gkn overview gkn aerospace overview capable to develop ti alloy, al, & ni powders optimised for...

GKN overview The global technology partner to the aerospace industry

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GKN AEROSPACE OVERVIEW

GKN plc: Tier 1 Supplier to the major Automotive and Aerospace OE manufacturers

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GKN Aerospace: the global technology partner to the industry

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The leading global Tier 1 aircraft supplier

Mexico

4 locations

China

2 locations

Landing Gear

Electrical and Wiring

Services

Aerostructures

Office locations

USA

24 locations

Netherlands

7 locations 2 1 1 3

2 2

1 1

India

2 locations 1 1

Romania

2 locations 2

Turkey

1 location 1

Belgium

1 location

Canada

1 location

1

Singapore

1 location

Thailand

1 location

United Kingdom

7 locations

1 3 3

Sweden

3 locations 1

Norway

1 location

1

Germany

1 location 1

Engine Systems

Transparencies

and Special Products

12 2 7 1 2

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1

1

2016 sales

£3.42 billion

Number of employees

17,950

Number of manufacturing

locations

52 in 14 countries

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Leadership in our chosen technologies

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[DOCUMENT NAME]

GKN Aerospace Filton & Western Approach

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GKN Aerospace Filton

Customers

Airbus

Dassault

Triumph

BAE Systems

Programmes: Large Civil: Airbus A320 family, A330, A380, A350XWB, Boeing 787

Military Transport: A400M

Business Jet: Dassault Falcon 5X

Military Fast Jet: Joint Strike Fighter

Investment:

> £40M capital investment since 2009

Approx £25M projected over next 3 yrs

Filton Engineering Centre established

− Over 200 design and engineering specialists

People:

Safety

Employee engagement

Education and Community support

Apprenticeship programmes

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GKN Aerospace - Filton Overview

>1,500 employees > £350M Sales

12 Value Streams

Wing Assembly Wing Systems Components

• Major structural assembly

• Metallic and Composite

• Automated and robotic assembly

• Full system capability – hydraulic,

pneumatic, fuel, anti-ice

• Electron beam welding, automated

robotic welding and assembly

• Large structural and complex parts –

max 6m x 2m

• Hard and soft metal capability

Business Support Capability

• Design - build capability

• Filton Engineering Centre

• Independent quality approvals

• Metrology and conformance engineering

• Additional capabilities through GKN network

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[DOCUMENT NAME]

GKN Western Approach

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GKN Aerospace - Western Approach Overview

GKN’s Centre of Excellence for major

composite primary structure components

Approx £235M invested in new state-of-the-art

composite structures manufacturing and assembly facility

near Avonmouth, Bristol.

Over 30,000m2 of floor space

First Advanced Fibre Placement spar manufacture

– largest composite part in GKN

First Fixed Trailing Edge automated moving assembly

system

Fully integrated product teams working closely with

customer and supply chain

Programmes

A350 XWB Spar manufacture and Fixed Trailing Edge

Assembly

A400M Spar manufacture

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Outer Spar

Mid Spar Inner Spar

A350 Fixed Trailing Edge

3 Spars total over 27m in length with an accuracy of +/- 0.3mm

Total weight of spar carbon is 1230kg/aircraft

FTE assembly weighs 1800kg

The FTE is 7% of total wing weight and supports 10x its own weight

First “large Scale” assembly operation undertaken by GKN

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[DOCUMENT NAME]

GKN Additive Manufacturing Jan 2018

Updated 06 March 2017

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Unrivalled materials, process and manufacturing expertise

Widest range of AM parts flying on seven major platforms

Further components undergone certification trials and awaiting clearance

Significant new investment in large scale deposition now underway

Global ecosystem of excellence centres and AM partnerships

Comprehensive suite of technologies: fine-blown to large-scale

Tier 1 with widest range of capabilities in AM design and manufacture

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[Document Name]

Bristol,

UK

Trollhättan,

Sweden

Oak Ridge

Laboratory, USA

2

Radevormwald,

Germany

Cinnaminson,

USA

Process Development

Design and Manufacturing

Powder Manufacture and

Development

AM partnerships in 6

countries

Bonn,

Germany

Global Reach

https://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjdzrqjrbPTAhVCCBoKHSXnAWgQjRwIBw&url=https://www.sheffield.ac.uk/ourplan/&psig=AFQjCNGNwnY_KnTY5kH_mZz0EaFfZXC5RQ&ust=1492788628253897

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GKN AM Strategic Positioning & Differentiation

Vertically integrated: Combining Powder Capability, Process Knowledge, Product Expertise

Global scale: Demonstrated ability to industrialise technology globally

End market access: Leader in Aerospace & Automotive supply chain

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Capable to develop Ti alloy, Al, & Ni

powders optimised for AM

Water & Gas atomising processes

Full technical support

GKN Powder Metallurgy

Titanium Powders for Powder Bed AM

JV with TLS

Production facilities in place in US

Full certified quality management

system

GKN Hoeganaes (Ancor brand)

2nd largest global supplier

25% market share

c. 300,000 tonnes per year

Fe based powder

Global industrial base

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GKN’s Diverse Range of AM Process Capability

LASER

(WIRE)

PICTURE

DESCRIPTION

DEPOSITION POWDER BED

DESIGNATED ICON

TWI

GKN Aerospace

TWI

GKN Aerospace

FINE SCALE DEPOSITION

• Lower material throughput deposition systems

• Focus on Ti and Ni alloys

•Add-ons and features

• High value component repair and modification

• Broad range of medium-size engine and structures components; fabrications

POWDER BED

• Lowest material thru-put

• Ti, Ni and steel alloys

• Nearest-net

• Intricate complex hi-value components

• Low material thru-put

• Ti6-4

• Highly net-shape

• Small – medium prismatics

LARGE SCALE DEPOSITION

• High material throughput deposition systems

• Focus on Ti Large-scale pre-forms

• Initial cost-driven introduction

• Applications including large aero structure components

L L L EB L

APPLICATIONS

Deposition of wire fused using laser

beam in a chamber to produce part

Laser beam selectively fuses

powder on a bed in a chamber to produce

part

Electron beam selectively fuses

powder on a bed in a chamber to produce

part

Deposition of wire fused using laser beam or plasma in a chamber to produce part

Deposition of powder fused using laser and

local shielding to produce part

POLYMER

POLYMER

L

Laser beam selectively fuses powder on a bed

in a chamber to produce part

Deposition of extruded polymer which solidifies in place to previous

layers

•Material thru-put can be high

• Wide range of thermoplastics


• Tooling, RP, components

•Medium throughput

• Nylon


• Tooling, RP, components

Powder / binder system requiring

down-stream consolidation

B

• Higher material throughput than other powder bed

• Ti6-4, Fe

• Not fully dense

• Used for casting moulds

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GKN’s Diverse Range of AM Process Capability

LASER

(WIRE)

PICTURE


DESIGNATED ICON

FINE SCALE DEPOSITION POWDER BED LARGE SCALE DEPOSITION

L L L EB L

POLYMER

POLYMER

L B

Radevormwald

Bonn

Trollhatten

Bristol

Oakridge

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AM at GKN – Already in Production

Free Form Deposition (Out Box) Powder Bed (In box) Powder

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Widest capabilities of any Tier 1

Fuselage, wing,

nacelle & pylon

Inflight opening

doors and

empennage

(tails)

Static & rotating

structures

Titanium engine

inlet parts

Transparencies

Ice protection

systems

Flotation devices

Fuel tanks

AEROSTRUCTURES ENGINE SYSTEMS SPECIAL PRODUCTS

Helicopter

landing gear

Composite

load carrying

landing gear

components

(drag brace)

Availability

services, MRO,

conversion and

completion for

mature and

legacy aircraft

WIRING INTER-

CONNECT SYSTEMS LANDING GEAR GLOBAL SERVICES

GLOBAL NO. 2 GLOBAL NO. 2 GLOBAL NO. 1 GLOBAL NO. 3 GLOBAL BRAND

Electrical Wiring

Interconnection

Systems (EWIS)

for aircraft &

aircraft engines

GLOBAL BRAND

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AM Successes - Aerostructures

Papendrecht

Bristol

Isle of Wight

EBM – Proof of concept metal leading edge

EBM, LPB, FDM – Tooling, Jigs, Guides, Proof of

concept parts, Airbus Catcher Bracket,

LPB – Proof of concept Topology Optimisation.

Lattice and Foam development for functional and

structural applications.

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AM Successes – Engine Systems

Trollhättan

Significant opportunities on Engine & Space Components

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AM Successes – Special Products

Kings Norton

Portsmouth

Luton

FDM - Dornier Seat Start Window

Frame

SLS, LPB, EBM – Ice tunnel trailing edge, Acoustic Liner

flight trial, Optical Ice Detection equipment housing Flight trial

LPB, EBM – Floatation manifold

demonstration and development

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[DOCUMENT NAME]

Powder Bed

The information in this presentation is proprietary and confidential

and shall not be disclosed to or used by a third party unless

specifically authorised by the relevant GKN plc group company

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LASER

(POWDER)

LASER

(WIRE)


DESIGNATED ICON

FINE SCALE DEPOSITION TROLLHATTAN

POWDER BED FILTON

L L L EB L

LARGE SCALE DEPOSITION ST LOUIS

Example Applications – Powder Bed

Titanium and Nickel

On case-by-case basis can demonstrate significant savings on near-net replacement

Part integration and structural optimization can lead to higher performance and further cost reductions

Functional systems for Acoustic liners or embedded Anti-ice

In Production




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The Bristol Centre is a substantial R&D capability

focused on powder bed

12 machines across a variety of AM technologies

Electron Beam Melting

Laser Powder Bed

Polymer / Indirect AM (FDM & SLS)

Dedicated Materials Laboratory

In-house Metrology

Working closely with site based conventional

manufacturing techniques

Production cell for series manufacture of Titanium

components using EBM

GKN Additive Manufacturing Centre, UK




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[DOCUMENT NAME]

Powder Deposition




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LASER

(POWDER)

LASER

(WIRE)


DESIGNATED ICON


POWDER BED FILTON

L L L EB L


Example Applications – Powder Deposition

Feature deposition

Modification

Repair

Thermal distortion management/modeling

Ti and Ni capability

In production




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Laser Powder Deposition application

Modification of a civil jet engine super alloy structure

Production equipment installed at GKN AES in

Trollhättan, Sweden




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[DOCUMENT NAME]

Laser Wire Deposition




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Wire Deposition Roadmap

Generation 1 Generation 2 Generation 3

En

gin

es

Air

fra

me

Generation 1 Generation 2 Generation 3

Next Generation

Optimized

Structures

Functionally

Graded

Properties

Net Shape Builds

Proof of Concept

Generation 4

Increased Complexity, Increased Criticality, Reduced Buy:Fly, Increased Process & Property Control

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Equipment – wire fed into melt pool propagated by a laser

beam – enabling accurate near-net deposition of feedstock

LASER

(POWDER)

LASER

(WIRE)


DESIGNATED ICON


POWDER BED FILTON

L L L EB L



Qualified process in GKN AES for bosses and grow-outs

Use in Space systems

Ti and Ni capability

In Production

Deposition of a boss or grow-out




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LASER

(POWDER)

LASER

(WIRE)


DESIGNATED ICON


POWDER BED FILTON

L L L EB L



Process Development for non round structures

Big and heavy –




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AM Laser wire (free form fabrication) capability in Ti6Al4V

Total weight per box is 18 kg

Buy to fly ratio 1.1:1 shown




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Summary

AM is a strategic priority for GKN Group

− Already in qualified production in multiple materials, processes and applications

GKN is uniquely positioned as a potential AM partner

− Vertically integrated: Powder to Part

− Multiple AM processes in production

− Established AM network

− Global industrial footprint

− Key end market applications in multiple sectors

gkn overview gkn aerospace overview capable to develop ti alloy, al, & ni powders optimised for...

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