Archived Aerospace Sector News - 2010

Editors - please refer to the Notes to Editors for background information on Umeco plc and its operating divisions.

QinetiQ’s Zephyr Solar-Powered UAV Shatters Flight Endurance Record using ACGs MTM®45-1 Prepregs

ACG Demonstrates Composite Expertise at Farnborough 2010 - 29th June 2010

ACG and JD Lincoln's Custom Range of Prepregs for Aircraft Interiors

ACG MTM®46 Prepregs Keep Watchkeeper 450 UAV Flying High

HTM143 Selected For New Space and Satellite Applications

ACG Launches New Bismaleimide (BMI) Tooling and Component Matrix Systems

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30th July 2010

QinetiQ’s Zephyr Solar-Powered UAV Shatters Flight Endurance Record using Advanced Composites Group’s MTM®45-1 Prepregs

MTM®45-1 epoxy resin based carbon fibre prepregs manufactured by Advanced Composites Group (ACG), a member of Umeco Composites Structural Materials (UCSM) – a Division of Umeco plc, have been used in a number of formats by QinetiQ to manufacture the wing and fuselage frames for its record-breaking Zephyr solar-powered unmanned aerial vehicle (UAV).

Hand launched by a small team, QinetiQ’s Zephyr UAV took to the skies above the US Army's Yuma Proving Ground in Arizona at 0640 local time (1440 BST) on Friday 9th July and remained aloft for 14 days and 21 minutes, having completed all aspects of its planned trial. 

The previous ‘official’ record of 30 hours and 24 minutes, set by a US Global Hawk UAV, was smashed in an ‘unofficial’ attempt when an earlier version of Zephyr flew for 82 hours and 32 minutes in 2008. Following the recent record-breaking flight, Chris Kelleher, QinetiQ’s chief designer said, “We have designed, built and delivered what will be remembered as a milestone in aviation history.” He continues, “Zephyr will transform the delivery of current services such as communications, and lead to many new applications which are not possible or affordable by other means, and now await the FAI (World Air Sports Federation) official confirmation of the world records.” QinetiQ’s aim was to produce "the world's first truly eternal plane, capable of providing a low-cost, persistent surveillance capability over months rather than days", and it would seem that the company has achieved this.

The new record can be attributed in part to the extended wingspan, now 22.5 metre (74 foot), and performance enhancements afforded by aerodynamic features, such as the radical wing and tail designs. Weighing just over 50 kilograms, Zephyr flies on solar power generated by amorphous, wafer-thin silicon arrays attached to the aircraft's wings; these arrays recharge lithium-sulphur batteries during sunlight hours to provide the power overnight.

The recent flight demonstrates the use of solar-powered high-altitude, long-endurance (Hale) UAVs. In addition to the obvious defence and security applications, commercial uses include environmental research, monitoring crops and pollution, providing tactical intelligence over disaster zones or forest fires, plus delivering mobile communications capabilities in remote areas.

ACG’s MTM45-1 is a variable cure temperature, high performance, toughened epoxy matrix system optimised for low pressure vacuum bag processing in both prepreg and film infusion formats. MTM45-1 can also be autoclave cured.

MTM45-1 may be cured at temperatures as low as 80°C, allowing the use of low cost tooling for prototypes and short production runs. After a free-standing 180°C post-cure, MTM45-1 is capable of 190°C/150°C dry/wet Tg and can offer a high level of damage tolerance

A number of MTM45-1 prepreg materials already have FAA approved design databases, allowing them to be used for Out-of-Autoclave (OoA) processed certified aircraft structures without extensive qualification testing. This offers considerable up-front cost savings, as well as lower manufacturing costs when compared to autoclave processes.   

Image copyright: QinetiQ Group plc.

ACG Demonstrates Composite Expertise at Farnborough 2010 - 29th June 2010

Advanced Composites Group Ltd. (ACG), part of Umeco Composites Structural Materials (UCSM), will be exhibiting its composite technology on Stand A12 at the 2010 Farnborough International Airshow from the 19th to 25th July 2010.

ACG, a manufacturer a wide range of epoxy, cyanate ester, bismaleimide and phenolic resin systems for use in aerospace, space and defence applications, will be co-exhibiting with Pattonair International Ltd, the global distribution and supply chain management business of Umeco PLC.

MTM®44-1, ACG’s Out-of-Autoclave (OoA) pre-impregnated (prepreg) system, which has received Airbus qualification in both fabric and unidirectional formats for primary and secondary structures, is a toughened epoxy matrix optimised for low pressure vacuum-bag processing curing at 130°C and full performance after a 180°C post-cure. Airbus and ACG have underpinned the qualification of MTM44-1 by signing a framework contract that will provide commercial and technical stability to Airbus subcontractors adopting this new technology over the coming years

Centre stage will be the BTT-3 Banshee aerial target system, one of a range of remotely piloted vehicles offered by Meggitt Defence Systems. Parts of BTT-3 Banshee have been moulded using ACG’s MTM®57 epoxy prepreg system. The Banshee is in active service in over 30 countries, including 10 within NATO.

ACG’s representatives will be on hand to discuss and demonstrate the full range of structural solutions exhibited on the stand.

ACG caters for the needs of all markets and delivers optimised product formats to short lead-times, a service which is supported by a global network of dedicated sales and support agencies.

Image copyright: - Meggitt Defense Systems

For further information, please contact:

Advanced Composites Group
Jon Stowell – Sales and Marketing Director
Telephone: +44 (0)1773 766204
E-mail: jstowell @ acg.co.uk

ACG and J. D. Lincoln's - Custom Range of Prepregs for Aircraft Interiors - 28th April 2010

Advanced Composites Group Ltd. (ACG) and J.D. Lincoln, members of the Composites Division of Umeco plc, will be exhibiting their prepreg materials on Umeco Composites Structural Materials’ (UCSM) Stand 5F9 in Hall B5 at the Aircraft Interiors Expo in the Hamburg Messe, Germany, between the 18th and 20th May 2010.

Collectively, the companies manufacture a wide range of prepreg materials, including: phenolic, epoxy and bismaleimide (BMI) resin systems which can be supplied in a number of different formats and fibre reinforcements, such as carbon, E, R and S-Glass.

These prepreg materials exhibit excellent fire performance characteristics such as low heat release and minimal emission of smoke and toxic gases, thus enabling components to meet the mandatory requirements of the FAA’s FAR25.853 and Airbus’ ABD0031 directives. Materials are currently in use on aircraft such as Airbus’ A380 and Boeing’s 787.

The phenolic prepregs manufactured by ACG and J.D. Lincoln are widely used in passenger cabin interior applications for components such as side wall and ceiling panels, partitions, seats, flooring and modular fittings. The latter includes lavatories, galleys, wardrobes and overhead luggage bins, where they offer very high stiffness to weight, particularly as honeycomb-cored structures. These prepregs are also used for seat outer shells, air ducting and cargo liners.

From prepreg manufacturing facilities in the UK and the USA, the Group services all markets around the globe by delivering custom products to short lead times. This is supported by a global network of dedicated sales and support agencies.

Image copyright iStockphoto.com

For further information, please contact:

Advanced Composites Group
Xavier Gambert – Aerospace Sector Manager
Telephone:
Direct: +33 478536649 or ACG: +44 (0)1773 766200
E-mail: xgambert@acg.co.uk

JD Lincoln Inc
Clint Refsnyder - Vice President Sales & Marketing
Telephone: Office 949/650-8106 or Cell 310/508-6132
E-mail: c.refsnyder@jdlincoln.com
Web site: www.jdlincoln.com

J. D. Lincoln - speciality materials and technology company that manufactures high performance adhesives and composite materials for aerospace, marine, medical, sporting, automotive and other extreme environment applications. JD Lincoln's products are technologically advanced including those designed specifically for aircraft interior applications. They are complementary to the other activities of Umeco Composites. Offices are located in Costa Mesa, CA and Adelanto, CA where we produced materials for over 350 customers worldwide.

Advanced Composites Group (ACG) MTM®46 Prepregs Keep Watchkeeper 450 UAV Flying High - 20th March 2010

ACG, a member of the Composites Division of Umeco plc, has been qualified by global defence electronics company Elbit Systems to supply materials for the construction of the Thales Watchkeeper 450 (WK450) Unmanned Air Vehicle (UAV).

Thales UK selected WK450 as the aerial platform central to their Watchkeeper surveillance system procured by the UK Ministry of Defence (UK MoD).

The use of ACG’s materials on the WK450, a development of the well established Elbit’s Hermes 450 - constructed from ACG’s LTM®26EL prepregs, strengthens the ties that exist between ACG and Elbit Systems. The build of the WK450 UAVs is carried out by Lola Composites Ltd, Huntingdon – UK and integrated at
U-Tacs, Leicester - UK.

Selected from a number of contenders, ACG’s MTM®46 epoxy prepreg system, one of a series of Out-of-Autoclave (OoA) processing aerospace systems, meets the requirements of the UK MoD and offers the manufactures, Thales, Elbit and U-TacS, a number of process advantages.

Developed by the Group’s global research facility in Heanor – UK for use in the primary and secondary structures of FAR23 approved aircraft and UAVs, MTM46 can attain a glass transition temperature (Tg) of 180°C and offers excellent retention of mechanical properties under ‘hot/wet’ conditions.

However, of great significance was the fact that MTM46 was developed for Out-of-Autoclave (OoA) processing. Following a low temperature/low pressure initial cure at 80°C, which can make use of low cost tooling, performance is further developed using a free-standing post cure to achieve the required material performance. Combined with excellent handling characteristics and extended out life of 60 days, MTM46 has proved to be an effective solution to the WK450’s structural requirements.

The Thales Watchkeeper programme provides the UK Armed Forces with an unrivalled Intelligence, Surveillance, Target Acquisition and Reconnaissance (ISTAR) capability.
The WK450 UAV, fitted with an advanced sensor suite and the Watchkeeper surveillance system, provides 24/7 all-weather, day and night exploitation.

In times of war, tension or during peacekeeping operations WK450 UAV can stay airborne providing data, thus saving the need to deploy troops into sensitive or dangerous situations.

Requiring a ground crew of just two to operate the system, one operator controls the mission whilst the other tracks the information being fed from the WK450’s sensors. The system is capable of rapid deployment and operation anywhere in the world.

Image courtesy of Thales - UK

For further information please contact:

Advanced Composites Group
Bernard Twist – Export Sales Manager -
Telephone: +44 (0)1773 766200
E-mail: btwist @ acg.co.uk

HTM143 Selected For New Space and Satellite Applications - 19th February 2010

Advanced Composites Group Ltd. (ACG), a member of the Composites Division of Umeco plc, has continued the development of HTM®143, a ground breaking cyanate ester system which has been specified on a number of large satellite projects

With a comprehensive data base to support it, HTM143, a low moisture pick-up resin matrix, which has a 0.55% weight gain on neat resin, exhibits one of the lowest moisture pick-up rates of all cyanate ester systems currently on the market. Measured on typical high modulus carbon laminate, the outgassing characteristics of HTM143 effortlessly meet the limits required by NASA: Total Mass Loss (TML) of 0.112%, Recovered Mass Loss (RML) of 0.023% and Collected Volatile Condensable Material (CVCM) of 0.002 % [ECSS-Q-ST-70-02C].

First launched in June 2009, HTM143, which is a non-ITAR listed resin system, can generate a very high glass transition temperature (Tg) after post-cure and is used to manufacture high accuracy, dimensionally stable space structures.

During recent tests, MTM®44-1, one of ACG’s new generation of Out-of-Autoclave (OoA) processing high performance, toughened epoxy resin matrices, also met the rigorous requirements set for space applications.

MTM44-1, which can generate a glass transition temperature (Tg) of a 180°C (356°F) after a suitable post-cure, offers a Total Mass Loss (TML) of 0.307%, Recovered Mass Loss (RML) of 0.056% and Collected Volatile Condensable Material (CVCM) of 0.002 % [ECSS-Q-ST-70-02C].

Both resin systems have an out life of 21 days and are available for use with a wide range of unidirectional, biaxial and woven carbon fibre materials.

Image: Copyright iStockphoto.com.

For further information, please contact:

Advanced Composites Group
Xavier Gambert - Aerospace Market Sector Manager E-mail: xgambert@acg.co.uk
Telephone: +44 (0)1773 766200

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ACG Launches New Bismaleimide (BMI) Tooling and Component Matrix Systems - 5th February 2010

Advanced Composites Group Ltd. (ACG), a member of the Composites Division of Umeco plc, announces the launch of two new additions to it range of Bismaleimide (BMI) matrix systems. The new matrix systems, which offer superior handling, performance and high temperature capability, are aimed at the structural tooling and component markets.

HTM® 556, developed specifically for structural applications where high service temperatures are required, offers continuous service temperatures of 200°C (392°F). HTM556 also offers improved toughness and resistance to micro-cracking which has long been a short falling of Bismalimide resins.

HTM®515-1 is a Bismalimide matrix system optimised for tooling applications. HTM515-1 offers similar improvements in handling and can tolerate thermal cycling to 250°C (480°F).

HTM515-1 also exhibits improved toughness and resistance to micro cracking leading to improved vacuum integrity and extended tool life.

For further information, please contact:

Advanced Composites Group
Dr. John Nixon – Technical Marketing Manager
E-mail: jnixon@acg.co.uk
Telephone: +44 (0)1773 766200

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