Archived Aerospace Sector News - 2008
ACG Reaches Development Milestone in Out-Of-Autoclave Capability for Complex Aircraft Primary Structures - October 2008
Advanced Composites Group Ltd. (ACG), a member of the Composites Division of Umeco plc, reached an important milestone when it successfully demonstrated the capability of its MTM®44-1 Out-Of-Autoclave (OOA) toughened, structural prepreg resin system on the first sub-scale wing box demonstrator produced for the collaborative research programme ‘ALCAS’ (Advanced Low Cost Aircraft Structures).
ACG is a major partner in the Business Jet Platform of this Airbus and Dassault Aviation led, 101m€ EU-funded programme aimed at validating the designs and technologies for lower cost aircraft structures.
ACG’s main focus in the programme is to design and manufacture the lower cover of a structural wing box demonstrator. This cover would then be used by four other partners (Alenia, Dassault Aviation, SAAB and Stork Fokker AESP) to complete the structure using different materials, designs and manufacturing options.
The four structures would subsequently be tested to validate and compare the embodied technologies.
The cover, composed primarily of MTM44-1/IMS UD prepreg, features ‘T’ shaped stiffeners co-cured to the underlying skin, which varies in thickness from 5 to 17mm. The structure was successfully cured in a one-shot, oven-vacuum bag cycle. Detailed stringer run out features were substantiated by coupon and sub-element level testing.
ACG’s cover was subsequently assembled with the rest of Fokker’s structure and the complete structural wing box demonstrator was sent to VZLU (Výzkumný a zkušební letecký ústav, a.s.) in Prague, where static loading, fatigue and impact tests were performed to assess ultimate failure load. The demonstrator failed at 10% over the specified design ultimate load, thereby proving the effectiveness of the materials, designs and technologies involved.
The cover panels destined for the remaining three structural wing box demonstrators have already been manufactured at Advanced Composites Engineering (ACE), ACG’s component manufacturing facility, using the same prepregs and OOA cure process.
When compared with other OOA structural systems, ACG’s MTM44-1 exhibits the highest mechanical performances and can compete with a wide range of high toughness, autoclave curable epoxy systems.
ACG first introduced OOA materials and technology for aerospace structural applications in the early 1990’s and has radically developed its product portfolio for this and many other demanding applications.
Numerous civil and military programs currently use ACG’s OOA materials to manufacture structures by hand lay-up and state-of-the-art automated systems, including Automated Tape Lay-Up (ATL) and Automated Fibre Placement (AFP).
Schiebel Corporation Chooses Advanced Composites Group Materials for its ‘CAMCOPTER’ UAV - September 2008
ACG recently announced that it has been selected by Schiebel as one of its preferred suppliers of material for its CAMCOPTER® S-100 Unmanned Air Vehicle (UAV). In particular, ACG’s MMT®49 and LTM®212 prepregs were selected for the manufacture of the UAV’s carbon-fibre monocoque fuselage and tooling. With strength-to-weight ratio being a fundamental consideration in all aircraft design, it’s hardly surprising that advanced composites materials were selected for the structure of Schiebel’s CAMCOPTER® S-100.
CAMCOPTER® S-100 is a highly versatile autonomous UAV system developed to provide a unique balance between advanced capabilities and operation in tactical environments. The system consists of a compact helicopter aerial vehicle that can be fitted with a wide variety of payloads tailored to meet diverse user requirements.
CAMCOPTER® S-100 UAV, which measures 3110mm (122in) long x 1040mm (41in) high x 1240mm (49in) wide, with a rotor diameter of 3400mm (133.9in), is capable of carrying a 25 kg (55 lbs) payload for up to six hours. The UAV is powered by an aviation-certified rotary engine. The S-100 is also being developed for maritime applications, where it is capable of landing on helicopter deck-equipped ships without the use of additional landing equipment.
ACG’s MTM49 component prepreg is an 80 to 160°C (176 to 320°F) curing, toughened epoxy matrix resin specifically formulated for the manufacture of components requiring excellent ambient and hot mechanical performance combined with good impact resistance. MTM49 exhibits a good balance of temperature resistance and toughness properties, and was considered to be ideal for the application. In brief, MTM49 accommodates a range of end use temperatures - depending on application and post-cure, making it suitable for a wide range of operating temperatures in different regions of the fuselage. Moreover, it exhibits good tack and drape, long out life, good impact resistance, and flexible processing via autoclave, vacuum bag or press moulding.
ACG supplies MTM49 prepregs, unidirectional tapes and fabrics in several carbon and glass fibres formats to accommodate Schiebel’s specific design requirements.
ACG’s LTM212 tooling prepreg system is based upon proprietary low temperature cure epoxy based formulations that may be post-cured to produce high end use temperature tooling capable of withstanding 210°C (410°F). At ambient temperature, LTM212 offers a maximum drape life of two and a half days and is autoclave workable for four days. It can be cured at a minimum initial temperature of 35°C (95°F), has a shelf life of twelve months and provides a maximum Tg of 210°C (410°F) at full post-cure temperature.
LTM212 tooling can be manufactured directly from low temperature epoxy and other suitable master model materials. LTM212 offers improved tool accuracy with low residual stress, can be post-cured in an unsupported (free-standing) state, and has a low CTE matched to ACG-supplied backing structures.
ACG’s fully equipped state-of-the-art Technology Centre, built in late 2006 with funding from Umeco plc, played an active role in determining product suitability by performing a series of tests. The tests, which were carried out in accordance with Shiebel’s exacting specifications, evaluated aging, fuel resistance and overall mechanical performance. Under the watchful eye of Mike Davies, ACG’s Test and Evaluation Manager, these ACG manufactured material specimens were subjected to tests following a prolonged (30 day) soak in ‘AVGAS’ aviation fuel heated to 40°C. Tests were performed on two product configurations, one at standard material thickness and the other on thinner samples using standard ASTM test methods, which proved that the product was ideally suited for the intended application.
Image copyright and courtesy of Schiebel Group.
ACG Simulates Flying High with Feet Firmly Planted on Terra Firma - August 2008
ACG recently signed a repeat contract to manufacture a number of cockpit simulator shells for Thales, a leading international electronics and systems group, addressing defence, aerospace and security markets worldwide.
ACG has been contracted to supply European Fighter Aircraft (EFA, Typhoon) cockpit simulator shells ready to accept an array of instrumentation and ancillary equipment for Thales Full Mission Simulators and Crew Trainers (FMS and CT). With positional accuracy of vital importance in replicating the ‘real thing’, leading the trainee pilot to believe that he is actually flying a real fighter plane, the shells are being manufactured at Advanced Composites Engineering (ACE), where the Group’s expertise, 5-axis CNC machining centre and fully equipped prepreg lay-up facility are applied to provide the desired end product.
The base structure of a simulator is in the form of a tubular steel platform onto which a fabricated aluminium display suite framework is rigidly-mounted. From this point, all features, including the inner and outer cockpit shells, and almost 600 individual composite components, are either mounted to or co-cured with the inner shell.
ACG’s TB720, a low density, low coefficient of thermal expansion (CTE) epoxy syntactic tooling block, can be readily machined and hand carved to exacting tolerances and used at temperatures up to 110°C (230°F). TB720 is being used to manufacture accurate and stable LTM®12 (Low Temperature Moulding) tooling, which is then used to mould the inner and outer shells, and a number of associated components - some of which are honeycomb cored to reduce weight, and improve rigidity and strength. The inner and outer shells, plus a range of components and stowage boxes, have been made using a combination of ACG’s MTM®56 advanced composite resin matrix and GF0100 and GF0700 glass fibre off LTM12 tooling.
MTM56, which has been specifically developed for component manufacture, is based on a 120°C (248°F) curing, toughened epoxy matrix that can be used at temperatures up to 100°C (212°F). Although MTM56 can also be vacuum bag and press mould cured, the shells and a number of smaller components for the cockpit simulator have been autoclave cured, thus providing exceptionally high quality surface finish and supreme consolidation.
About Thales:
Thales is a leading international group, addressing Defence, Aerospace and Security markets worldwide. Thales’ expertise in its core markets spans the entire value chain, providing all the capabilities its customers require, from equipment and systems to comprehensive support services, and including prime contracting on large-scale programmes.
Thales’ leading-edge technology is supported by 22 000 R&D engineers who offer a capability unmatched in Europe to develop and deploy field-proven mission-critical information systems. To this end, the group’s civil and military businesses develop in parallel and share a common base of technologies to serve a single objective: the security of people, property and nations. The group builds its growth on its unique multi-domestic strategy based on trusted partnerships with national customers and market players, while leveraging its global expertise to support local technology and industrial development. Thales employs 68 000 people in 50 countries with revenues in 2007 of € 12.3 billion.
For further information please contact:
Advanced Composites Group
Steve Barbour – ACE and ACG SA (PTY) General Manager - ACG Ltd.
Tel: +44 (0)1773 766200
ACG Custom Range of Prepregs for Aerospace Interiors - July 2008
Advanced Composites Group Ltd. (ACG), part of the Composites Division of Umeco plc, manufactures a range of aircraft interior prepreg materials which are qualified to Airbus specifications.
ACG's wide range of prepreg products includes epoxy, phenolic, and bismaleimide (BMI) resin systems that are supplied in a number of different formats and fibre reinforcements, such as carbon, E, R and S glass.
For aircraft interior applications, ACG's prepreg materials exhibit excellent fire performance characteristics that enable components to meet mandatory regulations, such as the Federal Aviation Authority's FAR25.853 and Airbus ABD0031 directives. ACG's phenolic prepregs are widely used in passenger cabin interior applications for components such as side wall and ceiling panels, partitions, and modular fittings, including lavatories, galleys, wardrobes and overhead luggage bins, where they exhibit remarkable stiffness even at minimal weight, which is particularly true for honeycomb-cored parts.
ACG's phenolic prepregs exhibit low heat release, as well as minimal emission of smoke and toxic gasses.
ACG also offers prepreg materials exclusively manufactured for other interior fittings, such as seat outer shells and inner structures, air ducting and mixers, cabin and cargo flooring, and cargo liners. The range includes high tack adhesive epoxies, high service temperature BMI and phenolics.
From its prepreg manufacturing facilities in the UK and the USA, the Group services all markets by delivering bespoke products to short lead times, a service which is supported by a global network of dedicated sales and support agencies.
For further information please contact:
Advanced Composites Group
Xavier Gambert - Aerospace Sector Manager - ACG Ltd. Tel: +33 478536649
NGCW Project Gets Go-Ahead - June 2008
On May 14th (2008), an announcement was made, via Umeco's web site, to the effect that Advanced Composites Group Ltd will partner with Airbus and other leading organisations in a major collaborative aviation research programme known as the Next Generation Composite Wing (NGCW).
Funding for the project (some £103 million) has been announced by the UK Government and industrial and regional partners. NGCW is seen as one of the most significant joint aircraft research and technology programmes launched in the UK for several decades, revolutionising aircraft technologies that will improve future wing design processes and help to maximise the eco-efficiency of future aircraft designs.
NGCW brings together 16 leading British organisations, both industrial companies and research bodies, to work on the three-year programme. The programme is led by Airbus in partnership with ACG, Aircraft Research Association, Atkins Ltd, Bombardier Aerospace, Delmia UK Ltd, Eaton Aerospace Ltd, GE Aviation, GKN Transparency Systems, Goodrich Actuation Systems, Hyde Group Ltd, KuKa Automation, Messier - Dowty, Morgan Professional Services, QinetiQ Ltd, Spirit Aerosystems Ltd., together with eight Regional Development Agencies or Devolved Administrations.
Clive Snowdon, Umeco plc Chief Executive, said: "We are honoured and proud to be selected as part of such a critical composites development project. It represents a massive step towards achieving light and more affordable aircraft, and demonstrates ACG's leading position in composites research and development."
For further details contact ACG Sales Department.
Aircraft Interiors Show at Hamburg - April 2008
ACG was present for the first time at the Aircraft Interiors show in Hamburg, Germany from 1-3 April this year. Primco became part of the Advanced Composites Group in December 2007, and the Primco range of aircraft interior prepreg materials are now included on the ACG product list.
The Aircraft Interiors Show at Hamburg, Germany was a good opportunity to inform the aerospace market that their requirements for all the Primco products will continue to be met through the worldwide sales force of ACG.
The ACG selection of specialist prepregs for aerospace interior structures is qualified by:- EADS Airbus Germany, Rolls Royce PLC - Aerospace Group, Westland Helicopters, Slingsby Aviation, Heath Tecna (Cabin Interiors).
Stand managers Mike Millward and Mike Seddon were kept busy with a steady stream of visitors over the 3 days. Many of the visitors were also visiting the JEC show, taking place in Paris on the same 3 days, where they were able to meet Xavier Gambert, ACG's aerospace sector manager.
It has been decided that ACG will continue to have a presence at this show therefore a booth has been booked for the 2009 event. ACG aims to have new products to launch at the 2009 show and has secured a good position to ensure more traffic to its stand.
For further details contact ACG Sales Department.
ACG Integrates Primco’s Phenolic Resin Based Prepregs – Presenting a Complementary Range of Materials for Aerospace Interiors and Exteriors - February 2008
ACG recently strengthened its position in the aircraft interiors business with the acquisition of Primco, a leading formulator and supplier of phenolic prepreg systems used in the aerospace, defence, medical, sporting and general industrial sectors.
The combined operation offers outstanding synergisms; Primco augments the Group’s existing hot-melt capabilities through state-of-the-art solvent towers that meet stringent environmental regulations. ACG manufactures a range of cost effective prepreg products, including epoxy, phenolic, cyanate ester, Bismaleimide (BMI) and thermoplastic resin systems in all formats and with all types of fibre reinforcement.
ACG Primco’s aircraft interior phenolic systems, qualified to Airbus specifications, exhibit superior surface finish, thereby reducing post-mould finishing while also contributing to reductions in both cost and weight.
ACG also offers a range of self-extinguishing epoxy prepreg systems that are used in demanding applications such as flooring and seating.
ACG is forging ahead in the development of new aerospace systems for both structural and interior applications. The Group’s proven research potential was enhanced in 2006 with the opening of a modern Technology Centre, staffed by approximately 60 people.
Customers can expect to benefit from the high level service for which ACG and Primco are renowned. From its prepreg manufacturing facilities in the UK and the USA, the Group services the market by delivering bespoke products to short lead times. This is backed by a network of sales agencies around the world.
The acquisition of George Cole Technologies Limited, which traded as Primco, was made by Umeco plc through ACG. Established for over 40 years, Primco's materials, manufacturing technologies and applications are highly complementary to those of ACG, and will further enlarge the Group's existing range of composite materials technologies and aerospace qualifications.
Clive Snowdon, Chief Executive of Umeco plc, commented: “The Primco acquisition further illustrates the progress Umeco has achieved in delivering complementary growth to the Group both in the UK and overseas. It will enable us to offer existing customers a wider range of material technologies, whilst allowing ACG to further consolidate its market leading position, in a continuously evolving composite arena.
Primco offers good long term value-creating growth and we look forward to realising operating synergies as we integrate it into our existing business."
For further details contact ACG Sales Department.