AEROSPACE TRENDS - EWI

AEROSPACE TRENDSAND NEW TECHNOLOGY DEVELOPMENTS1

TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Increasing Production Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Trends and Developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Lightweighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7New, Advanced Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Additive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Streamlining Assembly Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Nondestructive Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Next-Generation Repair Technologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Experienced Skilled Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13New Technology Developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Laser Coating Removal for Aircraft, Parts, and Dies . . . . . . . . . . . . . . . . . . . . . . . . . 15Low-Cost Honeycomb Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16High-Power Ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18About EWI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

INTRODUCTIONBy Brian BishopFollowing years of decreased defense revenues, the aerospaceindustry is poised for positive growth. Due to rising passengertraffic, accelerated equipment replacement cycles, decreasingcrude oil prices, and an increase in defense spending, aerospacemanufacturers are on pace for record production levels of nextgeneration aircraft.3.0%2.1%40.5%Global aerospaceand defense industryrevenues areexpected to grow at3.0% in 2016.1The 2016 FAAforecast predictsthat U.S. carrierpassenger growthwill average 2.1% peryear for the next 20years.2In 2016, an estimated1,420 largecommercial aircraftwill be produced—40.5% more than fiveyears ago.33

INCREASINGPRODUCTIONRATESIntense competition drives the pace of technologicalinnovation. This is especially true in the current aerospacemanufacturing landscape. To increase production rates tomeet high demand from OEMs and remain competitive,manufacturers will need to improve their operationaland manufacturing performance. Building aircraft,subassemblies, and components efficiently, sustainably,and cost effectively will require not only technologicalinnovation, but improved performance throughout all levelsof the supply chain.4

TRENDS ANDDEVELOPMENTSThis overview will examine some of the major trends and driverscurrently shaping the aerospace industry. It will also spotlightthree new technological developments that can enable aerospacemanufacturers to increase productivity, efficiency, and quality whilemeeting heavy demand.Trends:n Automationn Lightweightingn New, Advanced Materialsn Additive Manufacturingn Streamlining AssemblyProcessesn Nondestructive Evaluationn Next-generation RepairTechnologiesn Experienced Skilled LaborNew TechnologyDevelopments:n Laser Coating Removal forAircraft, Parts, and Diesn Low-costHoneycomb Panelsn High Power Ultrasonics5

AUTOMATIONIn comparison to the automotive industry, in which automatedprocesses are ubiquitous, the aerospace industry has much lowerproduction volumes, higher tolerances, and larger subassemblies.Additionally, certain materials used in aircraft manufacturing canmake automation more challenging. Challenges aside, automationpresents the promise of addressing constraints in capacity andgreatly increasing productivity. Aerospace manufacturers areinvesting accordingly.n Boeing plans to invest morethan 1 billion in automationover the next few yearsto boost production at itsassembly plants.46

LIGHTWEIGHTINGReplacing traditional materials with new lightweight, high-strengthmaterials is an effective path toward meeting the industry’s everpresent goal of increasing fuel efficiency, decreasing emissions, andreducing material usage. Incorporating lightweight materials into themanufacturing process allows manufacturers to reduce weight whileenabling new functionalities and innovations.n Carbon fiber bearings areused in the Airbus A340’shorizontal tail to reduce itsweight by 50% and costby 30%.5WEIGHT50%COST30%7

NEW,ADVANCEDMATERIALSWhether the goal is to achieve lower weight, increase fatigue life,or enable higher heat resistance, materials advancements arecritical to increasing aircraft performance. The aerospace industryhas traditionally been quick to incorporate advanced materialsolutions into design including advanced Al alloys, titanium, andengineered panels. However, new materials come with a wealthof new challenges. In order for aircraft manufacturers to be able tosuccessfully machine a greater range of materials and incorporatethem into new aircraft designs, fabrication technologies mustcontinue to develop.n Superalloys in the globalaerospace market are forecastto grow at a CAGR of 2.6% from2015-2020.68

ADDITIVEMANUFACTURINGThe aerospace industry has been an early adopter of additivemanufacturing. Aerospace companies are investing in additivetechnology in order to achieve weight savings, structural andspace optimization, and reduce part count and joining. More thanjust a technique for rapid prototyping, 3D-printed components arenow being produced for end use in aircraft manufacturing.n Global additive manufacturingin the aerospace and defensemarkets is projected to exceed 325 mil by 2022.7ADVANCING ADDITIVEMANUFACTURING INAEROSPACEFor more on additive manufacturingtechnology development in theAerospace industry, check outEWI’s eguide, Advancing AdditiveManufacturing in AerospaceAM-AERO149

REDUCINGWASTEConsolidating processes where possible allowsmanufacturers to reduce costs and greatly enhanceproductivity. Many avenues, including automation and additivemanufacturing, are being explored and employed to eliminatesteps in the aircraft manufacturing process.n Streamlining theassembly process forthe A350 XWB allowedAirbus to reduce thetime from start of finalassembly to aircraftdelivery by 30%.810

NONDESTRUCTIVEEVALUATIONBecause aerospace components are high-cost and low-volume,destructive testing methods are not a viable solution. As such,the industry makes extensive use of nondestructive evaluation(NDE) and inspection techniques. NDE is a cost-effective way tomeasure the quality of components and inspect welds.EWI continually develops new NDE techniques and capabilitiesto ensure the highest standards of quality. One such innovationis EWI’s use of ultrasonic matrix phased array-technology toassess welds made on aerospace-grade metals. In addition,automated advanced NDE capabilities and inspectiontechniques are currently in development.Read the article here.11

NEXTGENERATIONREPAIRTECHNOLOGIESA new generation of aircraft means a dramatic changein maintenance and repair technologies. Aircraft built withadvanced materials require a different approach than those builtwith traditional materials. Even more challenging is the need todevelop repair techniques for materials and parts that have notyet reached market, but are on the near horizon.n Survey of airlines predictsthat by 2020, 15-20% ofthe projected 83.2 billionMRO aftermarket spend forthat year could be affectedby new technology.915%to20%12

EXPERIENCEDSKILLEDLABORAs a greater number of aerospace workers reachretirement age, the industry finds itself facing a shortage ofskilled workers. As demand continues to rise, this situationwill only be exacerbated. Recruiting, training, and retainingyoung qualified individuals has proven challenging, andsome companies are partnering with external organizationsto expand their capabilities in the face of this shortage.n The average age ofaerospace workersis 47.1013

NEWTECHNOLOGYDEVELOPMENTSEWI has developed and demonstrated an array of new andenhanced technological capabilities that are particularly relevant toaerospace manufacturers in their pursuit of quality, performance,and innovation.THE NEXT THREE PAGES SPOTLIGHT THESE TECHNOLOGIES:Laser Coating Removal for Aircraft, Parts, and DiesEWI’s innovative laser paint stripping technologyLow-cost Honeycomb PanelsEWI’s fabrication technology for low-cost acreage thermalprotection panels made from bimetallic honeycombHigh-power UltrasonicsEWI-developed ultrasonic machining technology for increasingthroughput and quality14

NEWTECHNOLOGYDEVELOPMENTSLaser Coating Removalfor Aircraft, Parts, and DiesCurrent methods of removing coatings or contaminants includehazardous processes such as chemical stripping and plasticmedia blast, or time consuming processes like sanding. EWI’sinnovative laser paint stripping technology:n Reduces hazardous waste productsn Reduces de-paint timen Reduces costsn Has the precision to stop at primer orcompletely strip to the substrate15

NEWTECHNOLOGYDEVELOPMENTSLow-CostHoneycomb PanelsSandwich panels are critical components in aircraft interiors dueto their lightweight nature and the high mechanical performancethey provide. The aerospace industry commonly uses honeycombsandwich panels; however, producing these structures is costly.EWI has developed preliminary fabrication technology for lowcost acreage thermal protection panels made from bimetallichoneycomb. The structure consists of a bimetallic core withthin face sheets, protected by oxidation-resistant coatings. Thedeveloped product has passed NASA burner rig testing. Thismethod of manufacturing and choice of materials is expectedto significantly reduce costs and simplify construction forhypersonic vehicles.16

asonic assisted machining applies intense vibrationsto conventional metalworking tools for altering the frictionalcharacteristics of the cutter and material being removed.Aerospace manufacturers have found this technology to offersignificant reductions in heat generated by the cutting process,greatly enhancing the machinability of advanced aerospacematerials. Aerospace components prone to work hardeningor undergoing microstructure transformations during themanufacturing process can be produced faster with higher quality.EWI developed an innovative system that is now being taken tomarket by Acoustech Systems for installation on new or existingmachines. The reductions in heat and cutting forces offered byultrasonic assisted machining provides significant benefits tomanufacturers in the form of:n Higher production rates (2-10x)n Increased tool life (2-10x)n Superior surface finishesn Improved dimensional stability17