gkn antihielo leading the way toward more efficient aircraft

8/19/2019 GKN Antihielo Leading the Way Toward More Efficient Aircraft

http://slidepdf.com/reader/full/gkn-antihielo-leading-the-way-toward-more-efficient-aircraft 1/54

GKN Technology: Leading the way toward more efficient aircraft

Ashley Brooks - Manuela Cassissa - Susanna Halls | 17th July 2014



2

Making things flyGKN Technology




3

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 Driveline A world leading supplier of

automotive driveline systems

and solutions, including

all-wheel drive.

GKN Powder MetallurgyThe world’s largest manufacturer of

sintered components,

predominantly to the automotive

sector .

GKN Aerospace A leading first tier supplier to the

global aviation industry focussing onaerostructures, engine systems and

products and specialty products.

GKN Land Systems A leading supplier of technology-

differentiated power management

solutions and services to the

agricultural, construction, industrial

and mining sectors.

Driveline45%

PowderMetallurgy

12%

Aerospace30%

LandSystems

12%

Other1%

2013 - Sales by division

£3,416m

£2,243m

£899m

£932m

£104m



4

$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

GKN Aerospace



5

Transparenciesand Protection

Systems

Specialproducts5% of Sales 2013

Nacelle andPylon

Engine structures50% of Sales 2013

Engine Systems and ServicesWing Fuselage

Aerostructures45% of Sales 2013

A380 Fixed Trailing Edge

A350XWB Rear Spar

A330 Flap Skins

B767 Winglet

J-UCAS Fuselage

CH53K Aft Fuselage

B787 Floor Grid

HondaJet FuselageF35 Canopy

B787 Cabin Windows

V22 Fuel Tanks

B787 Anti-icing System

Full Engine MRO and support

Ariane 5 Exhaust nozzle

B787 Inner Core Cowl

A400M Engine Intake

B747-8 Exhaust

Engine structures Engine rotatives

GKN Aerospace – World class Product Portfolio

Global #3 Global #2Global

#1/2



6

A Broad Customer Base

2013 Sales

Civil 73%

Military 27%



Targeted Innovation – Technology

Future Wing

Technologies

Advanced

Fuselage

Protection

Systems

Transparencies

& Coatings

Engine

Rotatives

Engine

Statics

Nacelle,

Pylon &Exhaust

Composite Technology

Metallic Technology

Supporting Technology



Contemporary aviation objectivesThe Challenge




The Industry Drivers

Source: http://mashable.com/2014/03/14/visualization-air-traffic/

Fuel cost

Operating costs

Emissions

Aircraft noise

Passenger volume and travel trends



Industry Response

REDUCE FUEL

CONSUMPTION

Improve engine

efficiency

Reduce

weight

Reduce

dragRemove

bleed air

systems

Optimise

missions

Low-drag

surfacesIncrease use

of composites

Engine

technology

Advanced

Manufacturing

More Electric

architectures

Advanced

aircraft

designs

Composite

manufacturing

technology

Systems

integration with

composites

Reduce systems /

wiring weight

Reduce

power

consumption



Technology Focus at GKN Aerospace Luton

REDUCE FUEL

CONSUMPTION

Improve engine

efficiency

Reduce

weight

Reduce

dragRemove

bleed air

systems

Optimise

missions

Low-drag

surfacesIncrease use

of composites

Engine

technology

Advanced

Manufacturing

More Electric

architectures

Advanced

aircraft

designs

Composite

manufacturing

technology

Systems

integration with

composites

Reduce systems /

wiring weight

Reduce

power

consumption



GKN Aerospace Luton Products

Images: Various sources please see the end of presentation



Why ice protection systems are importantAircraft Icing




Aircraft Icing Effects

Disturbs airflow: increases drag, reduces lift and results in unpredictable handling

Increases weight and changes weight distribution: unwanted vibrations and trimadjustments

Engine issues: ice accretion can reduce thrust and cause blockage

Ice accretion is partly determined by surface geometry – leading edges most at risk



Icing Conditions

Ice accretion on surfaces is proportional to amount ofsupercooled liquid water present

Largest droplets are found just below 0ºC

Certain cloud types (tall) present highest risk



Icing-Related Accidents



Types of Aircraft Ice

Protection




Avoidance of Icing Conditions

Aircraft without IPS (Ice

Protection Systems) mustavoid icing conditions ifpossible

− E.g. Don’t fly in poorweather

− E.g. Find the shortest routethrough a weather front or

divert away

Descend/ascend issometimes best way out

Modern commercial/military aircraft need IPS to maintain practical operationalcapability



IPS (Ice Protection Systems)

IPS

De-Ice

Anti-Ice

Heated

Expulsive

Passive

Pneumatic

Electric

Coatings

Hot gas

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 commonlyapplied when aircraft are

on ground in cold

climates

Switched on once ice accretion is detected

Switched on once

icing conditionsare detected

Actuates thesurface in order to

loosen/shed ice

Elevates surfacetemperature so that

ice is melted or shed Make the surface

“icephobic”



20

Traditional Wing Leading Edge and Engine De-Icing

Typical Bleed-Air De-Icing Arrangement

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



21

Electro-Thermal Ice Protection

IPS

De-Ice

Anti-Ice

Heated

Expulsive

Passive

Pneumatic

Electric

Coatings

Hot gas

ADVANTAGES

− Reduces energy waste

− Precise heat distribution

− Hybrid anti-ice/de-ice

− Eliminates a source of drag

and noise (bleed air

exhausts)

CHALLENGES

− Significantly increases

aircraft electric power

demand

− Requires aircraft with moreelectric architecture

Need for fuel, noise and efficiency savings is driving industry to adopt electric ice

protection to a greater extent



22

A More Electric Aircraft Architecture

Standard aircraft

A mix of electrical, pneumaticand hydraulic power demand

More electric aircraft

Emissions reduction

Fuel savingsMore efficient

More versatile

Lighter structure

Aircraft Diagrams. Source: Courtesy of GKN Aerospace.



24

Thermal environment of a lightweight structureHeating a Composite Wing




25

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 Material limit typically <180ºC

• Good thermal conductor

• Structure heats up less for givensurface temperature

• Large amount of material thermalheadroom

• Poor thermal conductor

• Structure heats up to greater extent

• Tight on thermal limits of material



26

Heated Composite Components – Design Aims

Carbon/Epoxy Composite• We need to:

• Avoid overheating the composite• Maximise efficient heat transfer to

the surface

• Therefore we need:

• Careful selection of polymermatrix materials

• Heat source as close to the

surface as possible

• Robust and accurate control over

the heat source

• Extremely difficult to achieve withair bleed/hot gas systems

Material limit typically <180ºC

Desired surface temperature e.g. 60°C



27

Heated Composite Components – Design Aims

Electro-Thermal Heating• We need to:

• Avoid overheating the composite• Maximise efficient heat transfer to

the surface

• Therefore we need:

• Careful selection of polymermatrix materials

• Heat source as close to the

surface as possible

• Robust and accurate control over

the heat source

• Extremely difficult to achieve withair bleed/hot gas systems

Electric heaters are a good choicebecause 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



28

Integrated within composite structures

GKN Aerospace Heater Mat

Technology



29

GKN Aerospace Heater Mats

Thermal sprayconductors

Erosionprotection – thin

metal

Filmadhesive

Film adhesive

(if needed)

GRP basecoat andtopcoat dielectriccomposite layers

Unique application ofthermal spray

Automated processControlled electricalproperties for desiredheat output on a localscale

Applied directly tocomplex shapecomponents

Heater encapsulatedwithin compositematerial

Structural or passive

Compatible with

multiple types ofcompositesmanufacturingprocesses

Small and largecomponents

Bell V-22 Osprey EngineIntake

AW101 Main Rotor Blade

Images Source: Courtesy of GKN Aerospace.

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=pnFsfgZd6X8kLM&tbnid=PrBneJqubnSsEM:&ved=0CAUQjRw&url=http://www.compositesworld.com/articles/787-integrates-new-composite-wing-deicing-system&ei=XXSkU8r4J4Sg0QXdsYDgAg&bvm=bv.69411363,d.d2k&psig=AFQjCNGh9eH1JkXUnjImmxwKSnBFDvqavw&ust=1403372987911088




http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=08fyAhEgGuorDM&tbnid=Par66hcZMtjjgM:&ved=0CAUQjRw&url=http://www.navair.navy.mil/index.cfm?fuseaction=home.NAVAIRNewsStory&id=5027&ei=qnekU9DODOSt0QX0mIHQBg&bvm=bv.69411363,d.d2k&psig=AFQjCNHcKJoGKvCL1TwgheHXQ4zx0L4iJw&ust=1403373788227481







30

More than just aesthetic appeal….. Coatings




31

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 aproduct 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’

[1]

[2]

[3] [4]

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=1QmOAAYRVG8IdM&tbnid=8kGmHUK8F88ALM:&ved=0CAUQjRw&url=http://www.vtt.fi/service/oled_and_photovoltaics.jsp?lang=en&ei=K3yMU9m8H8Sy7Aa834GoDw&bvm=bv.67720277,d.ZGU&psig=AFQjCNFjlX3iamZZEr_rtOscFxt5TkOqWQ&ust=1401802137346641

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=x_6VCgnd48255M&tbnid=j-gERWQ0P87RVM:&ved=0CAUQjRw&url=http://www.european-coatings.com/Raw-Materials-Technologies/Applications/Automotive&ei=rUiMU-i6NcK40QXW6oCQBA&bvm=bv.67720277,d.ZGU&psig=AFQjCNF2WuB2ul0QPD69OlfgcDM9RafjsQ&ust=1401788934859359

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=zbWjoGCU30zQzM&tbnid=GaghoMp9v-hMnM:&ved=0CAUQjRw&url=http://www.angusmcphie.co.uk/pages/tints.htm&ei=UEiMU6i0EOO60QW62oCwBw&bvm=bv.67720277,d.ZWU&psig=AFQjCNEkBlSU75AMmV7l8tho4sNDeHl1mg&ust=1401788849281716



32

An Introduction to Coatings in Aerospace

Paint Systems:

Protection fromErosion,

Airline Insignias,

Aesthetic Appeal

Coating / Paint Example Locations: Fuselage

Cabin WindowsCockpit Windows

Aft of Leading Edges




33

Functional Aerospace Coatings

Icephobic Coatings:

Reduction in ice accretion,

Reduction in power requirement forIPS,

Could be placed in areas with no

‘active’ IPS




34


Low Drag Coatings:

Could be located anywhere where

drag performance is a factor.Reduction in fuel consumption.

Aids laminar wing concepts.




35


Composite Damage Detection: Could be located anywhere at risk of impact

damage; hail, ground support equipment

and runway debrisIncrease in confidence of visual inspection

processes, potential reduction in tolerance

requirements leading to lighter aircraft.




37

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 combinationthereof

‘Non-Stick’

Ability of ice to adhere is vastly

reduced

‘Non-Build’

Ice crystal growth is disrupted

preventing growth of ice layer

‘Thermal Transfer’

Surface can be heated or

transfer heat energy from a

heating source

Coatings subjected to icing conditions

and electro-expulsive tests.

Pictorial representation of ‘non-build’

surface structure .

Images Source: Courtesy of GKN Aerospace



38

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

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.

Applications for the Technology: Wings (leading edge and areas aft of leading edge)

Engine components (fan blades, spinners, splitters and guide vanes)




39

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

Surface profiles of super smooth

and structured coatings

An example of the spray

application process

Power

coated

composite

still

showing

fibre

texture

Primeredthen

topcoated

aluminiumpanel




40

Low Drag Coating Technology

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

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

blades, wings and winglets Images Source: Courtesy of GKN Aerospace

Functional Coatings Technology:



41

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 theassociated 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

detected utilising suitable light source inspection equipment

Before Impact Event

After Impact EventExposed to

UV Light

Microscope photographs of microcapsules as made (not dispersed into

a paint system)




42

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

Composite Impact Damage Detection Coatings

This technology therefore, could reduce the risk of aircraft flying with structural damage andenhance 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

Examples of potential impact damage sources




44

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




45

Development Focus




46

The Development Process

Source (clip): http://www.gkn.com/aerospace/technologyandinnovation/Pages/coatings1.aspx/

Develop new concepts

Test new technologies

Create marketable ideas

Improve current products

Interact with customers

Interact with suppliers

D l i N S l ti



47

Developing New Solutions

Source: Microsoft Office Clipart

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



48

Testing houses

Universities

Environmental

Agencies

GKN Sites

WorldwideGovernment

Institutions

EngineeringInstitutions

Testing

standards

CATAPULT

centres

The Development Process: International Teamwork

Source: Microsoft Office Clip Art Images

GKN A L t D l t F



49

Integration with “morphing” leading edge technology

− Application for GKN Aerospace “flexible” heater mat technology

− Challenge: fatigue and damage tolerance of surrounding structurevs flexibility

Combination of ice protection and acoustic liner technologyin 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 stablestructures for ultra low drag flight

All of the above?

GKN Aerospace Luton Development Focus

Integration of highly functional components and assemblies


GKN A L t D l t F



50

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

GKN Aerospace Luton Development Focus

Reduced power demand of ice protection systems


GKN L t D l t F



51

Recent programmes (Boeing 787, A350 XWB) haveindicated a higher rate environment for aerospacemanufacturing

Advanced technology is only exploitable if it can bemanufactured cost-effectively

Various technology strands being integrated intoGKN Aerospace’s next generation of ice protectionheater mats:

− Selection of composite processes

− Avoid long autoclave cycles, step change in processtimes

− Relax/remove out-life and storage controls for materials

− Automation e.g. robotic lay-up, element application androll-to-roll manufacturing

− Modular assemblies with common components acrossmultiple design configurations

GKN Luton Development Focus

Manufacturing costs and capacity


C l i



52

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, toachieve 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

Thank you



53

Thank you

Thank you for listening

Any Questions?

Manuela CassissaIPS Development Engineer

([email protected])

Susanna HallsCoatings Projects Lead

([email protected])

Ashley BrooksIPS Lead Project Engineer

([email protected])

References



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 Meteorolog y, Commonw ealth of Austral ia, 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-automotive-coatings-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

gkn antihielo leading the way toward more efficient aircraft

Documents