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0. Index 1. Presentation 2. Organisation of the Association 3. A summary of HEGAN’s activities. 3.1 Activities in the field of technology 3.2 Activities in the field of quality 3.3 Activities in the field of internationalisation 3.4 Activities of a general nature 4. Summary of the activities of Associate Companies 4.1 Aeroestructuras 4.1.2 Long haul civil aircraft 4.1.3 Regional civil aircraft 4.1.4 Military aircraft 4.1.5 Helicopters 4.2 Engines 4.2.1 Civil 4.2.2 Military 4.3 Space 4.4 Systems and equipment 4.5 Maintenance 4.5.1 Civil maintenance 4.5.2 Military maintenance 4.6 Trials 4.6.1 Structural and fire tests 4.6.2 Fluid-dynamic tests 4.7 R&D
5. Aggregate date
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1- Presentation by the President - 2003 Annual Report For HEGAN, the Cluster Association of Aeronautics and Space of the Basque Country, 2003 was a highly satisfactory year as it demonstrated that our companies have managed to surmount the first major crisis in this sector since the association was founded. This is an indication of the maturity of the Basque Aerospace Industry and we invite you to find out more about this industry by reading this annual report, which I have the honour of presenting. The 2003 Annual Report sets out the main activities and achievements of the companies associated with the Cluster and we are pleased to observe that besides the fact that the level of activity of our leading companies has remained high, there has been a substantial increase both in the number and importance of the activities of our smaller companies, who are adapting to the new demands of the sector. This has allowed us to consolidate our position in the sector and made us more competitive, and recognition of this fact is growing day by day. Data for the year 2003 confirmed a gradual recovery in the growth rate in this sector. Indeed, the increase in turnover of around 9% and, especially, the staggering figure of 21% of investment in R&D over sales, is an indication of the steadfast determination of our companies to continue promoting this sector and to take a leading role in its development. One of the major achievements described in this report is the fact that the associate companies of HEGAN who are participating in the AIRBUS A-380 project have made preparations in order to take part in the A-400M military transport aircraft, securing a 21% participation in the TP400-D6 engine which will propel this aircraft and have worked actively to obtain contracts for the manufacture of structural parts. In addition to consolidating their good relations with regular customers, the international customer base of our associate companies is increasing and the market niches in which our companies are active are increasing in size, especially in the field of maintenance. With regard to the major increase in investments in R&D, we should highlight the structural trials that are being carried out by the Aeronautics Technologies Centre (CTA) in long haul commercial aircraft, in addition to those being performed for regional civil aircraft and helicopters. With reference to engines, the CTA – which has been promoted by the associate companies of HEGAN since the beginning - has performed the aeroacoustic characterisation of its fluid dynamics test bed and perfected its data acquisition system. We should also like to mention an encouraging piece of news: the presentation of diplomas to students who have successfully completed the first “Specialisation Course in Aeronautical Technologies” given by Higher School of Engineers of Bilbao. This course is a long-term priority for the development of the Cluster and the associate companies of HEGAN have taken an active part in its creation. As a consequence of these activities, HEGAN has become a partner of ATECMA (Spanish Technical Association of Manufacturers of Aerospace Material) and has become the first regional association to be represented on the IAQG (International Advisory Quality Group) eloquent proof of the interest of our companies in management excellence. Finally, we should highlight HEGAN's leadership in the activities of the ECARE project at a state level as well as its participation in INTERREG projects, our greater presence abroad (LE BOURGET, ACE in Montreal and AEROSOLUTIONS in Bordeaux) and the organisation of the new forms of business meetings such as MET-Bilbao. The achievements of the Aeronautics and Space Cluster Association – HEGAN - in 2003 (which marked the celebration of the centenary of aviation), are the result of the perseverance of companies, technology centres, universities and government. The satisfaction we obtain
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from having made a modest contribution to its development encourages us to continue working in this stimulating project. Jorge Unda President of HEGAN 2. ORGANISATION AIMS The aim of the Aeronautics Cluster Association of the Basque Country is to carry out as many actions as necessary to promote, encourage and foster the development of an industrial, professional, technological and research framework capable of providing goods, products and services for the aeronautics market. To do this, the Association endeavours to achieve the maximum levels of co-ordination and synergy between the different social and institutional agents involved, obtain the recognition of the Basque aeronautics strategic subsector by the international community, contribute to the strengthening of our economy, and favour the creation of highly-specialised jobs, the scientific and technical development of our society and the restructuring of our industry towards activities that offer a more promising future and higher added value. GENERAL ASSEMBLY This is the highest body of the Association and is formed by all its partners. It is therefore the organ in which partners can voice their concerns. MANAGEMENT BOARD This is the Collegial Body of Administration and Management. Its members are appointed by the General Assembly. Members 2003 - César Fernández de Velasco (President) GAMESA AERONÁUTICA - Plácido Márquez (Vice President) ITP - Jorge Unda (Secretary) SENER - José Ignacio Tellechea (Member) Department of Industry, Commerce and Tourism of the Basque Government - Javier Hernando.(Member) Department of Industry, Commerce and Tourism of the Basque Government - Gaizka Grajales (Member). SK10 - Francisco Larrea (Member) TECNICHAPA - José Juez (Managing Director) HEGAN Current members - Jorge Unda (President). SENER - José Luis Osoro (Vice President) GAMESA AERONÁUTICA - Plácido Márquez (Secretary) ITP - José Ignacio Tellechea (Member) Department of Industry, Commerce and Tourism of the Basque Government - Javier Hernando.(Member) Department of Industry, Commerce and Tourism of the Basque Government - Román Arrasate (Member).AEROSPACE ENGINEERING GROUP - Francisco Larrea (Member) TECNICHAPA - José Juez (Managing Director) HEGAN TECHNOLOGY COMMITTEE (COMTEC) Set up in 1993, it is responsible for developing objectives relating to technological development, defined by the Management Board at an operational level, in order to increase the competitive edge of the sector through: - constant surveillance of the technological aeronautical environment. - promoting the conditions of the environment - projecting this environment abroad.
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Members 2003 - Juan Miguel López Uria. Department of Industry, Commerce and Tourism of the Basque Government - Juan Ignacio Burgaleta. (Secretary) / Javier Viñals, SENER - Plácido Márquez / José Luis Encinas, ITP - Rafael Pax / Iñaki Alti, GAMESA AERONÁUTICA - Iñaki Manero IONTECH - Ángel Alonso. NOVALTI - Alberto Fernández. SPRI - Juan Pedro Vela / Idurre Sáez de Ocáriz, CTA - Itziar Uribe, EITE - Estibalitz Erauzkin, EITE-INASMET - José Antonio Tárrago. UPV-EHU - Representante de HEGAN QUALITY COMMITTEE (CECAL) set up in July 1998, the aim of this Committee is to provide general guidance in matters relating to the quality of products and management of the companies in the Cluster. Members 2003: - Iñaki Cortijo. Department of Industry, Commerce and Tourism of the Basque Government - Jesús Murga.(Secretary). ITP - José Ramón Muro. GAMESA AERONÁUTICA - Pedro María Mugarra. SENER - José Antonio Castaño. MESIMA - José María Ruiz. NUTER - Juan José Urrutia. BURULAN - Representante de HEGAN INTERNATIONALISATION COMMITTEE (COMINTER)
Set up in 2003, the aim of this committee is to propose and assess the actions undertaken by associate companies, in cooperation, in the field of internationalisation. Members 2003 - All associate companies - HEGAN representative HUMAN RESOURCES COMMITTEE the aim of this committee is to defined and promote activities to improve the management of the human resources of associate companies. Members 2003: - Garbiñe Urrutikoetxea, GAMESA AERONÁUTICA - Arantza Hallet, ITP - Julián Rodrigo, SENER - HEGAN representative
GENERAL ASSEMBLY MANAGEMENT BOARD MANAGING DIRECTOR
CECAL
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3. A summary of HEGAN’s activities. The Aeronautics and Space Cluster Association of the Basque Country –HEGAN- began 2003 by transforming the guidelines set out in its Strategic Plan 2002-2004 into real activities. Although this plan might, by itself, be considered to be sufficiently ambitious, HEGAN has included even more activities of interest to this sector in its work schedule. 3.1 Activities in the field of technology In the field of technology, HEGAN's activities in the European ECARE project are of special interest. This association is a member of the consortium which is promoting the project and leader of the consortium in the Spanish State. This measure, included within the 5th European Framework Programme, is a pilot scheme for the 6th Framework Programme. The aim is to promote, together with other European regional aerospace associations, the participation of SMEs in Integrated Aeronautics Projects (IPs). Following the indications of the Commission, HEGAN has continued to work within the frameworks of collaboration and coordination with Spanish and European representatives of the SCRATCH and AEROSME projects, which are the other two measures included in the 5th European Framework Programme, the aim of which is to involve SMEs in European R&D&I projects. Besides disseminating the project through regional sessions such as the one that took place in May 2003 at Alava Technology Pack, the key activity of the ECARE project is summarised in a mapping questionnaire designed in order to standardise the format of applications received by IP leaders from SMEs and to facilitate the work of selecting participants. Seventeen SMEs from the Spanish state showed their interest in taking part by filling out the mapping questionnaire. This year, HEGAN will continue preparing mappings for the third call of the 6th Framework Programme, and will encourage SMEs to take part in the IPs as well as controlling and assessing the progress of the Project. Relations with the Telecommunications Cluster (GAIA) have been strengthened in a number of market research projects designed to assess potential business in the avionics market and work continues in search of other market niches to be developed in the region. In the form of a pilot scheme and at the request of COMTEC (HEGAN's Technology Committee) the 1st Basque Aeronautics Agents Seminar was held in November in order to bring together representatives of companies to offer technology (Basque Technology Centres) and companies in the sector that require technology (Basque Aerospace Companies). Those attending the seminar expressed their interest in holding a further seminar on the future. Finally, and as a result of the COMTEC meetings, the general design has been prepared for a Technology Surveillance Bulletin of use to companies belonging to HEGAN and work has begun on establishing the bases for the organisation of the 3rd International Congress on Manufacturing Trends for the Aerospace Industry, to be held in November 2004 in Bilbao. For this year's event, which has been given the name of AEROTRENDS, in addition to the invaluable collaboration of INASMET, a number of other technological centres and companies have been involved in the design of its contents. 3.2. Activities in the field of quality A major feature of the work done by HEGAN over the year was that it has become the first Regional Association to take part as a member of the IAQG (International Aerospace Quality Group), through the EAQG (European Aerospace Quality Group) and represented by the Secretary of our Quality Committee, Jesús Murga, Quality and Environment Director of ITP. This has allowed our associate companies to benefit from the participation in this group through cooperation, the main aim of HEGAN. Thanks to the fact that we are members of the ATECMA, we are taking an active role in the Quality Committee of this Association, in which we have meetings with the most representative agents of this area of the Sector, thus taking advantage of the first-hand information provided for the Basque Aerospace Sector.. 2003 saw the initiation of the first stage in the consolidation of the EN9100 aerospace quality standards (specific standard of the ISO9000/2000 for the sector), for which 70% of companies expect to be certified by the middle of 2004 and all of them before the end of that year. 3.3. Activities in the field of internationalisation Due to the wishes expressed by its associate companies, HEGAN has devoted a great deal of its time to furthering its activities in the field of internationalisation. This year, the Basque sector is consolidating its image at all levels thanks to the activities the Association has been pursuing for some time.
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TRADE FAIRS During 2003, HEGAN representatives attended the Le Bourget trade fair in Paris (France) and the ACE in Montreal (Canada). The former is one of the major events in Europe and in the world and HEGAN took part through the Spanish Pavilion coordinated by AFARMADE in collaboration with ATECMA. At this year's event we were accompanied by 12 of our associate companies. The latter is, in terms of importance, the most significant aerospace Trade Fair-Conference on the American continent and is held every two years alternating between the USA and Canada. Thanks to the excellent relations that HEGAN enjoys with Canadian industry, the Quebec region and SPRI, one of its representatives attended the fair on behalf of the Association, and provided us with the corresponding report. PROFESSIONAL MEETINGS HEGAN, together with 5 of its associate companies, attended the AEROSOLUTIONS 03 Fair for professionals (buyers-suppliers) in Bordeaux (France), in which most of the French companies in the sector and a selection of other countries took part. Also, together with the French Association of high-tech SMEs (Richelieu Committee), HEGAN organised the MET-Bilbao, at which more than 35 Basque and French companies had the opportunity to meet. At this gathering, about 110 prearranged meetings were held between participating companies in less than five hours, and a similar number of spontaneous meetings took place in the delegates' own time. INTER-REGIONAL RELATIONS Work has continued on a constant basis to strengthen relations with key regions for the Sector (as was indicated in our 2002-2004 Strategic Plan). Thus, HEGAN has taken part on a regular basis in meetings of the regional European aerospace associations organised by AECMA through AEROSME and meetings have been held with other entities such as the French Chambers of Commerce, the Regional Councils of Aquitaine and Midi-Pyrenées, the Delegation of the Government of Quebec in Spain, as well as embassies and consulates of a number of different countries. As a result of these contacts, HEGAN is taking part as a partner in the COAST Project (Community for Aerospace SMEs Business and Trade), financed by INTERREG IIIB, within the Atlantic space programme. This project, led by ADOUR COMPETITIVITÉ and whose third partner is WALES AEROSPACE, intends to foster trading relations and cooperation between companies in the three European regions. 3.4. Activities of a general nature During 2003, work has continued to give the Cluster's web site (www.hegan.com) greater weight, efficiency and content as a communications tool between associate companies, as well as a means of disseminating its activities. The web site has new download areas where it is possible to find the minutes of meetings, courses of interest to members, news items, and agenda, internal reports, the industrial fair newsletter, etc. Likewise, a new approach has been given to the web site's general image in the form of an Intranet provided with all the elements necessary for internal communications and a system of forums in which, by means of a system of different, highly structured levels of access, a wide range of users from different areas can log in. At the end of March 2003 and as a result of the good working relationship that has always existed between both entities, HEGAN is now a Senior Partner of ATECMA (Spanish Technical Association of Aerospace Material Constructors), with whom relations are getting stronger on a daily basis. In this way, collaboration in sharing information, contacts and many other activities are increasing day by day. Likewise, the permanently good relations with BaiE (Barcelona Aeronáutica y Espacio), will allow us to develop new frameworks of collaboration with the Sector in Catalonia. Contracts continue with key entities in the Sector at a state level such as ISDEFE (Industrial Cooperation Office) and AFARMADE (Spanish Association of Armament and Defence and Security Material Manufacturers); and European entities such as AECMA (European Association of Aerospace Material Constructors) and the European Commission. These fluid, permanent contacts provide HEGAN with updated sources of information with the advantages that this involves. In 2003 an agreement was reached with SPRI to publish a brochure for the Basque Aerospace Sector 2002. This has provided the Association with an additional promotional tool, which sets out the history of the sector together with an overview of the region. This document accompanied the 2002 Annual Report which was published in CD format in order to include this in the general brochure of the Association. Together with ITP, HEGAN organised the seminar "Centenary of Aviation in the Basque Country", at the Miramón Science Museum (Gipuzkoa) which was attended by leading figures in this Sector from all parts of the Spanish State. Delegates to the seminar, which reviewed the history of aviation in Spain and the Basque Country also had the opportunity to enjoy a photographic exhibition documented by the well-known expert Canario Azaola, several
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mockups including the first aircraft of the Wright Brothers and HEGAN's small stand where information was available on the capabilities of our Associated Companies. The logotypes of HEGAN companies included in this document feature those of three new firms, IMESAZA, AEROTEAM and UPM; who have joined the Association. The services offered by IMESAZA, a company specialised in heat treatments and approved by major companies in this sector, include a very special service in all types of vacuum treatments. AEROTEAM is a company devoted 100% to the Sector and is specialised in the design, programming and machining of aerospace parts, including both tools and airworthy parts. UPM, for its part, offers design, manufacture, control, start-up and assistance based on a high content of Development Engineering of aeronautical tooling. The programmes in which these two companies are involved (AIRBUS A340/380, BOEING 737, DASSAULT FALCON 7X, EMBRAER ERJ170, TRENT-900, etc), offer ample proof of their commitment to this sector. 4. Summary of the activities of Associate Companies 4.1. Aerostructures 4.1.1. Long haul aircraft GAMESA AERONÁUTICA is responsible for the design, manufacture of prototypes and production of section 19 of AIRBUS A380. In 2003, the company completed the design of the configuration for the delivery of the first prototype, as well as the assembly of the first unit, which was begun in mid May and was delivered on August 4. Since then, GAMESA AERONÁUTICA has delivered four completely finished prototypes at the AIRBUS-Spain facility. In 2003, GAMESA AERONÁUTICA redesigned part of the structure, obtaining a major reduction in weight and included modifications as a consequence of the increase in payloads. These modifications, which have affected most of the structure, began in mid 2003 and the new configuration and production line were ready for manufacture in November. The company BURULAN, a GAMESA AERONÁUTICA subcontractor, engaged in the machining and manufacture of components with CNC lathes and machining centres of up to five axes, has participated in the AIRBUS A310/320/380 programmes. For this last project, BURULAN has acquired a palletised five-axis machining centre. In 2003, BÓREAS, a wholly owned subsidiary of SENER, completed the design in composite material of the panels of central section of the Belly Fairing of the AIRBUS A380. Likewise, in collaboration with EADS (MTAD), the design of zone 2 of the metal structure of this component and several components in composite material of the A380 were completed. The consolidation of the composite material engineering achieved by BÓREAS during this period is of special interest as this company has integrated the design engineering and manufacturing engineering of these materials, obtaining a reduction in the delivery dates of the detailed information required in order to manufacture the components, as well as low wastage levels in the use of material and an increase in quality. Finally, we should mention the “BODEMAN” and “BOREAS TOOL” systems developed by BÓREAS. The first of these is used for controlling design cards in AIRBUS project environments while the second is of great use for the design of panels in composite materials, as these allow for rapid, precise optimisation and bring about a reduction in the weight of elements. NUTER has supplied parts for the landing gear for AIRBUS A310/320, while SIEGEL has manufactured structural components for AIRBUS A318/320/380. For its part, the company SPASA has manufactured machines parts in aluminium for the Belly Fairing of the A380. Tratamientos Térmicos TTT has done heat treatments for the AIRBUS A320/340/380 programmes. Mecanizados ASTORKIA, specialised in the manufacture of complex and precision parts, has consolidated its contribution to this sector by machining structural parts for the AIRBUS A380 programme. In addition to continuing with its machining and sheet metal working activities, METRALTEC has received AIRBUS certificates for special heat treatment and surface treatment processes for aluminium components and has delivered parts for the A310/320/340 and 380 programmes of AIRBUS. MESIMA continued its material management activities for the main state owned companies in the sector involved in AIRBUS programmes. In 2003, NOVALTI continued to increase its turnover in all its areas of activity (engines, space and structures), as shown by the inauguration of its new headquarters and production centre of more than 9000 m2 in Barakaldo. With regard to structures, we should mention that last April, 2003, was the month when the company delivered to AIRBUS
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all the metal components and subassemblies for the compatibility tests of section 19.1 of the A380, for which NOVALTI developed the manufacturing and production engineering. The experience the company has acquired in the machining of components for engines (centrifuge compressors for gas turbines, blisks, curved serrations, discs,...) has allowed AEROMEC to upgrade its manufacturing of structural components in aluminium for the A380. Likewise, commissioned by AIRBUS-ESPAÑA for the A380, TEGRAF has carried out the design for the manufacture, assembly and integration of a large number of manufacturing tools for composite material structures (its participation has extended to other customers such as HUREL-HISPANO and SONACA). TEGRAF has continued, together with its strategic partner AIT, in the design and manufacture of the final assembly line for section 19 of the fuselage for the A380. The company has been selected by AIRBUS as one of the preferred suppliers for technical publications and in 2003 continued its engineering work (design and calculation) of the engine cowlings for the same aircraft. 4.1.2. Regional Civil Aircraft ERJ 145 FAMILY, EMBRAER Last year, this family of EMBRAER aircraft continued its successful sales campaign with orders totalling 964 units (plus 543 options). At the end of 2003, Embraer delivered 745 aircraft to airlines throughout the world. This family consists of models ERJ 135, ERJ 140, ERJ 145 LR and ERJ 145 XR (commercial passenger aircraft), “Legacy Executive” and “Legacy Shuttle” (executive transport) and others used for defence activities. GAMESA AERONÁUTICA is taking part in this project as a risk partner, having participated in the development and certification of these aircraft and today is responsible for the manufacture and maintenance of wings, control surfaces, engine housings, air inlets and thrust reversers for all the models in the family. All are equipped with their corresponding systems and are ready for assembly in the aircraft. In 2003, GAMESA AERONÁUTICA delivered assemblies for 95 aircraft to EMBRAER bringing the total number of deliveries to 796 in eight years, without including spare parts. ERJ 170/190 FAMILY, EMBRAER The EMBRAER 170 is the first of the family made up of models 170, 175, 190 and 195 for these 70-110 passenger market niche. The Programme was launched in June 1999, and the first flight to place in February 2002. Today, the first member of the new family has already been certified. Sixteen world-class aerospace companies are taking part in the Programme. The use of the latest high-tech fly-by-wire system in these aircraft is of great historical importance. Previously, this technology was only used by military aircraft and large commercial aeroplanes, never for commercial aircraft of this size. In January 2003, the EMBRAER 170 successfully completed the most critical stage of the structural tests. The tests were carried out within the schedules established both for Embraer and its risk partners, including GAMESA AERONÁUTICA; others sections such as the horizontal stabiliser and the elevators, developed by GAMESA AERONÁUTICA, also successfully passed the static tests at the facilities of each of the partners. On June 14, 2003, EMBRAER announced the first inaugural flight of the EMBRAER 175: serial number 0014, took off from the company's facility, accompanied by its brother, the EMBRAER 170 S/N 007. On September 29, EMBRAER announced that the assembly of the fuselage for the first EMBRAER 190 had been completed satisfactorily. The coupling of the front, central and rear sections of the fuselage had been completed according to schedule. At the same time, progress on the certification of the Embraer 170 continued in accordance with the target certification date for the Programme of November 2003. The EMBRAER 175 is expected to be certified by the second quarter of 2004, the EMBRAER 190 by the third quarter of 2005, followed by the EMBRAER 195 during the second quarter of 2006. On November 13, EMBRAER 170 obtains the provisional certification of the Brazilian Authorities. On December 8 2003, Embraer 170 was given provisional certification by the FAA (US Federal Aviation Administration). Final certification was obtained in February 2004. There are 220 confirmed orders for the EMBRAER 170, 110 for the EMBRAER 190 and 15 for the EMBRAER 195 and 125, 150 and 30 purchase options, respectively, which represents an unprecedented success for a recently certified aircraft. The first units of the EMBRAER 170 will be delivered to airlines early in 2004. GAMESA AERONÁUTICA has been a part in the Programme since the beginning, and is responsible for the development (design, calculation and certification) of the rear section of the fuselage, horizontal and vertical stabilisers with their corresponding elevators and rudders. In this sense, GAMESA AERONÁUTICA continued working on the development of the different models that make up the family, and is responsible for their certification. Throughout last year, GAMESA AERONÁUTICA delivered assemblies for 24 aircraft, thus completing a total of 32 aircraft already delivered for this new family. The work was done at the FUASA facility (Berantevilla, Alava) and MOASA (Vitoria). CRJ700 AND CRJ900 PROGRAMMES, BOMBARDIER
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GAMESA AERONÁUTICA developed, and is currently engaged in the manufacture of the horizontal and vertical empennages and elevators for this family of aircraft, for the customer and final integrator, the Canadian company BOMBARDIER. GAMESA AERONÁUTICA delivers complete products, including the corresponding function tests and accessories to ensure correct assembly. 2003 was a year of consolidation for the CRJ700 and CRJ900 Programmes in GAMESA AERONÁUTICA, both with regard to production activities and other ancillary activities. The number of deliveries during 2003 increased by approximately 40% compared to the previous year, at an average rate of 4 aircraft/month. Thus, a total of 58 CRJ700 and 10 CRJ900 were delivered to airlines last year and MESA was the company that launched the new model CRJ900. Compliance with the delivery schedule both by GAMESA AERONÁUTICA, through its Seville-based company, EASA del Sur, and the final integrator, BOMBARDIER, reflects a sound industrialisation of the programme with regard to production means and methods and the company has been congratulated by BOMBARDIER for the high marks it has achieved both for quality and compliance with the delivery dates. The sales of these aircraft during 2003 amounted to 85 new aircraft (both versions), reaching 220 confirmed orders for the CRJ700 and 55 for the CRJ900, with total conditional options and orders for over 350 aircraft. Finally, for the CRJ700 and CRJ900 Programmes, 2003 was another good year and once again the Customer expressed his great satisfaction with the work done by GAMESA AERONÁUTICA. Tratamientos Térmicos TTT, METRALTEC, NUTER, Mecanizados ASTORKIA, MESIMA, BURULAN and SPASA have taken part in programmes such as: ERJ145/170/190, CRJ700. FALCON 7X PROGRAMME With regard to DASSAULT's new jet, SIEGEL manufactures structural components for this aircraft, SENER develops the manufacturing engineering of several composite material components and TEGRAF has performed several engineering tasks relating to the design of the leading edge of the wing. 4.1.3. Military aircraft GAMESA AERONÁUTICA has reached an agreement with EADS-CASA to assemble the complete fuselage for the C212 aircraft, restarting an assembly line which had been shut down for several years. The main assembly of large units is done by GAMESA AERONÁUTICA through its subsidiary company, EASA del Sur in Seville. Initially, 5 fuselages were contracted, and later these were increased to 7. During the year 2003, 2 fuselages were delivered to the San Pablo facility where EADS completes the assembly of the aircraft and its delivery. On several occasions, EADS-CASA has expressed its satisfaction with the work done by GAMESA AERONÁUTICA (EASA del Sur) in the assembly of its fuselages. SPASA continued its work on the P3B-ORION programme, manufactured parts for the EUROFIGHTER, collaborated in the manufacture of the ramp and door of the EADS-CASA C295, and manufactured parts (concurrent engineering with the customer, overall management of all machines parts and final processes) for the MRTT –this aircraft is the result of the conversion of the AIRBUS A310 civil aircraft into an air-air fuel supply aircraft. Tratamientos Térmicos TTT and METRALTEC have begun to work directly with EADS-CASA. MESIMA, a company specialised in special cutting techniques, the qualitative reception of materials and supplies of raw materials (pre-machines and preforms of aluminium and titanium parts) also works directly with EADS-CASA. It did 2D and 3D water cutting, supplied the slat and slat-tracks for the structure of the EUROFIGHTER and performed edging operations on its flaps. Another of the companies certified by EADS-CASA is BURDIN BERRI, which has focused upon the design and manufacture of aeronautical tooling (moulding, drilling, edging, assembly, deburring, etc) through precision CNC machine operations. For the CASA CN-235/295 military transport aircraft, TEGRAF has continued performing engineering work for its structural assemblies. 4.1.4. Helicopters In 2003, after obtaining the type certificate for the S-92 helicopter, Sikorsky Aircraft Coorporation continued with its sales campaign. The S-92 is a helicopter available in different configurations for a wide range of operating scenarios, from commercial passenger and VIP transport, to military, rescue operations and transport to maritime oil rigs. Its proven capabilities place it ahead of other helicopters available in the market. GAMESA AERONÁUTICA is a member of the international consortium engaged in the design and production of this helicopter; GAMESA AERONÁUTICA’s contribution includes the design, certification, and production of the turbine
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support structures, fire walls, upper fuselage structures, fuselage transition section, tail cone and horizontal stabilizer, as well as interiors. During 2003, structures have been delivered for 4 helicopters by companies in the GAMESA AERONÁUTICA Group. METRALTEC, Tratamientos Térmicos TTT and SPASA, have taken part in this programme. For its part, the last of these, SPASA, works in a number of different helicopter projects for BOEING. 4.2. Engines 4.2.1. Civil Engines The future AIRBUS A380 will have two engine systems, one of which is the ROLLS ROYCE TRENT-900, of which ITP has a 16.6% participation in the programme as a risk-profit partner. In 2003, new modules of the Low Pressure Turbine (LPT), for which ITP has responsibility for design, manufacture and instrumentation, were delivered. Through its subsidiary company ITA, ITP has also won a contract for the manufacture of half of the pipes for the development engines for this engine. In compliance with the initial planning of this programme, the first TRENT-900 development engine has been tested, in which technologies developed by ITP are being tested for the first time. For this reason, ITP engineers have taken an active part in these tests and in the monitoring of development engines with a view to the certification of the LPT and of the complete engine, whose turbines were completely assembled and instrumented by ITP. The results obtained were satisfactory. For the TRENT-900, ITP has also completed the design of the "externals" module and the design of the test bed instrumentation for the hot part of the engine, from the combustion chamber to the exhaust module, for all the tests engines and the first over-speed tests of the turbine disks on the test bed constructed at the ITP facility in Ajalvir. Continuing with ITP's activities with the family of TRENT engines, 2003 was an excellent year for sales of the TRENTt-500 (AIRBUS A340-600) engine, of which 119 LPT modules have been delivered. The certification in 2002 of the enhanced efficiency version (EP), which has facilitated the sales of new aircraft, has contributed to this success. Thus, in 2003, the delivery of the first aircraft with EP engines took place, beating the record for flights without stopovers from Singapore to Los Angeles. The EP version has a LPT completely designed by ITP. This LPT has obtained magnificent results with regard to the increase in efficiency and the reduction of costs and weight of the engine. In line with the improvements in quality and the reduction of production costs, ITP has been able to industrialise the Electrochemical Machining process (ECM) of thermo resistant alloys for application in the Rear Bushing Bracket of the TRENT-500. Associate companies such as NOVALTI, SIEGEL and SPASA, manufacture components for the TRENT 500, 700, 800, 900 and JR engines. The other associate companies approved by ITP are as follows: IMESAZA, which has increased its turnover in this sector through the heat treatment services (carbonitriding, vacuum treatments, ionnit-ox, etc.) the company offers components manufacturers, and LAZPIUR, who have worked for the machinery construction, tool manufacturing and precision component sector. In 2003, studies commenced on the feasibility of the TRENT-1000 engine, one of the options for the new 7E7 aircraft made by BOEING. For this purpose, an optimisation study has been made of the LPT. The tests performed on the Fluid Dynamic Testbed of the Aeronautical Technologies Centre (CTA) on the first prototype of the advanced turbine with which ITP seeks to validate the design tools and the new aerodynamic solutions that will be applied to new generation engines such as the TRENT-1000, have concluded. With regard to externals, ITP has delivered a complete set of the ANTLE engine fan module. In 2003, production began on the AS907 engine, re-baptised ATH7000, of which ITP has delivered 30 sets of parts to Honeywell. The engine was certified in August 2003 and in December the first production aircraft was delivered to the end customer The AS900 programme was designed for the propulsion of regional transport and VIP aircraft such as the BOMBARDIER CHALLENGER 300. This is a reflection of ITP’s great interest in diversifying its products, which the crisis in this sector as a result of September 11th had put at risk. The successes obtained in 2003 have removed to a great extent the sense of uncertainty that had hung over this programme. The major milestones in ITP's programme of collaboration with engine manufacturers include the development and manufacture of the first compressor housings for the GE90 engine of General Electric, and the delivery to SNECMA of the first 400 parts for the fourth stage Turbine Distributor of the LPT of the CFM56 engine.
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Special mention should be given to the NADCAP certificate secured by ITP for some of the Special Processes (XRAY inspection, Penetrating Liquids, Magnetic Articles and Plasma Spray coatings) as it was the first Spanish company to obtain this certification. Tratamientos TĂŠrmicos TTT, subcontractors of heat and surface treatments, with long experience in quenching and tempering, case hardening, high vacuum, carbonitriding, electroless nickel, etc., works for ROLLS ROYCE and ITP. NUTER is increasing its production of parts, especially in super alloys, for these companies. Likewise, IONTECH makes abradable coatings by means of thermal spray and plasma techniques in components (housings and hoods) for the TRENT-500/700/800/900, RB-211 and V2500 engines. SENER leads a consortium of five companies associated to HEGAN for the complete design (acoustic, thermomechanical, etc.), manufacture and integration of acoustic radial divisors in the reverse thrust of the TRENT-500 engine, of two gas exhaust cones and acoustic validation test pieces. SENER will test these two gas exhaust cones in a SNECMA CFM56-5B engine. SPASA, collaborates in the PAHN programme for SENER. 4.2.2. Military Engines In May 2003, the consortium of companies Europrop Internacional (EPI), made up of four of the most important engine industries in Europe (Rolls-Royce, MTU, Snecma and ITP) was selected by AIRBUS MILITARY for the design and manufacture of the engine that is to propel the A400M aircraft, called the TP400-D6. ITP's participation in this consortium amounts to 21%. Moreover, ITP was able to demonstrate the advantages of locating the consortium's head office in Madrid and in the end this was set up on the San Fernando de Henares Business Park. In November 2003, the first review was made of the conceptual design of the TP400-D6 engine. The concepts presented by ITP for the modules it is responsible for passed the review satisfactorily. This is the first time a high velocity turbine has been designed for a turboprop engine. On October 9 2003, the first EF2000 production aircraft with EUROJET EJ200 engines assembled by ITP was delivered to the Spanish Air Force. On the other hand, throughout 2003, ITP delivered sets of parts for the assembly of one hundred EJ200 production engines to its EUROJET partners, and the industrialisation of the Deep Chemical Milling process for the ISOGRID structures of the titanium housings for this engine was completed. ITP has begun work on a contract awarded by ROLLS ROYCE for the design of the stabilisation system for the F-135 engine of PRATT & WHITNEY of the JSF Arms System (F-35). Major events include the successful completion of the critical design review which was carried out in March 2003 and the delivery of the first structural nozzle for testing at the end of the year. The first module is virtually complete. Industrias TEY, is approved by ITP as a surface treatment subcontractor. TEY has purchased the PULSE-PLASMA technology that uses vacuum techniques (the first system of its kind in Spain) in order to carry out surface hardening treatments (nitriding), the best way of treating all kinds of steels. TEY is also approved by other companies in this sector such as EADS-CASA, CESA and MESSIER-DOWTY. NOVALTI, SIEGEL and NUTER manufacture components for the EJ200, as well as AEROMEC (specialist in the machining of titanium and other special alloys) who has supplied titanium and inconel rings for the gas exhaust nozzle of this engine. Tratamientos Superficiales IONTECH uses thermal spraying to treat components with metal coatings (introscope boss connection) for the EJ200 engine. TECNICHAPA, a company engaged in the specialised manufacture of boilers and makes the nozzle petals for the EJ200, as well as pipe brackets for the final production of this engine which will be fitted to the EUROFIGHTER combat aircraft. The company's experience in this programme has allowed it to join the ANTLE civil engine programme (in which MESIMA manages materials for ITP) and also supplies brackets. Its collaboration with SNECMA MOTEURS continues to grow and last year, it doubled its number of references and turnover. ITA, the subsidiary of ITP for the manufacture of pipe assemblies, has won a three-year contract for the manufacture of spare pipes for the RB199 engine of the TORNADO fighter aircraft by means of an electronic tender. In September 2003 the Council of Ministers selected the TIGER attack helicopter for its Armed Forces. This helicopter will be powered by an engine built buy a consortium formed by ITP and MTR (MTU, Turbomeca and RollsRoyce), re-baptised MTRI. Based on the MTR390 engine, MTRI will responsible for developing a new engine to
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obtain 14% more power than its predecessor, a key requirement so that the Spanish Army can operate on the missions it has planned for this Weapons System. In 2003, a new engine cycle was defined to obtain the required increase in power, in which ITP engineers have been responsible for the Power Turbine. 4.3. Space Since this company was founded, SENER has been extremely active as a supplier of orbit and attitude control systems, mechanisms, control electronics and complex structures for scientific exploration probes and satellites, as well as equipment for the International Space Station and has shown its commitment to the space sector by buying a financial interest in key companies in this sector; HISDESAT (5%), ARIANESPACE (0.56%) and GALILEO (14%). In 2003, the final adjustments were made to the development of securing systems for astronauts. During the Cervantes mission in the ISS, Pedro Duque used the SENER Crew Restraint system for the first time, a new securing system for astronauts in situations of weightlessness, designed for the ESA and based on an original idea of this astronaut. This mechanism is already included in the inventory of ESA systems and in NASA's equipment procedures archive. Together with the Astrobiology Centre of the INTA, SENER has also patented the SOLID, a robotised piece of equipment which allows the existence of biomarkers to be detected on the surface of Mars. SENER has joined the AURORA programme of the ESA which aims to relaunch space exploration, both in manned flights and with automatic probes. The activities currently being developed by SENER include defining the mechanisms of the probe and the system to join vehicles in orbit around Mars. In 2003, SENER signed the main contracts for the AOCS of the Herschel-Plank, with Dutch Aerospace, and of the GALILEO GSTB V2 with EADS Germany, thus consolidating its position as a supplier of satellite orbit and orientation control systems. Development also began of the Optical Bench Assembly for the Herschel satellite, structural-thermal support equipment for payloads at cryogenic temperatures. With regard to launchers, under contract from the French CNES, SENER has begun to study the reorbiting of different stages of the Ariane 5 rocket to avoid the generation of "orbiting trash" in its re-entry into the Earth's atmosphere. SENER played a major role in the development of the second generation of European meteorological satellites METEOSAT. Currently, it continues to work on the manufacture of several different elements (structures and calibration mechanisms) for the fourth MSG satellite. For the ROSETTA probe, successfully launched at the beginning of 2004, the company delivered fifteen thermal control blinds for the satellite and protective screens for the star sensor and for two cameras. Moreover, two different arms for the deployment of experiments in orbit were supplied. SENER provided the electronic control module for the GIADA experiment, developed jointly with the Astrophysics Institute of Andalucia, as well as the electronic unit for the OSIRIS instrument. The company has completed the development of a fine positioning mechanism for large reflectors, of great interest for space missions. SENER continues to play a major role in the development of equipment for the International Space Station (ISS). In 2003, the definitive delivery was made of the subsystems cabinets for the pressurised module and the support structures for experiments on the exterior of the European laboratory COLUMBUS, as well as the support structures for experiments in the Fluids Sciences Laboratory (FSL) and equipment for the training unit. SIEGEL has also taken part by manufacturing components for this project. SENER delivered four units of the mechanism to secure and point the band X antennas for the X-Star satellite and another six for Spainsat to Space Systems Loral, in compliance with the strict completion dates and reliability requirements imposed. Work has begun on the Pleiades programme, in which SENER supplies several high stability mechanisms and structures for two observation satellites. The main contractor is Alcatel Espace in France. Development has also begun on the panel deployment mechanisms for the MIRAS radiometer (for which the main contractor is EADSCASA), which will be fitted to the SMOS satellite. SENER is also taking part in the development of two items for the GAIA astrometry mission. One of them is a parasol measuring 11 m in diameter, with its mechanisms, structure and heat shield, which must deploy after the satellite has been placed in orbit, providing thermal stability to the telescope. The other items involve a fine positioning mechanism of the secondary mirror of the telescope.
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Besides, SENER designs the AOCS for an earth observation satellite in a project that forms part of the FuegoSat for the early detection and monitoring of fires in the Mediterranean area by means of a constellation of 12 satellites arranged in three orbital planes. On earth, SENER has continued work on the processing of images from Helios for the INTA, and has begun work on the SIGESTREDI (Data Management System) of the EMACON as a subcontractor of INDRA Espacio. SPASA does detailed design, calculations and structural analysis, definition of test protocols, both at source and onsite and integration and tests for the ELMER instrument (instrument designed to observe the sky in the lens with different modes of operation depending on the scientific objective). NUTER collaborates with SENER in the following projects and programmes: ANTENA PHOENIX, ENTRY BAFFLE COVER parts –MODEL FM4-, OPTICAL BENCH ASSEMBLY, XEUS and FSL SS. During the year 2003, NOVALTI developed a large number of space-related tasks: Satellite HOT BIRDTM 7A: In which they developed and verified the new designs for the payload components of the satellite to equip nearly 60 Ku band transponders; the KOREASAT 5 satellite, which will be South Korea’s first several communications satellite, in which NOVALTI has developed and manufactured Ku and C band transponders that provide access to broadband for multimedia and digital television services. In 2003, NOVALTI continued to develop, manufacture and certify all the components for 64 Ku and C band transponders for the STAR ONE C1 (South America communications satellite) and RC1 satellites (first pan African communications satellite). ARATZ has maintained its links with the sector by manufacturing tools and special machinery including such wideranging areas as the manufacture of prototypes, composite moulds, and tools for antenna and satellite component assemblies. 4.4. Systems and Equipment GAMESA AERONÁUTICA is taking part in the EUROFIGHTER-TYPHOON programme, in the development and production of the flare dispenser for this combat aircraft. The structure of the flair dispenser consists mainly of composite materials. The magazine is the only one in the world made entirely from advanced composite materials, with a consequent reduction in weight of the complete system. During the year 2003, GAMESA AERONÁUTICA continued with its campaign to introduce improvements in its products and mass production systems. In 2003, at ITP's factory in Zamudio, work began on the manufacture of the air intake and gas exhaust for the Auxiliary Power Unit (APU) for the A380 aircraft. In 2003, ITD, ITP's subsidiary company for the design of engine and aircraft structures, circuits and conduits, in collaboration with FOKEER ELMO, has continued work on the design of the in-flight testing instrumentation for the TRENT-900 engine Pylon for Airbus France. For the same customer, ITD is to supply the fan junction boxes for production. For its part, ITA, ITP's subsidiary company for the manufacture of pipe assemblies, has introduced new technologies to improve and increase its production capacity, such as x-ray radiography, swaging type staple fasteners, Permaswage, Rynlock and Harrison, and electrochemical marking of pipes for supplies to AIRBUS, from whom it has obtained certification for the supply of components. ITA's capabilities yielded their first results with the delivery to AIRBUS of the first set of pipes for the HTP of the A380, designed by ITD. ITD has begun collaboration with AIRBUS MILITARY in the conceptual design of the electrical systems of the A400M military transport aircraft. Likewise, the company has obtained one of the first aircraft contracts for the design and supply of the electrical systems for the modernisation of the NIMROD MRA4 aircraft; and, similarly, the A310 MRTT in-flight refuelling tankers, of which ITD has been responsible for designing the installation of the in-flight refuelling pod as well as the necessary modifications for its installation. This aircraft made its first flight in 2003. Thanks to more than 25 years of engineering and designing mechanisms, SENER has begun to work in a new area of activity: actuator and control systems in the aerospace sector. These systems adapt to the overall requirements of its customers, from the preparation of requirements to their conversion into totally developed and certified products, as well as later logistical support. In 2003, SENER worked on the design of the following systems connected to the Belly Fairing of the AIRBUS A380: the Emergency Ram Air, the Low Pressure Ground Connector, the Supplemental Cooling System and the actuated air intakes. SENER also delivered the LINZE system to UNIÓN FENOSA. This system is designed to increase performance and efficiency by means of automating the inspection process from helicopters. In 2003, Tratamientos Térmicos IONTECH continued to work with the Cermets type coating process by means of high velocity thermal spraying (HVOF) for components of the landing gear for the A380.
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NUTER supplies parts for the landing gear for the AIRBUS A310/320 and, in collaboration with CESA, parts for the forward landing gear actuator for AIRBUS A340. This company, collaborates with EUROFIGHTER in the Anti-skid off valve projects (wheel and break systems), arrestor-hook and the supplementary fuel tank ejector (tank-ejector-unit). TECNASA, specialists in high responsibility rubber and silicone parts, continued to produce O-rings, flat seals, moulded parts and fluorinated silicon in rubber for the ejector seats of combat aircraft manufactured by MARTIN BAKER. The certification of assembly processes for the ejector seats made by MARTIN BAKER AIRCRAFT began in 2003 with the delivery of the first units. On the other hand, attention should be drawn to the fact that TECNASA is the first Spanish company to obtain certification in order to participate in the Joint Strike Fighter (the future F35 combat aircraft). Of all our associate companies, DMP is one of the most active in the field of engineering, design and manufacture (precision cylindrical and cubic machining, spark erosion, micro finishes and systems integration). DMP manufactures components and mechanisms for flight systems, steering systems, landing gear, etc., all of which are considered to be critical systems in an aircraft. All this has been possible thanks to its having been certified by its customers (which include GAMESA, ITP, LATECOERE and MESSIER DOWTY), by being upgraded as a supplier by other customers (CESA and EADS-CASA) and to the initiation of activities with new customers (GOODRICH, LIEBHERR and SENER). For its part, NOVALTI developed the manufacture of engineering for the set of metal parts included in the landing gear of AIRBUS A380. It delivered the first assembly to be used for function tests to EADS-CASA in December 2003. 4.5. Maintenance 4.5.1. Civil maintenance In the area of product support, through its subsidiary company IKARUS AIRCRAFT SERVICES, GAMESA AERONÁUTICA has continued providing services in a number of different fields (technical assistance, technical publications, spare supplies, etc.) for the CRJ700/900 programme according to the requirements of BOMBARDIER; and also for the ERJ135/140/145 programmes of EMBRAER. IKARUS is engaged exclusively in maintenance activities, and currently its area of activity is limited to products designed by GAMESA AERONÁUTICA for airlines, but with the clear intention to include other products and to extend its services. Currently it has capacity to do repair work and maintenance operations anywhere in the world. At the end of 2003, ITP signed a contract with BAE SYSTEMS REGIONAL AIRCRAFTS for the maintenance of TPE331 engines, paid per hour of flight. The contract has a duration of two years. Continuing its international campaign in search of new civil customers, ITP has won contracts with EASTERN AIRWAYS (Great Britain) and TIKO in Madagascar, for maintaining TPE331 engines and in 2003, the company was been able to consolidate its relations with UNIAIR, AIRLEC, TAT and JET SYSTEMS for the maintenance of its fleet of TFE731, TPE331, CT7 and ROLLS ROYCE 250 engines, respectively. . During the year 2003, all the actions required to give ITP the full capacity to repair the PW100 family of engines, including the correlation between the test bed and Pratt & Whitney Canada were carried out. The JAR-145 certificates awarded by a Civil Aviation Authority to overhaul this family of engines were obtained. This has been necessary to comply with a contract signed for ten years with Air Nostrum for the maintenance of its fleet of turboprop aircraft. With a view to increase the technological level of its maintenance activities, ITP has continued to enhance its strategic technological skills in the repair of engine parts, having been appointed by the AROC Group as an Excellence Centre in the repair of honeycomb seals for the BR700 family of engines, with the opportunity to opt for the repair of the rest of the ROLLS ROYCE family of engines. The company has also obtained approval by Honeywell of the first repairs that the manufacturer had reserved for it, and so ITP is now included in the manufacturer’s manual as a supplier centre for these third party repairs. In 2003, these maintenance activities, which were practically non-existent in ITP until two years ago, led to an increase in the company's sales of €1.2 million (more than 50% with regard to the previous financial year), in work done for third parties, i.e., repairs of parts not coming from engines disassembled at ITP. The greater and greater involvement of ITP in the maintenance of civil engines has led to the allocation and modification of testing cells in order to be able to accept the new engines and adapt these to the requirements of Civil aviation, and to optimise the use of these cells to increase their versatility. Thus, Cell-5, used for testing industrial turbines, has been adapted for testing Honeywell TPE-331 engines. Celda-3 has been transformed to enable it to test PW-100 engines and workers began to modernise this cell for testing other engines such as the Honeywell TPE331 and T-55, Rolls-Royce-250, and Pratt & Whitney PT6T-3. In order to find alternatives to those engines that will
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be replaced due to their obsolescence or to the fact that they do not comply with international environmental regulations, an agreement has been reached with the manufacturer Pratt & Whitney Canada whereby ITP has been designated DOF (Designated Overhaul Facility) for the PW engines of the series 200. In this area, in 2003, the AEROSPACE ENGINEERING GROUP continued to pursue its activities in the manufacture of specialised maintenance of coils and the repair of the advanced range of stators, rotors, armatures and fields in AC/DC generators, generator starters, inverters, fuel pumps and electric motors for AMERICAN AIRLINES, DELTA AIRLINES, AEROMEXICO, LAN CHILE, SABENA TECHNICS, LUFTHANSA TECHNICS, IBERIA, SINGAPORE AIRLINES, CHINA NORTHWEST AIRLINES, etc. 4.5.2. Military maintenance: ITP reached a new agreement, valid until 2006, with the Moroccan Air Force to maintain its fleet of CT7, T53, T55 and TFE731 engines. In addition to this, it signed a contract with the Dutch Air Force for two years for the maintenance of its PT6T-3 engines. For the first time, the Portuguese Air Force has entrusted ITP with the repair of one of its engines, a Honeywell TFE731 and the company has won a tender for the repair of ROLLS ROYCE Model 250 engines of the General Procurement Office of the Republic of Mexico. Likewise, throughout 2003, other Air Forces, such as Botswana, Egypt, Chile and Jordan has sent their engines for repair to ITP's facility in Ajalvir. ITP's sales activities have enabled the firm to reach a contract with the Spanish Air Force amounting to €73 million for the maintenance of its fleet of engines. This contract has a duration of three years with the option of extending it for further periods. . ITP has begun a study to optimise the power absorption systems of test cells. This study includes the future needs of engines such as the TP400 and the MTR 390. As a support for the fleet of EF2000-TYPHOONs of the Air Force, ITP has completed preparations for the EJ200, consisting of the organisation and preparation of procedures for the technical support and engineering to coincide with the coming into service of the EF2000 in the Air Force. AEROSPACE ENGINEERING GROUP, specialised in the maintenance of electrical systems and components, has worked for: the US Air Force, the Dutch Air Force and the Spanish Air Force. 4.6. Testing 4.6.1. Structural and fire tests We dedicate this chapter in its entirety to the contribution made by the Aeronautic Technologies Centre (CTA) since its creation in 1997 at its headquarters in Miñano (Alava). Throughout 2003, the CTA-Miñano unit has been involved in several research programmes. TESTS ERJ170 Fatigue tests have continued on the horizontal stabilisers of the ERJ170, and are expected to be completed in 2004, marking the conclusion of the first major campaign of aeronautical certification of this Centre, thanks to work contracted by GAMESA. A-380 The first tests for the A-380 programme have been carried out, contracted with AIRBUS FRANCE and work has begun on the design and manufacture of test tooling contracted by SOCATA, SOGEMASA, GAMESA and CESA. A-340-600 The actuator impulse and fatigue tests have been concluded. The satisfactory results of this campaign have led to the contracting of similar tests for the A380 and an invitation to bid for the actuators of the fuel tank version A 330. Sikorsky S-92 The horizontal stabiliser fatigue tests have been completed and the contracting of fire behaviour tests of the materials in this helicopter has been extended. R&D LINES Having defined the CTA's lines of Research 2003, important results have been obtained and in some cases have led to the contracting of tests or have given rise to new industrial developments.. Combustion. The series of microgravity combustion projects has been completed. The design of new fire tests on fuselages, in cooperation with the FAA, have given rise to a new testing chamber which is now ready to provide services to this market. Work is continuing on an adimensional study of the behaviour of fire in aircraft cabins.
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New structures A low and medium energy impact accelerator has been set up for use in the development of new structures with higher impact resistance. A direct result of this was the contracting of a test to develop a fuselage to withstand the impact of the turbine blade of the Falcon 7X programme. Non destructive tests Work during 2003 focused on the use of infrared thermography to detect defects in composite materials as a complement to ultrasound inspection, with excellent results. An agreement has been reached on the development of the technique to inspect metals throughout 2004. Gyroscopic actuators A project has begun to develop a new generation of gyroscopic actuators for the satellite control system as well as the development of a specific test bed. 4.6.2. Fluid dynamic tests ROTARY TESTS and AEROACOUSTIC CHARACTERISATION of the INSTALLATION. During the first quarter of the year, Rotary tests work carried out on the experimental specimen of PTB1 turbine, with very satisfactory results. Likewise, a series of acoustic measurements were made in order to characterise the acoustic behaviour of the installation. R&D LINES Advanced instrumentation During the trials of the PTB1, the Traverse Area System has been used massively, and the operation has been optimised with a time-saving of more than 50% and with a high degree of precision in the measurements both of pressure and temperature.. AEROACOUSTICS As a consequence of the achievements that have been obtained and the future activities planned in this field, the general manager of CTA designated CTA-Zamudio as the leader of the VIRTUAL AEROACOUSTICS INSTITUTE project. (IVAe), in October 2003. The IVAe: the aim of the Virtual Aeroacoustics Institute is to promote the creation and dissemination of know-how on Aeroacoustics in Spain, by attaining and maintaining a high level of quality in this technology and enabling its members to take part in International R&D Programmes relating to Aeronautics Acoustics and making the Institute technically and economically viable. The system is under development to detect defects in aeronautical components during fatigue tests, with direct application in a component of the A380. Likewise, the Data Acquisition System for noise in the installation is currently at the final preparation stage. NEW DEVELOPMENTS The test bed has been provided with a small wind tunnel for the referencing and characterisation of advanced instrumentation. The secondary air consumption system, essential in order to characterise efficiency of low-pressure turbines, has been improved.
4.7. R&D In addition to signing a contract for its participation in a new project within the 5th Framework Programme called BASSA (Bond Assisted Single Step Assembly), GAMESA AERONÁUTICA increased its presence in this area in the form of new tools already included in the 5th Framework Programme. In this way, it took part in the preparation and presentation of proposals with the main manufacturers and research centres in Europe for the main projects in this sector. Thus, GAMESA AERONÁUTICA is taking part in the integrated FRIENDCOPTER projects (The environmentally FRIENDly heliCOPTER) and TATEM (Technologies And Techniques for nEw Maintenance concepts) and in the COCOMAT (Increasing safety and MATerial exploitation of COmposite airframe structures by accurate simulation of Collapse) and ARTIMA (Aircraft Reliability Through Intelligent Materials Application), and is the leader of the consortium that is promoting the mass of these projects. As part of the offer of ROLLS ROYCE of the TRENT-1000 engine for the new BOEING 7E7, optimisation studies have made of the LPT, in which ITP has introduced for the first time some of its own technologies developed within the ANTLE programmes of the 5th Framework Programme of the European Commission and the Second Aeronautics Technology Plan sponsored by the Ministry of Science and Technology over the last five years. Another important milestone in this field was the signing by ITP and the Spanish Ministry of Defence of a contract to develop
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infrared stealth technology and work has begun to characterise the levels of emissions of certain materials for application to engines that require a reduction in the infrared signal. In 2003, ITP invested more than €100 million in R&D&I programmes and has continued developing projects approved by the European Commission within the 1st, 2nd and 3rd calls of the 5th Framework Programme: The development of static structures of light gamma titanium sheet; the manufacture and modelling of manufactured structural components (MMFSC) (in this project, ITP has just replaced Rolls-Royce as leader); development of CFD codes for analysing turbine noise; aeromechanical design of turbine blades II (ADTURB-II); aerothemal research of turbine blades; participation in vehicle-1 of the Technology Platform EEFAE (technology demonstration platform); design of sturdy, damage resistant blades, (RAMGT); manufacture of integral turning structures (MANHIRP); study of non stationery aerodynamic flows in turbo machines (UTAT); optimisation of the Spray Forming process for the manufacture of aeronautical components in super alloys, led by ITP and, finally, research into engine and aircraft noise (SILENCER). SILENCER (Significantly Lower Community Exposure to Aircraft Noise) is an R&D programme of the technology platform TP6 "Low External Noise Aircraft" within the 5th Framework Programme. This is led by SNECMA with the collaboration of the main European manufacturers both of engines, SNECMA itself, Rolls Royce, MTU, etc., as well as the main aircraft manufacturers, AIRBUS, FOKKER, DASSAULT, ALENIA and the engineering company SENER. SIEGEL, CTA and SPASA have also taken an active part in this European project of the 5th Framework Programme, promoted, among other reasons, in order to reduce aircraft noise by 6dB. With regard to the first call of the 6th Framework Programme, ITP has presented 11 STREP projects and one Integrated Project, of which four have been approved: Aerodynamic characterisation of compressor and aero engine turbine conduits (AIDA); aerothermal research into turbine blades (TATEF II); development of CFD for predicting the noise produced by coaxial gas jets at the outlets of turbo reactor engines (COJEN) and the development of a virtual environment for modelling the complete cycle of engine and aircraft systems. (VIVACE) In the second call of the 6th Framework Programme, ITP expects to participate in five projects, among which the most important is the so-called VITAL project, in which ITP is taking part in the 6th work package that concentrates on the development of the technology of Lower Pressure Turbines. The budget presented for this project amounts to €10 million. In 2003, IONTECH took part in the Integrated Project proposal (IP) within the 5th Framework Programme IMPRESS, for the development of special coatings by means of thermal spray in aviation engine components. In 2003, NOVALTI began work on the different stages and tasks corresponding to two R&D&I projects in which the company is involved: AEROESTALKI; an aerospace coatings project in order to replace, on the one hand, cadmium coatings for other, more environmentally friendly coatings such as Zinc-Nickel, and on the other, to develop new technologies to obtain electrolytic connector coatings on magnesium alloys; and OMUX, in order to secure a major technological breakthrough as it is intended to use technologies that have not been applied before by any manufacturer to obtain new “Ku” band output multiplexor components. The AISHA project (Aircraft Integrated Structural Health Assessment) within the 6th Framework Programme, in which CTA plays an important role, has been approved. During the year 2003, this company also worked in the preparation of seven patents, the consequence of the work carried out in the centre and work is being done in order to secure the 13 patents submitted until now. SENER continues to coordinate the NEWTIRAL project, included within the 5th Framework Programme of the European Union, the main objective of which is to assess the manufacturing processes of metallic compound matrix materials (titanium) with applications in the Aeronautics sector, for the reduction of weight while still obtaining the same features, which implies a greater amount of thrust in the aircraft, less need for fuel and therefore, lower emissions of contaminating gases. The consortium that SENER coordinates consists of INASMET, the University of Bordeaux, QINETIQ, SETTAS, BODYCOTE, DONCASTERS, CESA, EADS CCR and INASCO. DART and TRISYD are two of the other seven critical technology projects with which it is intended to establish the bases for launching a demonstrator programme of the European TILT-ROTOR within the 6th Framework Programme of the European Union; the last one is a Technological Platform of the 5th Framework Programme of the European Union, the aim of which is to develop advanced technologies for the wings of commercial aircraft in order to reduce noise levels and turbulence and in this way improve the efficiency of combustion gases. DART (Development of an Advanced Rotor for Tilt-rotor) involves the design, manufacture and testing of an advanced rotor for implementation in a demonstrator aircraft TILT-ROTOR (aircraft propelled by propellers which can fly like a helicopter and like a conventional aircraft). The project sets out to improve the current designs of external noise, vibrations, safety and cost, as this will be the first rotor in the world with four blades. TRISYD (Tilt-Rotor Integrated Drive System Development) consists of developing the integrated actuator system. SENER is responsible for the detailed design and the calculation of components.
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HEGAN. Annual Report . 2003
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AWIATOR (Aircraft Wing with Advanced Technology Operation) has a budget of €18 million and the consortium is made up of work teams from AIRBUS Germany and United Kingdom, as well as more than 20 European industrial partners and Israel (ONERA, IAI...) Project involves technology validation flight tests amounting to more than 100 hours of flight. These tests will be done with a A340 (MSN001), an aircraft which has been modified for the AWIATOR project. SENER has carried out the design and validation of different devices and mechanisms that will be tested in flight in an AIRBUS 340: braking ailerons (successfully tested in flight during the last quarter of 2003) and currently in the design stage of the modified leading-edge of the flaps. SPASA is also dedicating a great amount of resources to the aforementioned projects, AWIATOR, DART and TRYDSID. Likewise, it is taking part, together with NUTER, in the LUBRIJET projects –a demonstration of the competitiveness of high-pressure lubricant jet machining in the machining of titanium base alloys - and AEROFIVE – development and implementation of higher speed machining technologies for the sector. SENER also continued its work in the POA project (Power Optimised Aircraft), the aim of which is to identify, perfect and validate innovating developments that contribute to optimising the management, generation and consumption of electricity in medium-size passenger aircraft. This programme has a duration of four years and a budget of €100 million, in which major European Aeronautics companies such as AIRBUS, ALENIA, HISPANO-SUIZA, LIEBHERR-AEROSPACE, ROLLS ROYCE, SNECMA MOTEURS, THALES and TRW are involved. For its part, SENER is taking part in the integration of equipment, as well as in the test bed and its design. SENER continues to work on the contract to supply RAFAEL with image processing systems for aerial surveillance “pods” and is involved in another contract with ZEISS, in Germany, to introduce image merging algorithms for “pods” for aiming and surveillance. SENER continues to work on the development of the SATE (luggage system) system for the new airport in Barajas, as well as the platforms of the dike and satellite for this airport; the company finished the project for the new airport of Cuatro Vientos, the terminals in Málaga and Alicante and also the basic project for new terminal in Warsaw airport, the detailed project for which will begin in 2004. SENER continued to work on nozzles with vector thrust control capacity. In the field of engines, it has also taken part in several European programmes such as HIPER-CRACK: "High-performance fracture approach to fatigue crack analysis and life prediction". This is a European project led by SENER, in which companies such as: CRF FIAT, ITSAK, UPCO, JRC, MSC, SAMTECH, nCODE and Volvo AERO have taken part. SENER has co-ordinated these projects and verified the methodology using conventional calculation methods.
5 Aggregate date Sales [ME]: 661 Exports [ME]: 545 Personnel: 4350 Investments in Technological R&S [ME]: 137
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HEGAN. Annual Report . 2003
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