JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 8

COMPANIES COMPANIES GKN Aerospace creates repair facility for metallic and composite structures Due to the substantial growth of its composite aero-structures design and manufacturing business, and in order to meet future market demand, GKN Aerospace has created a dedicated facility focusing on composite and metallic structure repair and support. T his new facility is located at the Cowes site in the UK, and exploits the Company’s expertise in composite materials to develop its extensive global maintenance, repair and overhaul (MRO) operation. It provides repaired and replacement metallic or composite airframe and aero-engine structures and transparencies. As airline needs expand and change due to growing air traffic and the increasing number of aircraft in service with high levels of composite structures, it is the Company’s aim to offer airlines a single reliable source for efficient repair or replacement of both composite and AN INTERVIEW WITH MR JEFF ARMITAGE, VICE PRESIDENT AND MANAGING DIRECTOR, NACELLES GKN AEROSPACE metallic structural components. Since commencing the MRO operation at the Cowes site in 2000, activity has grown from zero to a turnover approaching $10M. It started with wing part repairs on GKN Aerospace original equipment and is now providing a number of UK-based airlines with repairs to a broad range of composite parts not originally manufactured by the Company. The range of items being repaired today includes all flying surfaces and structural components and engine fairings. The new facility involved the complete refurbishment of an existing building on the site and is currently staffed by over research engineers to directly address the future needs of the composite business. Today, staff numbers have grown to 35 and are forecast to reach 40+ by year end. These figures provide an indication of the GKN Board’s commitment to technology development in the aerospace composite field. JCM: What specific processing methods and technologies do you use? J.A.: Out-of-autoclave processing has been an area of significant development for us over the last three years. When combined with self-heated tooling, the technique offers an opportunity to adopt a cellularbased manufacturing cell and avoid capital outlay and traditional bottlenecks associated with autoclave-based component curing. We have also pioneered a ‘lay flat and form’ process for large-scale wing spar components. This process utilises the deposition benefits of automated tape layup over hand lay-up and combines this with ‘hot drape forming’ to develop the 30 personnel, a number that is expected to grow over the coming years given the increasing need for efficient composite structure repair and replacement. GKN Aerospace has global market leads in its aero-structures, aircraft propulsion and transparencies businesses. It also has an aftermarket operation supporting all these businesses that currently represents some 15% of sales. The Company’s business plan aims to take this figure to near 40% of sales by 2012, largely through working in partnership with prime manufacturing customers to meet growing operator demand. www.gknaerospace.com C-section shape very efficiently. JCM: Has GKN considered working outside the aeronautics sector? J.A.: GKN is already a major player in the Tier 1 automotive industry. Some technologies translate across the two industries such as sintered gears. We are working towards exploiting this opportunity in aero-engine transmission systems and other systems such as pumps. JCM: What are your plans in the short term? J.A.: A brief summary of our plans include further work on: - the primary wing box structure, - secondary structures such as fixed trailing edge assemblies and winglets, - nacelle structures, systems and equipping, - smart structures, i.e. electrical de-icing systems embedded in slats, engine vanes & inlets, - engine components, fan cases, frames, blades, spacers and spinners. JEC Composites Magazine: What is the place of composite materials within GKN Aerospace today? JEFF ARMITAGE: Composites now account for roughly one third of GKN Aerospace’s turnover. We participate in a broad range of both military and civil programmes with the supply of airframe structures, nacelle products and engine components. Products comprise both primary and secondary structures. JCM: Do you plan to give composites more importance and invest in this sector? J.A.: Ongoing investment in this area is substantial and increasing year-on-year. Three years ago, GKNAS opened a new composite research centre employing 20 JEC Composites Magazine / No42 July-August 2008

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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008