GKN Technology:
Leading the way toward more efficient aircraft
Ashley Brooks - Manuela Cassissa - Susanna Halls | 17th July 2014
GKN Technology
Making things fly
GKN Technology: Leading the way toward more efficient aircraft
2
GKN PLC: Delivering to our markets
We have four operating divisions: GKN Driveline and GKN
Powder Metallurgy that focus on the automotive market; GKN
Aerospace, and GKN Land Systems. Every division is a market
leader, each outperforming its markets, giving unrivalled expertise
and experience in delivering cutting-edge technology and
engineering to our global customers:
GKN Aerospace
A leading first tier supplier to the
global aviation industry focussing on
aerostructures, engine systems and
products and specialty products.
GKN Driveline
A world leading supplier of
automotive driveline systems
and solutions, including
all-wheel drive.
2013 - Sales by division
£104m
Other
1%
£899m
Land
Systems
12%
GKN Powder Metallurgy
The world’s largest manufacturer of
sintered components,
predominantly to the automotive
sector.
£3,416m
Driveline
45%
£2,243m
Aerospace
30%
GKN Land Systems
A leading supplier of technologydifferentiated power management
solutions and services to the
agricultural, construction, industrial
and mining sectors.
Powder
Metallurgy
12%
£932m
3
GKN Aerospace
$3.5 billion Global Aerospace company, 35 sites in 9 countries, 11,700 people
Market leaders in airframe structures, engine components and transparencies
Increasing investment in technology and focus on deployment
Growing global footprint as part of drive for increasing competitiveness
4
GKN Aerospace – World class Product Portfolio
Aerostructures Global #3
Engine structures
45% of Sales 2013
50% of Sales 2013
Wing
Fuselage
Nacelle and
Pylon
Global #2
Engine Systems and Services
Engine structures
Engine rotatives
Special
products
Global
#1/2
5% of Sales 2013
Transparencies
and Protection
Systems
J-UCAS Fuselage
A380 Fixed Trailing Edge
B747-8 Exhaust
B787 Anti-icing System
A350XWB Rear Spar
CH53K Aft Fuselage
A400M Engine Intake
V22 Fuel Tanks
A330 Flap Skins
B787 Floor Grid
B767 Winglet
HondaJet Fuselage
B787 Cabin Windows
B787 Inner Core Cowl
Full Engine MRO and support
Ariane 5 Exhaust nozzle
F35 Canopy
5
A Broad Customer Base
Military 27%
Civil 73%
2013 Sales
6
Targeted Innovation – Technology
Engine
Statics
Engine
Rotatives
Future Wing
Technologies
Advanced
Fuselage
Composite Technology
Metallic Technology
Supporting Technology
7
Nacelle,
Pylon &
Exhaust
Transparencies Protection
& Coatings
Systems
The Challenge
Contemporary aviation objectives
GKN Technology: Leading the way toward more efficient aircraft
8
The Industry Drivers
Fuel cost
Operating costs
Emissions
Aircraft noise
Passenger volume and travel trends
Source: http://mashable.com/2014/03/14/visualization-air-traffic/
9
Industry Response
Improve engine
efficiency
REDUCE FUEL
CONSUMPTION
Optimise
missions
Reduce
drag
Remove
bleed air
systems
Engine
technology
Reduce
weight
More Electric
architectures
Reduce systems /
wiring weight
Increase use
of composites
Low-drag
surfaces
Reduce
power
consumption
Composite
manufacturing
technology
Systems
integration with
composites
Advanced
Manufacturing
10
Advanced
aircraft
designs
Technology Focus at GKN Aerospace Luton
Improve engine
efficiency
REDUCE FUEL
CONSUMPTION
Optimise
missions
Reduce
drag
Remove
bleed air
systems
Engine
technology
Reduce
weight
More Electric
architectures
Reduce systems /
wiring weight
Increase use
of composites
Low-drag
surfaces
Reduce
power
consumption
Composite
manufacturing
technology
Systems
integration with
composites
Advanced
Manufacturing
11
Advanced
aircraft
designs
GKN Aerospace Luton Products
Images: Various sources please see the end of presentation
12
Aircraft Icing
Why ice protection systems are important
GKN Technology: Leading the way toward more efficient aircraft
13
Aircraft Icing Effects
Disturbs airflow: increases drag, reduces lift and results in unpredictable handling
Increases weight and changes weight distribution: unwanted vibrations and trim
adjustments
Engine issues: ice accretion can reduce thrust and cause blockage
Ice accretion is partly determined by surface geometry – leading edges most at risk
14
Icing Conditions
Ice accretion on surfaces is proportional to amount of
supercooled liquid water present
Largest droplets are found just below 0ºC
Certain cloud types (tall) present highest risk
15
Icing-Related Accidents
16
Types of Aircraft Ice
Protection
GKN Technology: Leading the way toward more efficient aircraft
17
Avoidance of Icing Conditions
Aircraft without IPS (Ice
Protection Systems) must
avoid icing conditions if
possible
− E.g. Don’t fly in poor
weather
− E.g. Find the shortest route
through a weather front or
divert away
Descend/ascend is
sometimes best way out
Modern commercial/military aircraft need IPS to maintain practical operational
capability
18
IPS (Ice Protection Systems)
Switched on once ice
accretion is detected
Actuates the
surface in order to
loosen/shed ice
Pneumatic
Expulsive
Electric
De-Ice
IPS
Heated
Hot gas
Anti-Ice
Switched on once
icing conditions
are detected
Elevates surface
temperature so that
ice is melted or shed
Passive
Coatings
Make the surface
“icephobic”
19
Hot gas or “bleed air”
systems are common on
existing large aircraft
− Wing leading edges
− Engine intakes and
splitters/guide vanes
Pneumatic expulsive
systems (inflatable
“boots”) are common on
smaller aircraft with small
power budgets
De-icing/anti-icing
chemicals are commonly
applied when aircraft are
on ground in cold
climates
Traditional Wing Leading Edge and Engine De-Icing
Traditional architecture for large jet aircraft is for hot gas (“bleed
air”) to be used for wing anti-ice
Valves control flow of bleed air from the engines along the wing
Network of “piccolo” tubes distribute heat evenly
Spent gas is exhausted through holes on wing underside
Reduces engine efficiency
Exhausted gas contains wasted energy
Also generates drag and noise
Limited control of temperatures
Typical Bleed-Air De-Icing Arrangement
20
Electro-Thermal Ice Protection
Need for fuel, noise and efficiency savings is driving industry to adopt electric ice
protection to a greater extent
Pneumatic
Electric
−
−
−
−
Hot gas
CHALLENGES
Coatings
− Significantly increases
aircraft electric power
demand
− Requires aircraft with more
electric architecture
Expulsive
De-Ice
IPS
Heated
Anti-Ice
Passive
21
ADVANTAGES
Reduces energy waste
Precise heat distribution
Hybrid anti-ice/de-ice
Eliminates a source of drag
and noise (bleed air
exhausts)
A More Electric Aircraft Architecture
Standard aircraft
A mix of electrical, pneumatic
and hydraulic power demand
More electric aircraft
Emissions reduction
Fuel savings
More efficient
More versatile
Lighter structure
Aircraft Diagrams. Source: Courtesy of GKN Aerospace.
22
Boeing 787 – GKN Wing Ice Protection System (WIPS)
First large commercial airliner to adopt this type of technology
Supports a significant step change to an electric aircraft architecture in order to achieve
fuel savings
Images Source: Courtesy of GKN Aerospace.
23
Heating a Composite Wing
Thermal environment of a lightweight structure
GKN Technology: Leading the way toward more efficient aircraft
24
Heated Aircraft Surfaces – Thermal Environment
Aluminum Leading Edge
Carbon/Epoxy Composite
Heat transfer from surface to moving air
Desired surface temperature e.g. 60°C
Desired surface temperature e.g. 60°C
Material limit e.g. 500ºC
•
Good thermal conductor
•
Structure heats up less for given
surface temperature
•
Large amount of material thermal
headroom
Material limit typically <180ºC
25
•
Poor thermal conductor
•
Structure heats up to greater extent
•
Tight on thermal limits of material
Heated Composite Components – Design Aims
• We need to:
Carbon/Epoxy Composite
• Avoid overheating the composite
• Maximise efficient heat transfer to
the surface
Desired surface temperature e.g. 60°C
• Therefore we need:
• Careful selection of polymer
matrix materials
• Heat source as close to the
surface as possible
Material limit typically <180ºC
• Robust and accurate control over
the heat source
• Extremely difficult to achieve with
air bleed/hot gas systems
26
Heated Composite Components – Design Aims
• We need to:
Electro-Thermal Heating
• Avoid overheating the composite
• Maximise efficient heat transfer to
the surface
Electric heaters are a good choice
because we can:
− Deliver a precise amount of power
− Vary the amount of power
delivered to different areas of the
surface or structure
− Occupy a very thin layer with the
heater
− Get heat source very close to the
surface
• Therefore we need:
• Careful selection of polymer
matrix materials
• Heat source as close to the
surface as possible
• Robust and accurate control over
the heat source
• Extremely difficult to achieve with
air bleed/hot gas systems
27
GKN Aerospace Heater Mat
Technology
Integrated within composite structures
28
GKN Aerospace Heater Mats
Unique application of
thermal spray
Automated process
Controlled electrical
properties for desired
heat output on a local
scale
Thermal spray
conductors
Film
adhesive
Applied directly to
complex shape
components
Heater encapsulated
within composite
material
Structural or passive
Erosion
protection – thin
metal
Bell V-22 Osprey Engine
Intake
Compatible with
multiple types of
composites
manufacturing
processes
Film adhesive
(if needed)
GRP basecoat and
topcoat dielectric
composite layers
AW101 Main Rotor Blade
Images Source: Courtesy of GKN Aerospace.
29
Small and large
components
Coatings
More than just aesthetic appeal…..
GKN Technology: Leading the way toward more efficient aircraft
30
An Introduction to Functional Coatings
Functional coatings are found everywhere on modern technology. They can serve a variety of purposes,
be it to protect a surface from damage through scratches or transitioning to different colours depending
on light intensity levels or just to improve their appeal. Functional coatings can be used to add value to a
product by increasing the products longevity or giving the product a desirable characteristic.
Functional Coating Examples:
 Waterproofing
 Self-cleaning
 Damage protection
 UV Protection
 Scratch resistance
 ‘Non-stick’
[3]
[2]
[4]
31
[1]
An Introduction to Coatings in Aerospace
Coating / Paint Example Locations:
Fuselage
Cabin Windows
Cockpit Windows
Aft of Leading Edges
Paint Systems:
Protection from
Erosion,
Airline Insignias,
Aesthetic Appeal
Images Source: Courtesy of GKN Aerospace.
32
Functional Aerospace Coatings
Icephobic Coatings:
Reduction in ice accretion,
Reduction in power requirement for
IPS,
Could be placed in areas with no
‘active’ IPS
Images Source: Courtesy of GKN Aerospace.
33
Functional Aerospace Coatings
Low Drag Coatings:
Could be located anywhere where
drag performance is a factor.
Reduction in fuel consumption.
Aids laminar wing concepts.
Images Source: Courtesy of GKN Aerospace.
34
Functional Aerospace Coatings
Composite Damage Detection:
Could be located anywhere at risk of impact
damage; hail, ground support equipment
and runway debris
Increase in confidence of visual inspection
processes, potential reduction in tolerance
requirements leading to lighter aircraft.
Images Source: Courtesy of GKN Aerospace.
35
GKN Aerospace Functional Coatings Technology
Images
Source:
Courtesy
of GKN
Aerospace
.
36
Functional Coatings Technology Example: Anti-Ice
What are Anti-Ice Surfaces?:
 Anti-ice surfaces are surfaces that shed ice or reduce likelihood of ice accretion
 Such surfaces can be classed as; ‘non-stick’, ‘non-build’, ‘thermal transfer’, or a combination
Images Source: Courtesy of GKN Aerospace
thereof
‘Non-Stick’
Ability of ice to adhere is vastly
reduced
‘Non-Build’
Ice crystal growth is disrupted
preventing growth of ice layer
Coatings subjected to icing conditions
and electro-expulsive tests.
Pictorial representation of ‘non-build’
surface structure .
37
‘Thermal Transfer’
Surface can be heated or
transfer heat energy from a
heating source
Anti-Ice Coating Technology
Benefits of Anti-Ice Coating Technology:
 Reductions in the power requirements of the ice protection system used:
 electro-thermal, electro-mechanical or bleed air
 It can also be useful on parts where ice protection systems cannot be utilised, yet are still at
risk from ice accretion
Applications for the Technology:
 Wings (leading edge and areas aft of leading edge)
 Engine components (fan blades, spinners, splitters and guide vanes)
Images Source: Courtesy of GKN Aerospace
Technology Development Approaches:
 GKN Aerospace is in the process of developing icing / ice adhesion test equipment and a
predictive model, expanding the understanding of how ice accretes and sheds from
different surfaces. These also act as tools to enable rapid development and testing of novel
coating solutions.
38
Functional Coatings Technology: Low Drag
What are Low Drag Coatings?:
 Low drag coatings are surfaces which assist with reduction in drag (increased time to
turbulence) of the structure to which they are applied
 This can be achieved by appropriate structure, chemistry, uniformity and cleanliness
Images Source: Courtesy of GKN Aerospace
Power
coated
composite
still
showing
fibre
texture
Surface profiles of super smooth
and structured coatings
Primered
then
topcoated
aluminium
panel
An example of the spray
application process
39
Low Drag Coating Technology
Benefits of the Technology:
 Assist with enabling laminar concepts to be met when combined with appropriate structures
 Can reduce fuel consumption by a significant (measureable) amount. Even 1% fuel saving
would be a great benefit
Applications for the Technology:
 Any aircraft surface where turbulent flow is a significant risk, examples include engine fan
Images Source: Courtesy of GKN Aerospace
blades, wings and winglets
Technology Development
Approaches:
 GKN Aerospace is studying the
effects of various factors that are
thought to affect drag performance of
surfaces, with the intent of
generating a predictive model to
guide development
 Also GKN Aerospace has developed
substrate preparation and application
processes which will enable desired
characteristics to be achieved
40
Functional Coatings Technology:
Composite Impact Damage Detection Coatings
What are Composite Impact Damage Detection Coatings?:
These are smart coatings which when applied to a composite surface will provide an
indication/ signature of an impact event identifying the surface area impacted and the
associated energy transferred
This is achieved by the addition of microcapsules of various strength levels to already aircraft
certified paints. The microcapsules contain unique dyes, the signatures of which can be
Images Source: Courtesy of GKN Aerospace
detected utilising suitable light source inspection equipment
Before Impact Event
After Impact Event
Microscope photographs of microcapsules as made (not dispersed into
a paint system)
41
Exposed to
UV Light
Composite Impact Damage Detection Coatings
Images Source: Courtesy of GKN Aerospace.
Benefits of the Technology:
There are a variety of scenarios
where impacts to aircraft occur,
some of which may cause
damage to the underlying
composite such that a repair will
be required and others such
that the part would need to be
replaced
In many incidents damage
which causes a structural risk
can be very difficult to see
based on standard visual
inspection
Examples of potential impact damage sources
This technology therefore, could reduce the risk of aircraft flying with structural damage and
enhance the efficiency and accuracy of the inspection process
In the long term, such technology may also enhance the understanding of the behaviour of
composite structures and enable further weight reduction through reducing the number of
plies in a composite part
42
Composite Impact Damage Detection Coatings
Applications for the Technology:
 Any composite part of an aircraft that is susceptible to an impact event, such as fan blades, radomes
and doors or even wing skins
Images Source: Courtesy of GKN Aerospace
Technology Development Approaches:
 Microcapsules of various wall thicknesses and
chemistries synthesised with simultaneous
incorporation of fluorescent dyes, signatures of
which appears in response to incident light with
wavelengths outside of the visible spectrum.
Evaluation of impact performance with regards
to intensity and wavelength of fluorescence
emitted.
Photograph of signal
under UV light exposure.
43
Coating Technology Summary
 Coatings are able to provide more than just aesthetic appeal
 By incorporation of functionality, coatings can assist with achieving:
 reduced power requirements of aircraft, such as reduced energy consumption from ice
protection systems
 increased confidence in composite technology, through the use of damage detection
microcapsules
 reduced fuel consumption by the development of low drag coatings for composites and
metallic surfaces
Images Source: Courtesy of GKN Aerospace.
44
Development Focus
GKN Technology: Leading the way toward more efficient aircraft
45
The Development Process
Interact with customers
Interact with suppliers
Develop new concepts
Test new technologies
Create marketable ideas
Improve current products
Source (clip): http://www.gkn.com/aerospace/technologyandinnovation/Pages/coatings1.aspx/
46
Developing New Solutions
Developing new technologies
Developing a concept
−
−
−
−
Creating a strategy
Funding
Filling the market gap
Evaluating demand
Testing the idea
− Preliminary tests
− Rapid prototypes
Testing for certification
− Repeatability
− Reliability
− Manufacturability
Source: Microsoft Office Clipart
47
The Development Process: International Teamwork
Testing
standards
Testing houses
Engineering
Institutions
CATAPULT
centres
Environmental
Agencies
GKN Sites
Worldwide
Government
Institutions
Universities
Source: Microsoft Office Clip Art Images
48
GKN Aerospace Luton Development Focus
Integration of highly functional components and assemblies
Integration with “morphing” leading edge technology
− Application for GKN Aerospace “flexible” heater mat technology
− Challenge: fatigue and damage tolerance of surrounding structure
vs flexibility
Combination of ice protection and acoustic liner technology
in the same complex component
− GKN Aerospace Clean Sky scoop intake is on display at
Farnborough Innovation Zone, Hall 4 Stand 4/IZ/B10
Integration of advanced coatings e.g.
−
−
−
−
Composite structures which indicate damage events
Drag reduction coatings
Self-cleaning coatings
Icephobic coatings
Development of highly accurate, smooth and stable
structures for ultra low drag flight
All of the above?
Images Source: Courtesy of GKN Aerospace
49
GKN Aerospace Luton Development Focus
Reduced power demand of ice protection systems
Improve thermal heat transfer in the right direction
through the structure
− New materials manufacturing processes
Combine electric heating with passive techniques
such as icephobic coatings
Improve the use of ice detection to further optimise
power usage
− Current instruments measure “ice or no ice” in the wrong
place on the aircraft (fuselage)
− GKN has developed and flight tested an optical ice
detector which fits inside any aerodynamic surface
− Measures ice thickness, and could measure type of ice
also
Images Source: Courtesy of GKN Aerospace
50
GKN Luton Development Focus
Manufacturing costs and capacity
Recent programmes (Boeing 787, A350 XWB) have
indicated a higher rate environment for aerospace
manufacturing
Advanced technology is only exploitable if it can be
manufactured cost-effectively
Various technology strands being integrated into
GKN Aerospace’s next generation of ice protection
heater mats:
− Selection of composite processes
− Avoid long autoclave cycles, step change in process
times
− Relax/remove out-life and storage controls for materials
− Automation e.g. robotic lay-up, element application and
roll-to-roll manufacturing
− Modular assemblies with common components across
multiple design configurations
Images Source: Courtesy of GKN Aerospace
51
Conclusions
Advanced technology is needed by the aviation industry in order for it to respond to the
industry drivers
Within GKN Aerospace, and by collaboration with partners, suppliers and customers, new
technology is being developed and matured to meet these needs
At GKN Aerospace Luton, the development and manufacture of new ice protection
systems and novel functional coatings represent niche technologies with which have far
reaching benefits to the overall aircraft
These technologies can provide complete technological solutions to complex problems, to
achieve this we work closely with all levels of the supply chain
New ice protection systems and niche functional coatings are a part of the wide array of
technology strands currently being developed across the global GKN Aerospace
organisation
52
Thank you
Thank you for listening
Any Questions?
Manuela Cassissa
Susanna Halls
Ashley Brooks
IPS Development Engineer
Coatings Projects Lead
IPS Lead Project Engineer
(manuela.cassissa@gknaerospace.com)
(susanna.halls@gknaerospace.com)
(ashley.brooks@gknaerospace.com)
53
References
Slide 12: Heater mat. http://www.compositesworld.com/articles/787-integrates-new-composite-wing-deicing-system
Slide 12: Aircraft. Source: http://www.gkn.com/aerospace/products-and-capabilities/Pages/default.aspx
Slide 12 Cockpit window: http://www.gkn.com/aerospace/products-and-capabilities/transparencies/windshield-cockpit-windows/Pages/default.aspx
Slide 12: Cabin window: http://www.gkn.com/aerospace/products-and-capabilities/transparencies/passenger-cabin-windows/Pages/default.aspx
Slide 12: Scoop and NACA duct. Source: Courtesy of GKN aerospace.
Slide 14: Image source: AOPA Air Safety Foundation – Air Safety Advisor SA11, Weather No. 1 (2008)
Slide 14: Image source: http://www.woodardfamily.com/nonplane/airbusice.htm
Slide 15: Source: “Hazardous Weather Phenomena – Airframe Icing” – Bureau of Meteorology, Commonwealth of Australia, Feb 2013
Slide 18: Image source: AOPA Air Safety Foundation – Air Safety Advisor SA11, Weather No. 1 (2008)
Slide 31:[1] http://www.creativematch.com/news/hi-tech-launch-revolutionary-new/96558/
Slide 31: [2] http://www.angusmcphie.co.uk/pages/tints.htm
Slide 31: [3] http://www.european-coatings.com/Raw-Materials-Technologies/Applications/Automotive/Photodegradation-of-multilayer-automotivecoatings-tracked-in-detail
Slide 31: [4] http://www.vtt.fi/service/oled_and_photovoltaics.jsp?lang=en
Slide 50: Source (top image): AMT Airframe Handbook, Chapter 15, Federal Aviation Authority
54