighted that Zephyr should soon enter the world record books as it is set to transform the delivery of current services such as communications, and lead to many new applications which are not possible or affordable by other means. We’ve now proved that this world-beating aircraft is capable of providing a cost effective, persistent surveillance and communications capability measured in terms of weeks, if not months.”

www.qinetiq.com

Walter answers aerospace tooling demands

Wed, 25 Aug 2010 09:03:59 GMT

With tools for aerospace machining accounting for an increasing proportion of Walter’s turnover, the company is responding to the industry’s unquenchable thirst for high performance cutting tools.

The doubling in the number of large passenger aircraft that utilise new, ever more complex components in difficult-to-machine materials and which are required in shorter production cycle times are factors that add to the constant pressure, says Walter GB’s managing director, Gerry O’Hagan.

“Titanium alloys such as Ti5553 and composites like CFRP – where there is a lack of long-term machining experience - as well as high-speed and 5-axis machining, are setting new, higher demands for tooling suppliers,” he said. “Walter continues to respond with, for example, new drills and boring tools for machining composites. The tools are designed specifically to overcome the ‘notching’ effect often inherent when, for instance, producing holes in composites.”

Tooling for CFRP machining must cut the fibres cleanly, he continued. “If the fibres are torn, there is an extremely high risk of fracture. Other aerospace materials such as titanium, high temperature steel and nickel-based alloys, in particular, also place extremely high demands on process reliability and machining quality.

“Walter’s response has been to develop new indexable inserts with optimised geometries and coatings, as well as internally cooled solid carbide cutters manufactured from newly developed substrates.”

He went on to add: “The use of aluminium as an aerospace material remains important, although its proportion of use may be reduced. In both the Boeing Dreamliner and the Airbus A350 XWB, aluminium accounts for only around 20% compared with 50% composites. That said, Walter also continues its tooling developments in this field and is addressing the demand for optimised/higher quality production with a series of new milling cutters.”

Pointing out Walter’s constant development of titanium and solid carbide tooling for jet engine components made from titanium alloys, high temperature steel and nickel-based alloys such as Inconel 718, O’Hagan also adds that tools from the comprehensive ranges of Walter, Prototyp and Titex are proving particularly successful when milling, for example, turbine discs, main landing gear and landing gear beams.

For instance, the new F4030 Xtra.tec face mill features the new Tiger.tec Silver WKP35S trigon indexable inserts or, alternatively, PVD aluminium oxide Tiger grades WSM35 and WSP45.

Available in diameters from 25mm to 63mm, F4030 is one of a host of Xta.tec milling tools now available with the new generation CVD-coated Tiger.tec Silver inserts. These claim to promise 50-100% improvements in cutting performance in milling, turning and drilling applications.

The F4030 is typical of the new, high-performance tooling being developed for aerospace machining. Mounted in a ‘flat’ 0-21º position to encourage feeds per tooth of up to 3.5mm and at cutting depths of 1mm, and with six usable cutting edges on each insert to minimise costs, the F4030 is said to be ideal for high-speed applications such as angled plunge cutting, plunge cutting and pocket milling as well as face milling, in both dry and wet applications.

“Over the years we have developed a considerable range of tooling for our aerospace customers, as we have done for other major industry sectors, and it is clear that industry-specific ‘standard ranges’ are now part of Walter’s ongoing success strategy,” he concluded.

www.walter-tools.com

Growing performance gap in the UK aerospace industry

Wed, 25 Aug 2010 09:03:59 GMT

According to the latest Plimsoll research, there is a real mixed bag of company performance in the UK aerospace industry at present with the analyst indicating that with 158 companies in trouble, 340 others powering ahead and a further 137 set to be taken over, the market has never been more fragmented.

David Pattison, author of the new Plimsoll Analysis - Aerospace explained: “Having rated 158 struggling companies as Danger and given 340 others a Strong rating, I am surprised at the gulf in performance in the market. Despite all other factors, success still comes down to how well a company is run.”

When pressed on what the consequences of this polarisation in the market will be, Pattison’s response is emphatic: “Acquisitions. The market, in the current economic climate cannot support this many companies. There has to be further, more radical consolidation in the market. Strong companies will be buying up distressed competitors in the next 12 months.”

The new Plimsoll Industry Analysis – Aerospace provides an instant performance rating on 800 companies and highlights those ripe for acquisition. Each company is assessed using the Plimsoll Model - A graphical and written analysis that lays bare the facts and gives you instant opinion.

Readers of Aerospace Manufacturing are entitled to a £50 discount of this new special edition of the Plimsoll Industry Analysis – Aerospace. Call 01642 626400 for further details and quote reference PR/EG05.

www.plimsoll.co.uk

Local MP urged to support move to balanced economy

Wed, 25 Aug 2010 09:03:59 GMT

Local MP Gordon Henderson visited Aeromet International in Sittingbourne, Kent, recently and cited the company as an exemplar organisation in helping the UK move towards a more balanced economy.

The visit, organised by EEF, which represents manufacturers, highlighted the way in which companies such as Aeromet is able to lead the world through research and development, capital investment and manufacturing excellence.

Aeromet has a global reputation for producing aluminium and magnesium sand castings, aluminium investment castings and forming titanium parts for the aerospace and defence industries – and through its commitment to customer service and innovation has grown a customer base that includes some of the biggest names in these sectors.

As part of the meeting with Henderson, chief executive Jeff Smith was keen to hear how companies such as Aeromet can best communicate with the incoming Local Enterprise Partnerships now that Regional Development Agencies are being phased out.

“Having open dialogue directly with local and central government through trade associations, such as EEF and A|D|S will ensure that high value manufacturing in the South East receives the support it needs,” he said. “With the right support, manufacturing in the UK will continue to provide growth, employment and value to both local and national economies.”

Aeromet, like many other companies in the aerospace manufacturing sector, has experienced the effects of a severe industry downturn over the past eighteen months. But through steady investment in research and development, capital equipment and training, Aeromet is well positioned for future growth and the increasing order book will lead to recruitment of additional staff during 2011

“I am delighted to have the opportunity to discuss some of the key issues currently of concern to manufacturers, particularly as it is the stated intention of government to move towards a more balanced economy,” stated Henderson. “Aeromet demonstrates how it is possible for local companies to be successful on the world stage through a culture of best practice, innovation and technical excellence.”

Commenting on Government’s commitments to create a more balanced economy, Jeff Alexander, head of external affairs for EEF in the South East, said: “Manufacturing is such an important sector for the future of the South East economy that it deserves to be celebrated and recognised as a key contributor to wealth and prosperity. With manufacturing in the South East estimated to be worth around £18 billion and employing 320,000 people, we must encourage government to create an environment that is conducive to success so that the stated objective of a more balanced economy becomes a reality.”

www.aeromet.co.uk

(L-R; Jeff Smith, Chief Executive - Aeromet International Plc, Gordon Henderson MP, Jeff Alexander, Head of External Affairs – EEF)