anual report
2005
Index 1. Presentation …………………………………………………………………………
3
2. Organisation of the association ……………………………………………………
4
3.
Summary of HEGAN activities 3.1 Internal area ……………………………………………………………………… 6 3.2 External area ……………………………………………………………………… 8 3.3 General area ……………………………………………………………………… 9
4. Summary of the activities of associate companies 4.1 Aerostructures 4.1.1 Large aircraft ……………………………………………………………… 12 4.1.2 Regional aircraft …………………………………………………………… 16 4.1.3 Business aircraft and general aviation …………………………………… 18 4.1.4 Defence sector aircraft …………………………………………………… 18 4.1.5 Helicopters ………………………………………………………………... 19 4.2 Engines 4.2.1 Civil sector engines ……………………………………………………… 20 4.2.2 Defence sector engines …………………………………………………… 23 4.3 Systems and equipment…………………………………………………………… 27 4.4 Maintenance 4.4.1 Civil sector maintenance ………………………………………………… 30 4.4.2 Defence sector maintenance …………………………………………….. 31 4.5 Space …………………………………………………………………………...
32
4.6 R&D projects …………………………………………………………............... 36 5. Statistics 2005 ……………………………………………………………………… 44 6. Specialist areas and main aerospace customers ..........……………………………… 46
Design: SORTUZ©
7. Acknowledgements ………………………………………………………… ………… 48
HEGAN is an adhered member of ..................
HEGAN is member of ...‌.....................
HEGAN participates in the Regional Associations Meetings of ...............................
HEGAN is founding partner of ...........
HEGAN is member of the consortium of ......
This publication is sponsored by:
INTERREG IIIA
2. HEGAN, Annual Report 2005
1- PRESENTATION It is for me a source of great satisfaction, once again, to present this Annual Report, which aims to set out the excellent results of the Basque Aerospace industry in 2005 and the promising future that lies before us. In spite of the complex international situation, with the high price of oil on world markets (which means that we must develop more efficient aircraft and engines), a peculiar euro-dollar parity and the management of complex raw materials (which oblige us to be ever watchful of the competitiveness of our companies), the growth in air traffic in 2005 of around 7.6 percent provides ample proof of the permanent growth in aircraft sales. One of the motives for the satisfaction of the companies that form part of the Cluster Association of Aeronautics and Space of the Basque Country, HEGAN, is the turnover of this sector in 2005, which reached a figure of 756 million euros, representing an increase of almost 8 percent. Moreover, in the case of SMEs as a whole, the increase in turnover amounted to 24.3 percent. We should also like to draw attention to the continuing upward trend in the employment levels in the aerospace sector, which, with an increase of 7 percent, has reached a figure of 5350 jobs. The value of the exports of the Basque aeronautics and space industry has not varied, maintaining the same level as in 2004 at 525 million euros. With regard to R&D, although the percentage over turnover has dropped to 10%, the average annual percentage since 1992 amounts to 19 percent of the turnover of our companies. Among the major developments recorded during 2005, one of the most important was the start of production on the A380. The first deliveries of this aircraft will take place at the end of 2006. Another major project is the development of the A350, which has just suffered a delay in its official launch. It is an honour for me to say that our associate companies collaborate directly with all the divisions of Airbus (France, UK, Germany and Spain) in a number of different work packages for most of its programmes. Other significant events include the contracts signed for new programmes such as the Boeing 787, for which ITP will collaborate in the development of the Trent 1000 engines as risk-profit partner, or the Boeing 747-LCF, in which GAMESA AERONÁUTICA is already playing an active role in the development of one of the most critical sections of the fuselage of this aircraft, the opening and loading area. And to end this section on major events, SENER has completed the design of the guidance, navigation and control subsystem of the automated vehicle that will operate on the International Space Station to provide astronauts with support in maintenance work repairs and rescue operations. In addition, we should mention the favourable development of our associated SMEs, which, having achieved a higher level of diversification in their customer base, allow us to speak of the increasing maturity and consolidation of the Basque Aerospace industry.
2005 was a year in which several technology centres joined our association, and today our membership stands at 32 companies. We should like, therefore, to welcome the CTA, the “son” of the first partners of HEGAN, FATRONIK and TECNALIA AEROSPACE, which has played a very active role since the creation of the Cluster Association, through INASMET. With this decision, the Association is more of a “Cluster” than ever. Our associate members are capable of working in virtually all the aerospace subsectors and of carrying out the complete cycle of development of products and services from R&D and design to manufacture, integration, testing, certification and product support. I should like to take this opportunity of calling on all financial entities and institutions to get involved in this process as their counterparts are doing in other Spanish and European regions. The aim would be to provide an adequate financial tool to support the entire sector, especially SMEs and which would lead to the materialisation of new RRSP contracts – ‘Risk Revenue Sharing Partnership’ -, the basis for the long-term growth and stability of our companies. During 2005, the HEGAN association began to implement the tasks and actions set out in its 2005-2015 Strategic Reflection, and has gradually incorporated a range of activities, considered to be of real interest for the Basque Aerospace sector, into its daily work. Thus, in 2005, HEGAN continued to pursue a wide range of activities in its different areas of responsibility: technology, quality, internationalisation, representation and promotion. Major developments include our leadership in the Spanish state of the European project ECARE (European tool designed to help SMEs in their participation in Integrated Projects of the 6th Framework Programme), which will be maintained in the 7th FP with ECARE+; as well as the joint attendance of trade fairs such as the Paris Air Show and, for the first time, what will probably become a regular event, an invitation to attend the Delegated Commission of the ATECMA (Spanish Association of Aerospace Material manufacturers). Moreover, it was a source of great pride for this Association to receive the invitation from the European Commission to share the experience of HEGAN among representatives of the new Member States in the autumn of 2005, an initiative which will be repeated during the forthcoming AERODAYS in Vienna. This encourages us to continue working with even more determination towards the goals we have set for this Association. Having come to the end of my term as president of HEGAN, I have the honour of handing down to my successor an exciting project - the development of this Basque Aerospace sector. Thanks to everyone who works in it, this sector, which I have had the satisfaction and honour of presiding, enjoys ever-increasing international recognition. Jorge Unda President of HEGAN
2 - ORGANISATION OF AIMS
The aim of the Aeronautics and Space Cluster Association of the Basque Country– HEGAN –is to take as many actions as may be required to foster, promote and stimulate the development of industrial, professional, technological and research infrastructures capable of supplying goods, products and services for the world aerospace market. In this way, the Association seeks to reach the maximum levels of coordination and synergy among all the agents involved and to secure international recognition for the Basque aerospace strategic sector, contributing to a strengthening of the economy, favouring the creation of highly specialised jobs, the scientific and technical development of society and to redirect industry towards activities that offer a better future and higher added value. ORGANISATION
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. GOVERNING COUNCIL This is the Collegial Body of Administration and Management. Its members are appointed by the General Assembly. • Members 2005 - Jorge Unda (President), SENER - José Luis Osoro (Vice President), GAMESA AERONÁUTICA - Plácido Márquez (Secretary), ITP - José IgnacioTellechea (Member), BASQUE GOVERNMENT - Javier Hernando (Member), BASQUE GOVERNMENT - Román Arrasate (Member), AEROSPACE ENGINEERING GROUP - Luis Urkidi (Member), TECNICHAPA - José Juez (Managing Director), HEGAN
EXECUTIVE COMMITTEE The Executive Committee was created in 2005. This group, delegated by the Management Board, acts as its executive body in the activities of the Cluster and meets on a two-monthly basis. Its members are as follows: -
Juan Ignacio Burgaleta, SENER Alfredo Esquisabel, GAMESA AERONÁUTICA Plácido Márquez, ITP Juan Miguel López Uria, BASQUE GOVERNMENT Román Arrasate, AEROSPACE ENGINEERING GROUP Joseba Cano, AEROTEAM Eduardo Junkera, DMP Luis Urkidi, TECNICHAPA José Juez, HEGAN
With effect from this year, HEGAN’s permanent committees have been restructured as a result of the 2005-2008-2015 strategic plan. These committees have become temporary and flexible work groups engaged in specific activities and report to the Executive Committee. These work groups are created and dissolved according to the wishes of our associate members.
4 .HEGAN, Anual Report 2005 Annual 4. HEGAN,
Report 2005
OF THE ASSOCIATION
3. SUMMARY OF H
During 2005, the Aeronautics and Space Cluster Association of the Basque Country – HEGAN –performed the tasks and actions contained in the 2005-08-15 Strategic Plan, considered to be of real interest for the Basque aerospace sector. The most relevant activities carried out by the Association in 2005 are summarised below.
3.1 INTERNAL AREA 3.1.1 COMPETITIVENESS: TECHNOLOGY
ECARE / ECARE+ Projects In the field of technology, HEGAN’s activities in the European ECARE project, which ended in 2005 after two years of work, is of special interest. The Association was member of the consortium that is promoting the project and leader of the consortium in the Spanish State. This project, included within the 5th European Framework Programme, began as a pilot scheme for the 6th Framework Programme. The aim was to promote, in collaboration with other European regional aerospace associations, the participation of SMEs in integrated aeronautics projects (IPs). ECARE has become a practical and useful tool and, as a consequence of the positive results obtained after the second call of the 6th Framework Programme, has earned the praise of the European Commission. At the end of 2005, the continuation of this project was confirmed with the approval by the European Commission of ECARE+, confirming the favourable view of the EU of the role of Regional Associations to support SMEs.
(www.aerosfin.org), an “AERODEMO” took place at the installations of FATRONIK, where practical demonstrations were given of production systems (thin wall machining, friction stir welding, incremental sheet metal forming, etc.). The demonstration was attended by almost 60 people from 25 different entities.
AEROSFIN Project In 2005, the European AEROSFIN project (AEROnautical Spanish and French INterregional network) was passed within the framework of Interreg IIIA subsidies. The aim is to stimulate interregional cooperation and reinforce the social and economic cohesion of neighbouring regions. AEROSFIN is a technical and scientific collaboration project to improve aeronautical machining. The partners in this project are the Engineering Schools of Tarbes and Bilbao, the Basque technology centre FATRONIK and the associations of ESTIA Innovation (France) and HEGAN. The first three take part as research partners and the last two are developing links with industry to ensure real progress in the field of research and to resolve the practical problems of industry. In 2005, in addition to the Association’s research, coordination and dissemination activities
Coordination in technology and innovation HEGAN tries to maintain a role as coordinator of the technological-aerospace area and dedicates effort and resources to the management of information and technological dissemination of the sector at all levels: information on aid for R&D, encouragement of cooperation project initiatives, etc. In this area, HEGAN has continued working with Spanish and European representatives of the SCRATCH and AEROSME projects, which, like ECARE, are the other two measures of the European Framework Programme, to foster the participation of aerospace SMEs in the different European R&D Projects. HEGAN has attended technological conferences, organised visits from companies for potential collaborations and has disseminated the Technology Surveillance Bulletin of this sector.
6. HEGAN, Annual Report 2005
HEGAN ACTIVITIES
3.1 INTERNAL AREA 3.1.2 COMPETITIVENESS: QUALITY AND INNOVATION IN MANAGEMENT
EN9100 standard Following the work of recent years relating to the promotion of the EN9100 certificates, all member companies suitable for certification under this standard had already received this aerospace certification before the summer. 2005 saw the culmination of a process that began in 1999 with the development of our own quality standard, which brought together criteria from the ISO 9000:94 standards and from the European and American aerospace industries. This standard was given the name of HEGAN 9000. This process has placed the Basque Aerospace sector within the leading group with regard to the number of companies that have this European aerospace standard and has made quality a part of the culture of our companies. PRI/NADCAP Certification Following the presentation to suppliers of the main aerospace manufacturers in the Spanish State of the NADCAP scheme for the certification of special processes, organised by ITP and HEGAN in Derio-Bizkaia, the Basque sector has maintained its firm commitment to the new PRI/NADCAP regulations. In just one year, more than 50% of the existing special processes were certified in 2005 and the certification of the remainder has been planned for 2006. IAQG/EAQG Another indication of the commitment of the Basque aerospace industry to quality, was HEGAN’s participation as full member in the EAQG programme (European Aerospace Quality Group), and the organisation of its biannual meeting at the Hotel Sheraton in Bilbao, in February 2005. These meetings are held in different European locations and the Bilbao meeting attracted a record number of delegates, with 50 representatives from virtually all the European companies in this sector. This figure was higher than the average participation for these committee meetings, which is usually about 35. The hosts of this event were also HEGAN and ITP, representative of the Basque aerospace industry in the EAQG quality group. The aim of this meeting was to examine the strategy of the European sector and to review the progress of the initiatives put into motion for
the meeting of the IAQG, which took place in April 2005 in Amsterdam. These meetings of the IAQG (Internacional Aeroespace Quality Group) are attended by representatives of the three sectors into which this international organisation, created in 1998, is divided. The meeting was attended by its European members, through EAQG; American members (AAQG), as well as members from the AsiaPacific region (APAQG). In total, about 60 aerospace companies from the whole world met with the intention of starting initiatives to bring about a significant improvement in quality, safety and cost reduction in the supply chain through the establishment of cooperation activities based on the aim of winning the confidence of international aerospace companies. To do this, common standards and requirements were established, as well as processes of continuous improvement for products and procedures throughout the supply chain, methods to share results and implementation plans to carry out initiatives as these arise. Environmental Agreement At the end of 2005, HEGAN also showed its firm commitment to the Environment by collaborating in efforts to initiate the signature of the Environmental Agreement for the Aeronautics sector as part of the strategy of Basque institutions for the integration of environmental issues in the main industrial sub sectors. This agreement will involve an important contribution to environmental quality as well as support from the Government at a technical, economic and administrative level. In the broader perspective, the application of Environmental Agreements will favour the home market and rules of competition based on obtaining goods and services of high-quality. After several information sessions organised by IHOBE, Public Environmental Management Company, to complement the information distributed to companies by HEGAN, a large number of these companies backed this process through the signing of a letter of undertaking. It is expected that the Territorial Planning and Environment Department of the Basque Government and representa-
Annual Report 2005, HEGAN. 7
3. SUMMARY OF H
3.2 EXTERNAL AREA
3.2.1 TRADE FAIRS, MISSIONS AND PROFESSIONAL MEETINGS
tives from these companies will formalise the Agreement in 2006. Specialisation course in Aeronautics HEGAN has continued supporting the Specialisation course in Aeronautic Technologies given by the Higher School of Engineering of Bilbao (ESIB), and attended the 2005 graduation ceremony. An important feature of this course is its attention to the needs of companies, given that it was designed by Basque companies in the sector and the ESIB in collaboration with the Higher School of Aeronautic Engineers (ETSIA – Polytechnic University of Madrid). The most important members of this Association collaborate actively in the form of internship programmes for students, providing them with support in their End of Course Project. Others The Association has drawn the attention of its members to business opportunities through support for the training of workgroups that promote market surveys or business groups, and the pooling of industrial processes and management improvement groups.
Le Bourget 2005 As every year ending with an odd number, HEGAN, made great efforts to take part in the Paris Air Show 2005, possibly the most important aerospace trade fair at an international level. The show is held near Paris (at the Le Bourget aerodrome), and the Association placed a 50 sq m stand at the disposal of its members. For several years, the Basque Country has consolidated its position as the second largest aerospace centre in the Spanish State after a Madrid and at the same level as Andalusia. These three autonomous communities account for about 90% of the total Spanish turnover and employment in the Aerospace sector. This specific weight can also be seen in their participation in Le Bourget 2005: of the 25 stands included in the Spanish Pavilion, a third of these belonged to Basque entities, occupying almost 40% of the available exhibition space. HEGAN’s most noteworthy activities at this fair included attending the stand and the needs of its associate members present at Le Bourget (there was a total of 200 visitors from companies, institutions, private individuals and authorities); the organisation of personalised meetings between companies through other entities and regional associations and the presentation of a talk at the closing ceremony of the ECARE project, which took place in the auditorium of the EADS stand in the presence of representatives from the European Commission, miscellaneous European associations and IMG4. SUBCONTRACTING 2005 2005 saw HEGAN’s participation on a trial basis at the 2005 Subcontracting Fair held in Bilbao within the framework of the Industrial and Technological Summit 2005. After reaching an agreement with the organisers, BEC (Bilbao Exhibition Centre), HEGAN and four of its members formed what it is hoped will be in the future a Basque aerospace island within the pavilion. There were a number of visits of certain relevance and the success had at this fair suggests that there will be future agreements with the organisers for further participation. AEROSOLUTIONS 2005 HEGAN, this time with nine of its associate companies, took part in these business meetings in Bordeaux. One of the successes of these meetings lies in the fact that companies take part by contracting a predetermined agenda of meetings with contractors and clients in the sector. The good results of this activity for members of HEGAN are reflected in the number of interviews and meetings held between the latter, as subcontractors, and 71 different aerospace customers.
8. HEGAN, Annual Report 2005
HEGAN ACTIVITIES
3.3 GENERAL AREA
3.3.1 INFORMATION AND MANAGEMENT
COAST Project Once again, the Cluster took part in the COAST project, financed by INTERREG IIIB, within the Atlantic Space programme. The regional associations taking part in this project (ADOUR COMPETITIVITÉ, WALES AEROSPACE and HEGAN) aim to favour the establishment of commercial relations and co-operation between aerospace companies in the three regions. This project continues to pursue its aims of establishing a platform of trust between the three regions in order to promote the generation of business between their companies and with the hope of taking part in new projects with other regions. As a result of its work in this project, as well as its activities in ECARE, HEGAN has been invited to take part in other projects such as TECINNOV and SIDEREUS, which other regions are fostering within the framework of collaboration of COAST. Market surveillance and opportunities HEGAN is attempting to consolidate the presence of the sector in meetings, missions and visits. The Association takes part in international conferences and events and manages a large amount of marketing information from a large number of sources, and places this at the disposal of its members through the intranet of its web site.
In 2005, HEGAN dedicated a great deal of time to improving, maintaining and adding practical and useful contents to the internal system of forums included in our intranet. The forum of HEGAN’s web site is a system with different and structured levels of access in which, on the one hand, different entities can enter simultaneously in order to debate a wide range of different issues and subjects and, on the other hand, members are provided with a business information tool. With regard to handling information on its members, in 2005, the HEGAN Association adopted the Organic Law for Data Protection (LOPD),
Also during the last financial year, 7 new members joined the Association: four industrial companies, ADS, AERODLTOOLS, TALLERES AIBE and ELECTROHILO; and the technology centres CTA, ‘son’ of the first partners of HEGAN, FATRONIK and the corporation TECNALIA AEROSPACE, which has been an active member of the Cluster since its creation, through INASMET. Together, these 32 entities work in almost all the aerospace subsectors and are capable of carrying out the complete development cycle of products and services: R&D, design, manufacture, integration, testing, certification and product support.
3.3.2 REPRESENTATION AND PROMOTION
2005 saw a large number of actions in the area of representation, communications and promotion and institutional relations, with the aim of strengthening the image of the Basque aerospace sector, maintaining a fluid relationship with all the decision-making agents in the sector and developing communications with the world aerospace industry and the rest of society. Contacts in have been maintained therefore with key entities in the sector at all levels, both public and private. Special attention should be drawn to the invitation to take part on a permanent basis in the Delegated Commission of the Spanish Association of Aerospace Material Constructors (ATECMA). In September 2005, HEGAN was invited by the European Commission to the conference entitled “Developing new Member States’ capabilities in Aeronautics research’’ to share the experience of HEGAN with different representatives of the new member states of the European Union. As for the dissemination of its activities, the Association has initiated a special communications plan commissioned from a specialised advertising agency in order to ensure that our Cluster Association is given maximum coverage in the media.
Annual Report 2005, HEGAN. 9
4- SUMMARY OF THE ACTIVITIE
4.1 AEROSTRUCTURES 4.1.1 Large aircraft 4.1.2 Regional aircraft
4.1 AEROSTRUCTURES 4.1.3 Business aircraft and general aviation 4.1.4 Defence sector aircraft 4.1.5 Helicopters
4.2 ENGINES 4.2.1 Civil sector engines 4.2.2 Defence sector engines
TIES OF ASSOCIATE COMPANIES
4.3 SYSTEMS AND EQUIPMENT
4.4 MAINTENANCE 4.4.1 Civil sector maintenance 4.4.2 Defence sector maintenance
4.5 SPACE
4.6 R&D PROJECTS 4.6.1 Aircraft and space engineering 4.6.2 Processes and materials 4.6.3 Tests 4.6.4 R&D tools
4- SUMMARY OF THE ACTIVITIES OF
4.1 AEROSTRUCTURES 4.1.1 LARGE AIRCRAFT
AIRBUS – A380 GAMESA AERONÁUTICA is responsible for the design and manufacture of prototypes and for the production of the metal structure of the so-called Section 19 for the fuselage and leading and trailing edges, as well as the joining elements of the boxes of the horizontal stabiliser for the Airbus A380 aircraft, through its subsidiary company ICSA in Toledo. During 2005, GAMESA AERONÁUTICA consolidated production while the first aircraft made its maiden flight in April. The company worked on performing the necessary tests for its certification expected for the last quarter of 2006 when it will deliver components for 24 aircraft. Work was also been done on the campaign of “full scale” static tests for the passenger version.
GAMESA AERONAÚTICA
Throughout 2005, the company has participated with the AIRBUS on the following projects: technical assistance in the conceptual design of Section 19 of the A350 at its Getafe facility; development of new versions of the A380800F cargo aircraft, which will continue until mid 2006; joint collaboration with EADS-CASA in the preparation of the certification documentation for the “Belly Fairing” of the A380 and, through its subsidiary ICSA, on the stiffeners and angle bars of the S-19 of the A380. In March 2005, through its subsidiary company EASA DEL SUR (Seville), GAMESA AERONÁUTICA was awarded a contract for assembling the cargo door for the Airbus A300/A310 family, and made 15 deliveries during the course of the year. Another of its subsidiary companies, ICSA, continued manufacturing metal elements for the A320.
AEROMEC
In accordance with its strategic priorities, TECNICHAPA has began a series of investments in new manufacturing processes in the field of sheet metal transformation and integration of assemblies, which will be operative during the year 2006. With its strategic commitment to the development of aeronautics activities, TECNICHAPA is making considerable progress in order to obtain more business and more diversification (new clients, new fields of application and more new programmes). During 2005, TECNICHAPA initiated new activities in the field of structures, specifically in the development and manufacture of new structural parts applicable to Section 19.1. within the A-380 programme. During 2005, AEROMEC, specialised in the machining of titanium and other special alloys, has enjoyed a presence in the area of large aircraft in which it has manufactured structural aluminium parts for the Airbus A380, such as the structural diaphragms that form part of the wing of the A380. NOVALTI has also developed the manufacturing engineering of metal parts for zone 5 of the ‘Belly Fairing’ for the Airbus A380, and has delivered a number of different components, subassemblies and assemblies to EADS-CASA for the aircraft planned for the series.
12.HEGAN, Annual Report 2005
NOVALTI
OF ASSOCIATE COMPANIES
4.1 AEROSTRUCTURES
BURULAN, engaged in the machining and manufacture of components, extended its range of machinery in 2005 with a 5axis machining centre and has worked on aeronautics projects as a subcontractor of GAMESA AERONÁUTICA on the A380 programme. TRATAMIENTOS TÉRMICOS TTT was news in 2005 when it obtained certification for the EN9100 and the NADCAP aeronautics certification for its special processes. It is the first heat treatment subcontracting company to have obtained such a certification and the company is currently being certified by a number of clients such as CESA, Messier-Dowty and EADS-CASA. TTT continues to be involved in the A380 programme. Another of the companies engaged in heat treatments, in this case specialised in the heat treatments of alloy steels which provide exceptional mechanical strength and performance, is TEY, which is taking part in the manufacture of this aircraft within the TTP-Wing programme. SPASA offers more and more integrated solutions for the aeronautics sector and is optimising its capacity for the production of structural components and developing its engineering and assemblies system. Within the A380 programme, it machines parts for zone 2 of the “Belly Fairing”. Mecanizados ASTORKIA, specialised in the machining of aeronautics components, is taking part in
the A380 programme with the manufacture of structural components, as well as NUTER who is manufacturing parts for section 19 of the A380. METRALTEC has maintained its links with the aeronautics sector through its work for this programme in CNC and ASTORKIA high-speed machining processes, sheet metal shaping, painting and heat treatments. The company has expanded its offer to include aeronautics subassemblies with a higher and higher level of integration. The activities of the company BURDINBERRI have focused on turnkey projects for the manufacture of aeronautics tooling and the automation of assembly processes. Its resources allow the company to manufacture of large size tools with the capacity to undertake and manage large projects and long manufacturing series with very short delivery dates, as is the case of its participation in the A380 programme, in which it supplies automatic slipways, curing tables and casting tools. MESIMA is specialised in special cutting operations in processes and in the management and qualitative reception of materials and is engaged therefore in the supply of raw material and preforms in aluminium, titanium and steels. Its role in the A380 programme is as supplier to different subcontractors of preformed or premachined raw materials. SIEGEL has developed and strengthened its activities in the manufacture of machined components for different programmes in the aerospace sector including a number of different structural components for the AIRBUS A380, the result of its efforts in order to obtain the maximum aerospace quality certificates, as well as certifications from a number of important clients in the sector. ARATZ continued working for the aeronautics sector with the manufacture of tooling, machinery and special parts with machining processes using up to 5 axes by CAD-CAM, covering such wide-ranging areas as the manufacture of prototypes, moulds for composites and tools for assemblies. The company is also working on the A380 programme. SENER has a presence in the main European aeronautics programmes. In addition to its long experience in the design and certification of composite material elements, the company is working on the engineering of complex metal elements subject to high fatigue requirements, a field in which SENER has a great deal of know-how. Within the A380 programme and during 2005, SENER has successfully completed the final details for the panels of the ”Belly Fairing”, and has begun work on the certification of the landing gear and
Annual Report 2005, HEGAN.13
4- SUMMARY OF THE ACTIVITIES
4.1 AEROSTRUCTURES
horizontal stabiliser box. These components have been designed by AIRBUSESPAÑA and SENER’s role is to certify this design with the new loads obtained in the flight trials. Likewise, the company is working in collaboration with AIRBUS-ESPAÑA on the design of the horizontal stabiliser for the freighter version of the A380. For this same aircraft, AEROTEAM supplies the milling tools, parts for the Rudder, the Elevator and strengtheners for Section 19. Other associate companies that have taking part in other AIRBUS programmes, such as the A320 and A330/340 families, are as follows: BURULAN, TRATAMIENTOS TÉRMICOS TTT, SPASA (machining cabin elements), ASTROKIA, BURDIN BERRI, MICROFUSIÓN DE ALUMINIO, METRALTEC, ARATZ, MESIMA and SIEGEL. CTA (Centro de Tecnologías Aeronáuticas) was one of the technology centres are joined the Cluster Association in 2005. CTA has provided services for the aerospace industry since its foundation in 1997, and throughout 2005 it continued to perform structural tests for the A380 programme at its headquarters in Miñano-Álava for a number of different customers such as AIRBUSFrance, Airbus-Spain, Socata, GAMESA AERONÁUTICA and CESA. The company has secured a contract from AIRBUS-Germany for the performance of tests on a wing component for the same programme. Likewise, the company has negotiated the performance of tests for AIRBUS-United Kingdom, which now means that the company is working for all the countries taking part in the AIRBUS programme. In the field of aerostructures, CTA has obtained certification of the flame propagation test chamber for fuselage insulation panels, and this is now available for industrial tests. This technology centre has continued its adimensional study of fire behaviour in aircraft cabins, the performance of behavioural tests in the presence of fire and fume density tests for the development and certification of materials for a number of different customers, in accordance with the approval of the General Civil Aviation Bureau and has put into motion a metal foam project to enhance leading edges in cooperation with another associate company, SPASA.
SENER
BURULAN
METRALTEC
On the other hand, TECNALIA AEROSPACE, which joined the association in 2005, has been engaged in development activities for aerospace customers in several subsectors. With regard to structures and bearing in mind the concern of the sector to obtain more environmentally friendly processes, TECNALIA AEROSPACE has collaborated in several programmes on the development of chrome free protection systems and on the incorporation of nanomaterials, on improving the features of structures from the point of view of their properties and of resistance to ice and lightning, to give just a few examples. As a result CTA 14.HEGAN, Annual Report 2005
TIES OF ASSOCIATE COMPANIES
4.1 AEROSTRUCTURES
of this concern for the environment, the company has developed a system to recycle aeronautics quality composite materials for subsequent use in less demanding sectors. In Europe, TECNALIA AEROSPACE has worked on the manufacture of composite materials using alternative processes to the autoclave that offer sufficient features for non critical applications but at a lower cost. In this same area, the company is working on the capacity of nanomaterials as active elements in the control of vibrations for their application in the field of structures.
SIEGEL
MESIMA
BOEING In 2005, GAMESA AERONÁUTICA continued its work on the design of the structure for the Boeing’s 747 “Large Cargo Freighter”. This is a specially modified 747-400 passenger aircraft, which will be used to transport large structures for the new Boeing 787 Dreamliner. The larger perimeter of the future Large Cargo Freighter will allow it to carry 300% more cargo on the main deck than the largest freight aircraft currently in regular service, the 747-400. The Large Cargo Freighter is due to be certified in 2006. With the contract which was signed at the beginning of 2005, GAMESA AERONÁUTICA has become the first Spanish supplier for the 787 Dreamliner programme, and is working with Boeing on the engineering analysis and development of the “swing zone,” the critical section of the Large Cargo Freighter. The “swing zone” is a very complex structure, which opens the rear fuselage to allow the large composite material structures of the 787, such as the wings or fuselage, to be loaded and unloaded. Participation in this huge Boeing project offers ample proof of the engineering capacity and technological potential of GAMESA AERONÁUTICA. The main work of AEROTEAM, associate member of the Cluster and engaged in the aerospace sector since its foundation, is the design, programming and machining of aeronautical parts, tooling, devices for assembly and airworthy parts. The company has started to work actively in the Boeing 787 project. In this aircraft which has been given the nickname of “Dreamliner”, AEROTEAM designs in manufactures tooling for the FanCowls, Spars, Skins, RMT and Door Drapage.
AEROTEAM
Lastly, for larger aircraft and specifically for BOEING, throughout 2005, BURDINBERRI continued to supply tooling for moulding the covering of the rudder for Boeing’s 737.
BURDINBERRI
Annual Report 2005, HEGAN.15
4- SUMMARY OF THE ACTIVITIE
4.1 AEROSTRUCTURES 4.1.2 REGIONAL AIRCRAFT
EMBRAER As in 2004, the tendency in the sales of the ERJ 145 family of Embraer, continued to fall due mainly to the logical decline in the programme as it comes to the end of its life, although this programme has exceeded the initial market expectations. In November 2005, aircraft number 900 was delivered (an ERJ135). For GAMESA AERONÁUTICA, this programme has brought about its definitive consolidation and leadership in the regional aircraft market both at a national and international level. This family consists of the ERJ 135, 140, 145 LR/XR and Legacy models. GAMESA AERONÁUTICA is a risk partner in this project, in the development and certification of these aircraft and is responsible today 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 integration into the aircraft. In 2005, GAMESA AERONÁUTICA delivered assemblies for 56 aircraft to EMBRAER, bringing the total number of deliveries to 952, without including spare parts. It is also interesting to note that in 2005 the company delivered components for five aircraft to Embraer’s plant in China (J-V HARBIN), which has been in operation for one year. Embraer has announced the end of the XR series for June 2006, for which GAMESA AERONÁUTICA delivered the last product in March 2006. Of this line of products only the two versions of the Legacy models mentioned above and those dedicated to defence will remain. GAMESA AERONÁUTICA also participates in a number of different programmes for the 170/190 family as sole supplier of the structures assigned during their service life, such as the rear section of the fuselage, the horizontal and vertical stabilisers, with their corresponding elevators and riders, having responsibility for their development and certification (design, calculation and certification). This family of aircraft, which carries between 70 and 114 passengers and is made up of the EMB170, 175, 190 and 195 models, passed one of its major milestones with the certification of the EMB190, on August 30 2005, and the delivery of the first units to the operator JETBLUE. This was a major milestone for the growth and consolidation of these aircraft. At the beginning of the year, the launch of two new versions was announced (Advance Range –AR) for models EMB190 and EMB195, combining greater range and flexibility in its operations. One member of the family, the EMB195, can carry 108 passengers and certification is planned for the second half of 2006, thereby consolidating the entire family on the market with firm orders for 202 EMB170, 26 EMB175, 234 EMB190 and 29 EMB195, thus guaranteeing a bright future for this aircraft. During 2005, GAMESA AERONÁUTICA delivered assemblies for 52 aircraft, thereby completing a total of 140 EMB170 and 28 assemblies for a total of 34 EMB190 which have already been delivered. The work was done at the GAMESA
16.HEGAN, Annual Report 2005
GAMESA AEROANUTICA
GAMESA AEROANUTICA
ARATZ
TIES OF ASSOCIATE COMPANIES
4.1 AEROSTRUCTURES
PRODUCCIONES AERONÁUTICAS, FUASA and MOASA production facilities in Alava. A major event was the start-up and commissioning of a new assembly plant in Brazil (GAMESA Do BRASIL), which has begun to manufacture and assemble the horizontal stabilisers for the Embraer 190/195. 24 deliveries were made to the client during 2005. Other associated companies that have taken part in these EMBRAER programmes are as follows: BURULAN, TRATAMIENTOS TÉRMICOS TTT, ASTORKIA, METRALTEC, ARATZ and MESIMA. AEROMEC makes structural aluminium parts for the Embraer 170/190 programme; NUTER manufactures parts for the horizontal and vertical empennages of the 170 and 190 and parts for the wings of the 145. SPASA manufactures some assemblies and elements from many of the EMBRAER programmes (134, 145, 170 and 190). BOMBARDIER 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 functional tests and accessories to ensure correct assembly. During 2005, GAMESA AERONÁUTICA delivered 56 aircraft. Completion of the delivery plan of GAMESA AERONÁUTICA through its company located in Seville, EASA del Sur, continues to improve with regard to the previous year. Finally, 2005 was another good year for the CRJ700 and CRJ900 Programmes, and once again the Customer expressed his great satisfaction with the work done by GAMESA AERONÁUTICA.
TEY
Likewise, GAMESA AERONÁUTICA has collaborated and provided technical assistance at an engineering level in the development of large carbon structures such as the rear fuselage, vertical stabiliser and belly fairing and has worked at Bombardier’s production facility in Canada for the new range of Bombardier products, the C series. Other HEGAN associate companies that have taken part in these BOMBARDIER programmes include TRATAMIENTOS TÉRMICOS TTT, and ARATZ.
TRATAMIENTOS TÉRMICOS TTT
Annual Report 2005, HEGAN.17
4- SUMMARY OF THE ACTIVITIES
4.1 AEROSTRUCTURES 4.1.3 BUSINESS AIRCRAFT AND GENERAL AVIATION
EMBRAER In the LEGACY Executive and LEGACY Shuttle series belonging to the ERJ 145 family of this Brazilian company, GAMESA AERONÁUTICA participates as a risk partner in the manufacture and maintenance of wings, control surfaces, engine cowlings, air intakes and thrust reversers, all equipped with their corresponding systems and ready for integration into the aircraft. As commented above, the particular nature of these models is that, together with the defence versions, they would be the only models of the ERJ 145 family present in the sales catalogues of Embraer for the coming years. SPASA is supplier for these series and manufactures some assemblies and elementary parts. DASSAULT The Falcon 7X, the latest model of the higher range of business aircraft produced by the aeronautics builder Dassault Aviation, made its maiden test flight from Bordeaux-Mérignac airport in 2005. The aim of the maiden test flight of the Falcon 7X was to verify the correct operation of all aircraft systems, especially the electric flight controls use for the first time in a business aircraft. Presented officially in February 2005, the Falcon 7X is a luxury tri-jet with a maximum capacity for 19 passengers. The company expects to sell between 300 and 400 units of the coming of 15 to 20 years. Fifty aircraft have been ordered representing two years of production. The certification and first deliveries will be made at the end of 2006. The French builder is leader in this sector with 40 percent of sales, ahead of its two competitors the American Gulfstream and the Canadian Bombardier. Three years ago, Dassault celebrated the 40th anniversary of the maiden flight of the Mystere 20, the starting point for the development of its Falcon business aircraft. AEROTEAM participates in this programme by manufacturing tooling for ribs and strengtheners for the structure. Other HEGAN companies that have taken part in this DASSAULT programme include TRATAMIENTOS TÉRMICOS TTT, ARATZ -who supply assembly frames and milling tools for this and other programmes of this French manufacturer, and CTA, who have performed “Fan Blade Burstout” impact tests for this business aircraft (CTA also makes this kind of impact tests for several EADS-SOCATA
AEROTEAM
18.HEGAN, Annual Report 2005
4.1.4 DEFENCE SECTOR AIRCRAFT
AIRBUS A400M During 2005, at its COASA plant in Galicia, GAMESA AERONÁUTICA has continued to develop, design and manufacture carbon fibre components contracted by AirbusGermany for the wings of the future military transport aircraft, the A-400. This programme is outstanding for its high technological content. The first delivery was made in December after a number of design changes in July. There are seven deliveries of prototypes planned for 2006. At its other plant in Toledo (ICSA) it manufactures the TIP and FORMA A400M ribs (EADS CASA) (ICSA), also for this aircraft. Within the A400M military transport aircraft programme, SENER has begun the design of the wing in collaboration with AIRBUS-UK and AIRBUS-GERMANY for the English composite manufacturer BROOKHOUSE. This involves a completely new design in composite materials, as traditionally this was designed in metal. In collaboration with AIRBUS-ESPAÑA, SENER is working on the design of the stabiliser box as well as on the supports for the systems installed in the stabiliser. The company continues to collaborate with ARIES as first level consultant in a number of different fatigue tests both for the A380 and A400M. AEROTEAM is manufacturing tooling for the Stringers of this aircraft as well as machining the Main Fitting. ARATZ and BURDINBERRI are the other associate companies participating in this programme.
TIES OF ASSOCIATE COMPANIES
4.1 AEROSTRUCTURES 4.1.5 HELICOPTERS
CASA C-101/212/235/295 GAMESA AERONÁUTICA manufactures and assembles through its company ICSA, engine cowlings for the C295 and through its company EASA DEL SUR, is collaborating with EADS CASA on the so-called Working Party (integration stage of the of the fuselage for the CN295 and 235) which is being manufactured at its factory in San Pablo.
SIKORSKY S-92 The S-92 is 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 on 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 support structures, fire walls, upper fuselage structures, fuselage transition section, tail cone and horizontal stabilizer, as well as interiors. During 2005, GAMESA AERONÁUTICA has consolidated its mass production continuously, reaching 20 helicopters at the end of the year. Sales forecasts for this year are very good and up to now 39 units have been delivered. Attention should be joined to the congratulations expressed by our customer Sikorsky for the work done during the preliminary design stage for the new H-92 (version of the S-92 with split tail). Sales of this new aircraft had been made to Canada which has initial supplies of 28 helicopters.
SPASA manufactures subassemblies and basic structure elements for the 235 and 295, and AEROTEAM makes a range of structural parts for the 295 Other associated companies that have taken part in these EADSCASA programmes are as follows: TRATAMIENTOS TÉRMICOS TTT, TEY, ASTORKIA, Microfusión de Aluminio and SIEGEL. OTHERS SPASA manufactures subassemblies and elementary structures for several defence programmes: MRTT, in which SIEGEL is also taking part, AWACS, P3B and EUROFIGHTER, in which METRALTEC, MESIMA and ARATZ are also taking part; AEROTEAM manufactures parts for the F18 and ARATZ is working for DASSAULT defence aircraft.
GAMESA AERONAÚTICA
NUTER manufactures internal and external structural parts for this helicopter; AEROTEAM is participating in this programme with a range of different machining operations and moulding tools for DOORS and BURDINBERRI supplies assembly and milling tools. Other associated companies that have taken part in these EMBRAER programmes are as follows: TRATAMIENTOS TÉRMICOS TTT, TEY, ASTORKIA, Microfusión de Aluminio and SIEGEL.
BURDINBERRI
ARATZ
TIGER EUROCOPTER GAMESA AERONÁUTICA’s subsidiary, ICSA, is participating in the EUROCOPTER programme, and manufactures panels for the rear empennage and stabiliser for this helicopter.
Annual Report 2005, HEGAN.19
4- SUMMARY OF THE ACTIVITIES
4.2 ENGINES 4.2.1 CIVIL SECTOR ENGINES
ROLLS ROYCE The TRENT1000 engine will power the Boeing 787 aircraft, which is expected to enter service in 2008. In 2005, ITP and Rolls-Royce reached a final agreement whereby ITP becomes a risk-profits partner in this programme as supplier of the low-pressure turbine, consolidating this company’s position as a key supplier of the low-pressure turbines of Rolls-Royce in engines with thrusts of over 35,000 pounds. ITP’s participation in the TRENT1000 programme was set at around 12%. According to this contract, ITP will be responsible for the complete design of the turbine and the manufacture and assembly of the complete low-pressure turbine module. The development programme for this engine was shortened by eight months compared to the time nominally needed for these programmes. 2005 saw the preliminary and critical design reviews (PDR and CDR) of this busy programme, as well as the manufacture and instrumentation of the first turbine prototype, which was despatched in December to Rolls-Royce, where the first engine tests will be carried out in 2006. ITP’s subsidiary company, ITA, is responsible for the design, development and supply of all the external pipes for this engine. PCB is taking part in this project with the supply of castings to ITP (Hub Tail bearing housing, stator components and sealing segments). The company also supplies parts to Rolls-Royce such as the high HPBH turbine bearing housing). The TRENT900 engine is one of the two propulsion options for the Airbus A380. ITP has a 16.5% participation in this engine and is responsible for the low-pressure turbine and engine support structures. ITA is also taking part in this project and supplies all the external engine tubes. The major activity during 2005 was to optimise the design based on data obtained from the bench tests on both in the engine and in experimental modules. In spite of this activity, the ITP programme of test flights has
20.HEGAN, Annual Report 2005
been carried out simultaneously on a especially prepared A340, as well as on the A380 aircraft itself, the maiden flight for which took place in April 2005, equipped with four TRENT900 engines. When these initial stages had been completed, production began in the first units with a view to the aircraft entering service during the first months of 2006. PCB casts the three stage stator blades (NGVs) of the turbine and one of the milestones in 2005 was the supply of the first units to ITP. The company also supplies ITP with the other stator components, the Hub Tail rear bearing housing and sealing segments and supplies Rolls-Royce with the high HPBH turbine bearing housing. The TRENT500 is the engine used exclusively to power the A340-600, the largest aircraft Airbus currently has in service. ITP is participating with a 10.1% share, with responsibility for the design and supply of the low-pressure turbine module. Since the aircraft came into service in 2002, more than 372 turbines have been despatched. The company’s subsidiary, ITA, is also participating in this engine and supplies 50% of the external tubes of the engine, as is the case of PCB, who supplies the same range of parts as for other TRENT engines (vanes, HPBH, segments, etc.). In order to ensure the continuous improvement of ITP products, in 2005, developments took place that will allow improvements in their features and especially in their specific consumption. PCB has taken part in the programme this year by re-engineering the stator blades. During 2005, ITP delivered turbine number 2000 for the TRENT800 engine from its factory in Ajalvir. ITP’s participation in the TRENT 700/800 engines, which equip the Airbus A330 and Boeing 777 aircraft, represented the company’s first incursion in the field of civil engines, attaining a 3.5% participation. ITA is also taking part in the TRENT800 engine, supplying all external engine pipes. ITP’s subsidiary company, ITA, has signed a contract with Rolls-Royce for the supply of all V2500 engine tubes.
TIES OF ASSOCIATE COMPANIES
4.2 ENGINES
These parts will be manufactured jointly with the Mexican subsidiary ITR, for direct delivery from its plant in Querétaro (Mexico) to Pratt & Whitney in USA. The activities of a number of different companies associated with the Cluster corresponding to civil engines made by the British manufacturer Rolls-Royce are highlighted below. TECNICHAPA has secured new business opportunities within the ITP Group, both in the civil sector and in defence. ITP has developed and manufactured new brackets for the “external” elements of the TRENT1000 engine. Simultaneously, TECNICAHPA has continued to manufacture bracket type parts for the different programmes of the TRENT, 500, 700 and 900 family.
company is working almost 100 percent. Of special interest is the work being done on the TRENT 900 and 1000 civil engines for which the company manufactures the Top Core Vanes, LE, TE, Bottom Core Vanes, machines the HUB TAIL and several engine dressing operations to enable the welding of these assemblies.
AIBE constructs tools for the manufacture of NGVs, housings and other common processes for the different TRENT engines in Rolls Royce, 500, 900 and 1000. NUTER manufactures parts for the BR-715 and TRENT 500, 800, 900 and 1000 engines. As in the case of structures, in 2005, NOVALTI continued making the range of different mass-produced components to continue its deliveries of components and subassemblies for the TRENT900 engine.
TALLERES AIBE
IONTECH, a company engaged in surface treatments (HFPD, PLASMA, HVOF, etc), performs abradable coatings for plasma and engine hoods TRENT 500, 700, 800, 900, 1000 and RB 211 engines by means of Thermal Spraying by Plasma, as well as other components of the V2500 engine. An important milestone for this company was obtaining NADCAP accreditation in 2005. SPASA is taking part in a number of different Rolls-Royce engine programmes and machines rings and housings.
IONTECH
ELECTROHILO is mainly engaged in the machining of parts by means of spark erosion (both by wire and penetration) and also by means of conventional machining for the Aeronautics industry, for which the
ELECTRHILO
Thanks to the NADCAP special processes certification that allows the company to work on any programme, ELECTROHILO has been growing at the same rate as the sector, doubling its workforce and extending the range of machinery (machining centres and a three-dimensional verification machine). TECNALIA AEROSPACE has worked on the development and final adjustments of a testing system to assess the wear and water
Annual Report 2005, HEGAN.21
4- SUMMARY OF THE ACTIVITIE
4.2
ENGINES
tightness of nozzle seals, for the validation of designs developed by ITP. TECNALIA AEROSPACE is also doing research into a new system to test low-pressure turbine blades in a more reliable manner from a point of view of combined fatigue (high and low cycles) and high temperature. This technology centre will also developed a mathematical model that will allow the behaviour of this material to be predicted during the test. The complexity of the testing system and the acquisition of data will require a multidisciplinary project with design, analytical and testing equipment for the units produced by TECNALIA AEROSPACE. Other associate companies who have taken part in several Rolls-Royce programmes are as follows: TRATAMIENTOS TÉRMICOS TTT, ARATZ, MESIMA and SIEGEL.
ITP
vidual partner of General Electric for this engine. The LMS100 has been designed to be the most efficient turbine on the market, with a 50% increase over the typical efficiency currently achieved, as with a power of 100MW it has a single cycle performance of 46%, much higher than most of the turbines in a similar range. The value of this association for General Electric is the application of aeronautical technology to energy generating turbines in which, due to high fuel prices, aeronautical technology has many more advantages, in spite of the fact that the industrialisation costs are usually higher. On the other hand, for ITP it means the diversification towards new markets and customers, with the advantages this brings in terms of having a more stable client base. According to this contract, ITP has, for the first time, responsibility for designing, developing, and manufacturing a General Electric component, the TRF or Turbine Rear Frame, as well as management of the complete module, the power turbine. The LMS100 is the most powerful engine in which ITP has taken part, and as a consequence of its dimensions, it will be necessary to purchase new machinery for the Zamudio facility, enabling the company to handle a much larger range of engines than it has been able to until now. With regard to the General Electric LM2500 engine, which is also aeroderived and within the power range of the 25MW, ITP also supplies parts of high technological value such as spindles, rotating seals, electrochemically machined parts, etc. Moreover, engineering work has been done such as calculations of the service life of both new and modified key components, using aeronautical methodologies that will allow the optimisation of engine life cycle costs.
GENERAL ELECTRIC, GOODRICH/LUCAS, HONEYWELL and SNECMA The GE 90 is the General Electric engine that propels the Boeing 777, and is therefore a direct competitor of the TRENT800. However, in virtue of the technology and quality available to ITP, this company has secured contracts for the production at its Zamudio facility of several key components for this engine, such as the TRF of the GE 90-115 and the Dove Tail of the GE 90-94. ITP signed a contract with General Electric to take part as risk partner with a 5.8% share of the General Electric LMS100 turbine, which makes this company the indi-
NUTER supplies parts for Goodrich-Lucas engines and AEROMEC manufactures Honeywell engine housings for corporate aircraft. Both of these associate companies are working in the field of civil aeronautical engines. In the new field of Nacelles and Thrust-Reversers,
SPASA
22.HEGAN, Annual Report 2005
TIES OF ASSOCIATE COMPANIES
4.2
ENGINES
4.2.2 DEFENCE SECTOR ENGINES
In the defence sector, we wish to highlight the role played by our associate company ITP as first level partner in the engine development projects of the three main European programmes: the Typhoon –Eurofighter-, the A400M transport aircraft -Airbus-, and the Tiger helicopter–Eurocopter-, in addition to participating as subcontractor in the American Joint Strike Fighter -JSFprogramme.
NUTER
TECNICHAPA has reached an agreement with AIRCELLE - SAFRAM Group-to develop and manufacture new high precision boiler parts. AIRCELLE selected TECNICHAPA for the manufacture of parts for their Nacelles and Thrust Reverser systems within the A380 programme. In 2005, Snecma Moteurs and PCB signed a major contract for the long-term supply of investment testing components for CFM56 air propulsion engines. Snecma Moteurs is considered to be the largest French company in the sector and one of the international leaders in the aeronautical and engine market. For PCB this deal ensures a high rate of turnover for the coming years and reaffirms its international presence.
EJ200 This engine, which propels the Eurofighter aircraft, is manufactured by the EUROJET consortium. ITP participates with an 18% share, designing, manufacturing and developing the logistics support for the variable geometry nozzle, the housings of the bypass line and afterburner, the turbine outlet cone and external elements (pipes and wire bundles). On April 15 2005, EUROFIGHTER and EUROJET signed the first export contract for the EJ200 engine. The contract covers the manufacture of 36 installed engines, two spare engines and an initial service support package for the Austrian Air Force. The programme of deliveries will begin in July 2006 and the last deliveries are planned for September 2008. AEROMEC, with its capacity and experience in centrifuge compressors for gas turbines and curved gear teeth of any diameter in parts such as blisks, compressors, titanium disks, Inconell, etc., makes components for this Eurofighter engine, such as the titanium and Inconell rings that from part of the gas expulsion nozzle.
AEROMEC
During the year 2005, NOVALTI continued to manufacture, optimise and deliver a number of different metal components for the mass production of the EJ200 engine and TECNICHAPA has continued to produce brackets and nozzle pedals. IONTECH makes metal coatings by means of the thermal spraying of components for the EJ200 engine and TEY also participates in the heat treatment of parts for this engine. ELECTROHILO is also present in this programme – semi-segmentation of the TEC-, as well as NUTER and SIEGEL. TP400 The TP400, designed and manufactured by the Europrop International consortium (EPI), formed by Rolls Royce, SNECMA, MTU and ITP and whose central headquarters are in San Fernando de Henares (Madrid), will be the turboprop engine that will power the future European four-engine military transport aircraft of Airbus Military (AMSL), the A400M. This engine will be the highest power propulsion plant built in the West with approximately 11,000 hp. 2005 may be considered as the year that marked the beginning of the export stage of this aircraft, whose sole power source is the TP400-D6, due to the
Annual Report 2005, HEGAN.23
4- SUMMARY OF THE ACTIVITIE
4.2 ENGINES
contracts signed both with the Republic of South Africa and Malaysia. In this engine, ITP participates as a partner of the manufacturing consortium with a 21% share. The company is also responsible for the design, development and manufacture of the low-pressure turbine, the structural support of the front bearing, the turbine cone, the gas exhaust duct and external elements (tubes and wire bundles). The Turkish company TEI, which represents ITP and takes responsibility for design, has undertaken the design of some of its components. ITP is also responsible for maintainability, the develoITP pment of the logistics support for first level maintenance and the design and construction of an open-air testing bed for the engine-propeller unit. The company’s activities during 2005 have been directed by the Critical Design Review, as well as the production and delivery of the first turbine module, and the first prototype of the engine assembled by ITP (called the TP3), which is a highly instrumented development of the TP400-D6, fully assembled at the Ajalvir facility. It is interesting to note that both the design, materials and production have been carried out in accordance with ITP’s own specifications, which means a higher level of design and certifying authority, giving the company a great deal of autonomy to undertake future engines. With regard to the validation stage, in addition to validation at a component level, testbed number 5 of ITP has been modified in order to be able to test a turboshaft engine of this size, and the civil works on the open air
24.HEGAN, Annual Report 2005
ITP
TIES OF ASSOCIATE COMPANIES
4.2 ENGINES
testbed which is being constructed for this engine in Morón de la Frontera have been completed. One of the tasks of this testbed is to study the acoustic emissions of the engine, which requires the installation of advanced instrumentation and data analysis equipment and a specific adaptation of the infrastructure.
PCB also takes part as the supplier of castings for several companies in the consortium, such as ITP (3 NGV stator blade stages, the housing of the rear bearing and sealing segments), Rolls-Royce (intermediate and high pressure bearing housing and cast strut ring) and MTU (sealing segments).
The most relevant milestones at a programme level achieved during 2005 are given below: - October 28 2005: First trials of engine on testbed (FETT – First Engine To Test) at the facility the German company MTU has in Ludwigsfelde, Berlin, Germany. Until now, the engine has reached maximum power and has completed more than 35 hours of testing. TECNICHAPA
- February 28 2006: First trials of the TP400-D6 engine with the FH386 propeller manufactured by Ratier-Figeac (FEPTT - First Engine plus Propeller To Test) at an open air testing facility (OATB – Open Air Test Bed) in Istres, France. This second milestone not only belongs to the engine development process, but also is a milestone for our client -AMSL-comprising seven nations, end customers and their operators.
For TECNICHAPA, 2005 saw the beginning of the development and manufacture of new bracket type parts within the TP400 Programme.
AIBE
PCB
AIBE builds tooling for manufacturing NGVs, housings and other common processes for the TP400 engine, and IONTECH makes coatings by means of thermal plasma spraying in the labyrinth seal of this engine. ELECTROHILO is also present in this programme (manufacture of the Lug Top Core Vane), as well as NUTER and SIEGEL
Annual Report 2005, HEGAN.25
4- SUMMARY OF THE ACTIVITIE
4.2
ENGINES
MTR390-Enhanced At the end of November 2005, a contract was signed allowing the execution of the programme to develop the MTR390E engine and the mass production of engines for Spain and France. Throughout the year, ITP continued to work on the design and development of the engines in accordance with the established programme to comply with the delivery requirements. The design has passed the Design Reviews at a Concept and Preliminary level and purchasing has begun of components with the longest delivery dates. The increase in power, which will be obtained with this engine, has involved the design of a refrigerated turbine for the first time. This represents a qualitative increase in turbine technology, with which ITP is establishing the bases for obtaining more advanced products in this civil and military sectors. The process of transferring the manufacture of components from a number of consortium companies such as MTU and Turbomeca to ITP has also continued. This Programme therefore represents their first experience in the complete life cycle of a gas turbine for powering helicopters. ELECTROHILO manufactures the STRUT, and NUTER is also present in the engine manufactured by this consortium.
ITP
26.HEGAN, Annual Report 2005
F135 The F135 is a military turbofan engine, which will be fitted to the Joint Strike Fighter (JSF), the American multipurpose vertical takeoff combat aircraft. Within this project and as a Rolls Royce subcontractor, ITP is responsible for the design of the stabilisation subsystem during vertical takeoff and landing manoeuvres (Roll Post System) as well as for the instrumentation and dressings of the lift fan, developed by Rolls-Royce in North America. During 2005, standard no. 2 of the stabilisation system has been designed and manufactured, as well as the design of the standard no. 3.
TIES OF ASSOCIATE COMPANIES
4.3 SYSTEMS AND EQUIPMENT
A major feature of this section is GAMESA AERONÁUTICA’s consolidated participation in the Eurofighter programme for the development and production of the Flare Dispenser, mounted in this aircraft. This structure has been designed fundamentally in composite materials with the consequent reduction in weight of the entire system. Its magazine, made completely with advanced composite materials, is the only one in the world of its kind. One of the major events of 2005 was the approval and launching of the second production and manufacturing batch for the programme in which GAMESA AERONÁUTICA is taking part by supplying these components, amounting to a total of 255 flare dispensers. For this Eurofighter programme, the associate company NUTER has manufactured parts for the following elements: braking system, ejection system of the 1000 litre auxiliary tank, locking system for the emergency arrester hook and radar refrigeration system. GAMESA AERONÁUTICA’s subsidiary company, ICSA, is taking part in the production of the container for the IRIS-T with RTM technology for the defence company DIEHL-BGT. One of its subsidiary companies, AEROMAC, is manufacturing part of the TAIL BOOM for military in-flight refuelling tankers based on civil models of the Airbus aircraft, and have collaborated and participated in the assembly of the first tail boom. For these two pieces of equipment, in 2005 CTA contracted ICSA to carry out combined vibration and temperatures tests (vibro-environmental tests) for the container of the IRIS-T programme and has contracted CESA to carry out tests on the components of the in-flight refuelling tail boom. For the same customer, CTA has performed development and certification tests for the landing gear actuators and cargo ramp for the A400M programme. AEROTEAM is working on the systems and equipment subsector for the aforementioned programme, manufacturing assemblies and accessories for the FTI of the hydraulic assembly MLGD, that form part of the support for its fuel tank. The ITP Group, through its subsidiary companies ITD and ITA, is taking part in a number of different aircraft
programs, mainly in the field of systems. During 2005, work started on the Airbus A380 programme for which ITD designs and supplies the fuel and hydraulic systems for Section 19.1 and the horizontal stabiliser -HPT. The company began delivering products to the assembly line and during the “sustaining” stage provided engineering support for modifications deriving from the support for the certification of these sections. Moreover, as part of the development programme, work has been done on the weight reduction package of the Section 19 electrical system, consisting of the redesign of all the supports and cable bundles, which were previously the responsibility of Airbus Germany and now is the responsibility of Airbus Spain. Within the A380 programme, Airbus Germany adapted the cabin bundles to the requirements of Singapore GAMESA AERONAÚTICA Airlines; and with regard to the new Airbus A350 programme, the company has taken part in the conceptual design of the horizontal stabiliser-HTP-and Section 19/19.1 -the responsibility of Airbus Spain. We should also mention its collaboration with Airbus France and Airbus UK in different packages for the A350 and A380 programmes. SENER has continued to make progress in this area of activity with the design, development, mass production, integration and testing of drive and control systems applied to aeronautics, defence, propulsion, industrial machinery and electromedicine, a field in which SENER has more than 25 years of experience in the engineering and design of mechanisms, electronics and control systems. 2005 was a year of intense activity for the new Integration and Testing Centre, which began production of several drive and control systems. Moreover, SENER is participating in the A380 programme, having successfully completed final adjustments to the systems connected to the “Belly-Fairing” of this aircraft-“Emergency Ram Air” (ERA), “Low Pressure Ground Connector” (LPGC), “Supplemental Cooling System” (SCS) and area intakes “AGU NACA”-transferring the control of the engineering to SACESA.
272005. 27 Annual Report HEGAN, 2005, Anual HEGAN. Report
4- SUMMARY OF THE ACTIVITIES OF
4.3 SYSTEMS AND EQUIPMENT
With regard to participation in other programmes relating to aircraft for the defence sector, the participation of ITD in the modernisation project for the NIMROD aircraft of the RAF deserves special mention. With regard to this programme, in 2005 work was completed on the development aircraft and 3 aircraft were allocated to the test flights currently in progress. In February 2005, a contract was signed with BAe Systems for the production aircraft, which is expected to enter service in 2009. With reference to in-flight refuelling aircraft, work has begun on the structural and system modifications for the A330 MRTT RAAF aircraft, which is the responsibility of EADS CASA, as well as the instrumentation for in-flight tests. The design work has now been completed for the A310 MRTT GAF programme. Work has also been completed on the design of the A310 MRTT ARBS in which ITD has modified the structure and systems of the rear fuselage. Work on the conversion of this aircraft was finished in 2005. The ITP Group has taken part in the structural modifications and systems for the CN-235 of the SASEMAR programme, an aircraft designed for patrolling and maritime surveillance for the Spanish Government. Work done on the “Engine Build Up� -EBU- for the A400M aircraft, during the conceptual and detailed design stages of both electrical and fluid systems together with oil cooling ducts and the particle separator -IPS-, which is the responsibility of EADS-CASA is of special relevance. Lastly, we should mention the collaboration with Airbus France on the in-flight testing instrumentation work packages, and with Airbus UK on the design of the electrical systems for the wing of the A400M. DMP continued its policy of growth and development in the field of engineering, design and manufacture in order to achieve a higher degree of integration in its products, for which purpose the company has contracted additional qualified personnel. A large part of the activity developed during 2005 corresponds to the engineering and manufacture of components for flight control systems for unmanned aircraft, finally assembled by 2005 SENER. During 2005, DMP has oriented its activities towards the French market where it has been able to take part in programmes of certain importance for the largest manufacturer of landing gear in the world, Messier Dowty. Together with Messier Dowty, DMP is participating in the manufacturer of components for the main landing gear within the AS332-Super Puma programme. It is also taking part in the manufacturer of parts for the front landing gear for the new FALCON 7X aircraft and has made several components for the landing DMP
28.HEGAN, Annual Report 2005
gear for the South Korean T50 Golden Eagle combat aircraft. The use of cadmium as a protective system in landing gear components has become widespread. Nevertheless, environmental legislation forbids the use of this element and therefore TECNALIA AEROSPACE is doing research into alternative coatings that offer the same features and are permitted by current legislation. Several alternatives are being studied including the use of electrolytic coatings and paints. Moreover, TECNALIA AEROSPACE is seeking alternatives to lead for soldering electronic circuits. In line with the progress being made by AIRBUS in the development of the A380, NOVALTI has continued to implement the changes required in order to optimise the manufacture of components and sub assemblies of the landing gear for the A380. The company has delivered a range of different components and sub assemblies to EADS-CASA for a number of new aircraft that are already in production, increasing the number of manufacturing units with regard to the previous year and preparing new units for the future. Likewise, the company has developed a number of different modifications to the design of new parts, as well as the retrofitting of models that have already been delivered.
OF ASSOCIATE COMPANIES
4.3 SYSTEMS AND EQUIPMENT
MICROFUSION DE ALUMINIO, a company with long experience in investment casting and which works with materials such as aluminium, steel and nickel and cobalt based super alloys, works mainly MICROFUSIÓN DE ALUMINIO in the aeronautics and defence sectors. The company manufactures boxes to house electronic circuit boards and components in general, lens supports, avionics boxes, defence radio communications boxes, levers, blades, brackets, and components for avionics systems, electronics, radio communications and optics, etc. for programmes such as: A380, A400M, Eurofighter, F16, ATR42 and 72. All its products are manufactured in accordance with quality control means including vision spectrometers, dimensional control equipment, penetrating liquids and x-ray equipment, designing and manufacturing tools with CADCAM systems. TECNASA, specialised in technical parts in rubber and silicone, was founded in order to take part in the development of aerospace projects on an exclusive basis. TECNASA’s systems control all the processes: from the development of materials, including design of tooling, to the finished part and in 2005, the company continued to design, manufacture and supply “O” rings, flat gaskets and parts moulded in different TECNASA materials (rubber, silicone, fluorinated silicone, viton, etc.) to integrate the launching rings of ejector seats made by MARTIN-BAKER. By producing parts for aircraft equipped with these seats, TECNASA has a presence throughout the world. The advantages of these materials supplied by TECNASA compared to the
ones used until now are as follows: Greater flexibility at low temperatures, higher resistance to the lubricants used, exceptional resistance to ozone and the same conditions of flexibility with the safety paints used in these elements. To reach a higher level of integration, DMP and TECNASA have collaborated to manufacture firing handles for the aforementioned seats. DMP is responsible for manufacturing the terminals and their engagement with the cable as well as the final unit load test. TECNASA produces the rubber coating within the required parameters and ranges, preparing the rings for their final assembly. Both associate companies have resolved the requirements of a greater level of integration demanded by end customers. We end this chapter with the description of a number of operations performed by some of our associate companies in a number of the aforementioned programmes. Industrias TEY participates in the heat treatment of parts for equipment and landing gear for programmes such as the A340 or the C-295. SPASA participates in several programmes such as machining the hydraulic tank of the A380, or ramps, seats and doors for the C-295. NUTER has manufactured parts for a number of different systems such as the landing gear locking system for the A340, parts for the landing gear of the A320 and 310 and elements for A340 actuators. AEROMEC makes components for the front landing gear of the C-295 aircraft, and TECNICHAPA works in the area of systems and equipment thanks to an agreement with HONEYWELL, which the company will supply with complex assemblies with the clear intention of offering more and more integrated solutions.
SPASA
Annual Report 2005, HEGAN.29
4- SUMMARY OF THE ACTIVITIE
4.4 MAINTENANCE 4.4.1 CIVIL SECTOR MAINTENANCE
One of the new features of the TRENT1000 programme of Rolls Royce is TotalCare® maintenance. This service has been offered to airlines and has also been incorporated into the other programmes of this British manufacturer. With this service, Rolls-Royce takes responsibility for engine maintenance, which allows the airline to concentrate on the main aspects of its business. By paying an agreed amount per flying hour, TotalCare® offers airlines the chance to eliminate uncertainties in the management of their fleets and provides greater financial reliability, as during the management of an aircraft there are certain predictable costs. As a further extension of ITP’s participation in the entire life cycle of the product, the company also participates in this stage of the business. In 2005, ITP’s main activities included the maintenance of several different types of engines, and the incorporation and consolidation of customers for the maintenance of the Rolls-Royce M-250 engine. This was a consequence of the opening of new maintenance installations in Arganda del Rey (Madrid), brought about as a result of the signing of a maintenance contract for this engine with the US Army and the conseITP quent segregation of this engine line. This new development has had the effect of attracting other customers from outside the field of defence, such as: the Buenos Aires Police Force, Skytech, EADS-SECA, Mexican PGR, Italian O&S, etc. The consolidation of commercial relations with the Mexican Attorney General’s Office (PGR), with an agreement for the maintenance of its M-250 turboshaft engines and accessories, as well as an agreement with the Ministry of Security of the province of Buenos Aires, are some of the most relevant new developments.
tion of its business, especially in the increase in its customer base for the supply of materials for the EMB170/190 and S-92 programmes. It is also interesting to note that the company has begun to repair structural elements of other operators, that have not been manufactured by GAMESA AERONÁUTICA. AEROSPACE ENGINEERING GROUP, a company engaged in the maintenance and general overhaul of electricity generator components–IDG, CSD, starter dynamos, alternators, APU generators, APU starters, engine starters and the rewinding of internal components (stators, rotors and armatures), has done work for several airlines, operators and manufacturers of a range of different aircraft, including the AIRBUS A300, the 320 family, 330/340; BOEING 737, 747, 757 and 767; BAE 146; MD 80 and the ATR 42 and 72.
Also during 2005, ITP has continued maintenance of the Pratt & Whitney PW100 turboprop for the Air Nostrum fleet, and has signed contracts with CASA, Eurocopter and Binter. Through its subsidiary company, IKARUS Aircraft Services, GAMESA AERONÁUTICA offers all the operators that use its products integrated 24hour services consisting of material and technical support, field service and added value for developing programmes. This company offers and performs maintenance activities for airlines. Currently, its scope is limited to products designed by GAMESA AERONÁUTICA, but the company’s clear aim is to expand its activities towards other products and to broaden its range of services. For IKARUS, 2005 saw the consolida-
30.HEGAN, Annual Report 2005
ITP
TIES OF ASSOCIATE COMPANIES
4.4 MAINTENANCE 4.4.2 DEFENCE SECTOR MAINTENANCE
In February 2005, ITP put a new helicopter engine maintenance centre into operation at Arganda del Rey (Madrid), with the support of its Ajalvir facility, for the repair of components and accessories. This centre covers a surface area of 2500 m2 and employs 40 people. It is equipped with machinery for the disassembly, cleaning, nondestructive testing, inspection, balancing of rotary units and final assembly of Rolls Royce M-250 turboshaft engines. This facility was opened as a result of winning a US-Army tender for the maintenance of 144 Kiowa helicopter engines with an option for a further 126 engines for 2006. Consequently, ITP has provided more space for this line of engines, quadruplicating its production of 85 engines, plus 100 engine modules. ITP has continued to develop its relations with the Spanish Ministry of Defence. This maintenance activity revolves mainly around Snecma’s ATAR engine, as a result of the extension of the service life of the Mirage F1 fleet of the Air Force, and in spite of a drop in the lines of Honeywell T53 and T55 engines, brought about by the low level of activity in the fleets of HUEY and Chinook helicopters of the Army, the Ministry of Defence continues to be the largest individual customer for ITP’s Ajalvir facility. In this context, the technical assistance and maintenance contracts for the EJ200 engine (Eurofighter Typhoon), as well as the maintenance of the F404 engine that powers the F-18 are some of the company’s other major developments. Another major contract was the one signed with Snecma for the maintenance of the international fleet of ATAR engines. As a result of this policy, the following agreements were signed for the ATAR engine: repair of accessories for the Brazilian Air Force (FAB), renovation of the maintenance contract for the Egyptian Air Force (already a customer of ITP), and the first sales were made to the Peruvian Navy. Moreover, ITP and Snecma signed a definitive agreement that designates ITP’s Ajalvir facility as a repair centre for ATAR 9C/9K accessories and engines. At present, this centre maintains Snecma engines, with the exception of the French Air Force.
support activities for EJ200 engines in service during the period January 2006 to December 2008. Together with this contract, the Spanish Aire Force and ITP also signed Annex PC11, the Complementary Engine Logistic Services (CELS), which covers support for Spanish EJ200 engines. In 2005, ITP also signed a new contract with the Portuguese Aire Force for the maintenance of its TFE731 engines and renewed the existing contract with the Royal Moroccan Air Force, for the maintenance ITP of its General Electric CT7, Honeywell T55 and T53 and General Electric CF700 engines. ITP continued to work for the Mexican and Argentinean Armies through an existing contract with EADS-CASA. Finally, the extension of the maintenance contract with the Royal Air Force of the engines for its fleet of Tucano trainers until 2010, with an option to continue until 2014 is also worthy of note. The first and second maintenance stages are carried out at ITP’s facility in York (UK), while the third stage is performed at its Ajalvir workshops. One of the highlights of ITP’s year has been the modernisation of cell no. 4 of turboshaft engines for the testing of turboprops and helicopter engines of up to 5000 SHP, for which more than 150 tests are performed every year. The company uses its own technology for data gathering and controlling tests. As in the case of its activities in the civil engine maintenance sector, AEROSPACE ENGINEERING GROUP has carried out specialised maintenance of components and electrical systems for several Air Forces on a wide range of aircraft and programmes including the F16 and 18, P3; C 101, 130, 212, 235 and 295; CL215; etc.
On December 20 2005, NETMA and EJ signed the “ILS PC11 Second Operational Stage” contract, covering
Annual Report 2005, HEGAN.31 AEROSPACE ENGINEERING GROUP
4- SUMMARY OF THE ACTIVITIE
4.5 SPACE
SENER, the leading Basque company in the Space subsector, plays a major role as supplier of orbit and attitude control systems, mechanisms, control electronics and structures for probes and scientific exploration satellites, as well as equipment for the International Space Station. XTAR 2005 began with the launching of the XTAR satellite to work alongside Spainsat, which was placed into orbit more recently. For these satellites, SENER has delivered to Loral a total of 10 deployment and pointing mechanisms for band X antennas, all of which are currently in operation. METEOSAT-9
SENER
Meteosat-9 was also launched in 2005. SENER has played a crucial role in the development of the SEVIRI radiometer, the heart of the satellite. The company has worked on the Calibration Unit, on the ejectable Cover of the refrigeration system, on the optical Screen artificial system and its cover and on the Linear Actuator or Drive Unit. HERSCHEL - PLANCK In one of the most important international programmes, the Herschel-Planck scientific satellites, in which SENER leads the AOCS of Planck and collaborates with Dutch Space on the Herschel satellite, the development stage has been brought to an end with a successful QSR review. In 2006, this programme will enter the final acceptance stage and delivery of the flight model.
International Space Station SENER completed the design for the subsystem of the GNC of the automated inspection vehicle ASVIS (Automatic Servicing Vehicle for ISS Surveying) which will provide a range of services for the International Space Station including maintenance, repair, support for astronauts or rescue operations. For this project, in which SENER is the main contractor, funds from the Technological Studies and Development Programme of the ISS (STEP) have been employed. Work began on the development and mechanical analysis of an automatic tool change device to facilitate complex extravehicular activities, to increase the safety of the crew and reduce the time and cost of this kind of operation. SENER is participating in these activities alongside the Italian company Galileo Avionica, as main contractor, and Tecnomare. GAIA mission Due to its relevance in the future mission, a major development has been the conclusion and presentation at ESTEC of two important research programmes
32.HEGAN, Annual Report 2005
(TRP’s) of mechanisms for the GAIA scientific mission: the deployment system for the solar parasol and the mechanism with five degrees of freedom of adjustment of the secondary mirror of the instrument (M2M), both with excellent results. The ambitious objective of the ESA mission, which is expected to be launched by 2010, is to make the most exact map of our galaxy, for which it will examine more than one thousand million stars. National Observation Satellite SENER led the first study of the National Observation Satellite with optical instrumentation. During the second half of the year, SENER concentrated on the study of the telescope and other payload elements and at the end of the year, the Ministry of Industry announced confirmation of the programme. IBDM, CONEXPRESS, OBEFONE, TEMSEN-4 At the beginning of the year, SENER secured an important deal for the development and manufacture of the electronics and “softdocking” mechanism of the IBDM (International Berthing and Docking Mechanism). This project was developed with Verhaert for the ESA, and a future demonstration mission has been programmed. Phase B of ConeXpress, the innovating commercial project to prolong the life of geostationary satellites, concluded with the recent successful delivery of PDR documentation.
TIES OF ASSOCIATE COMPANIES
4.5 SPACE
OBEFONE (Optical BEam FOrming NEtworks) is a project financed by the ESA in which SENER is the main contractor and the Polytechnic University of Valencia and the Polytechnic University of Catalonia are subcontractors. The object is to develop an OBFN demonstrator based on True Time Delay (TTD) and to carry out the corresponding tests. At the same time, future developments will be identified to allow their integration into space systems. In accordance with the results, it is expected to define the strategy to be followed with the development of a system scaled to the needs of a real application such as a SAR antenna. Also, during 2005, SENER completed the TEMSEN-4 module that will study and measure the ignition properties of its last layer and which is expected to be launched from Kiruna (Sweden) in May 2006. SIEGEL, manufacturer of metal components, ARATZ, manufacturer of tools and parts and MESIMA, supplier of several different materials, are suppliers of SENER in these different space programmes. DEXARM, SNAPDRAGON, SMOS AND PLEIADES NUTER has taken part in the manufacture of elements for the following projects: DEXARM JOINT (Dextrous Robot System), which is the development of a robot arm (called DEXARM) that may be used for applications in space robotics to perform tasks that were originally designed for human beings. The main application would be the handling of platforms in space and robotics designed for planetary exploration. SNAPDRAGON Deployment Hinge Mechanism; SMOS PLM Hold-down and Deployment mechanism, the aim of which is to provide humidity maps of the ground and the salinity of oceans as well as data to help examine the structure of the cryosphere. The PLEIADES HR Shutter mechanism programme consists of two satellites that will form part of a constellation in synchronous orbit with the sun and will ensure the continuous operation of the earth image service from the SPOT series satellites. These elements form part of the system that will open and close the diaphragm, located in the opening of the telescope, preventing the sun from lighting and heating the detection equipment in the case of an emergency. The company NOVALTI, S.A has consolidated its activities in the space sector after the major increase in its business the previous year. The company now has its own manufacturing installations and two white rooms for the integration of space equipment.
SENER
STAR ONE NOVALTI is working on a number of different space programmes such as STAR ONE C2, a project that began at the end of 2005. This is the “twin brother” of STAR ONE C1, developed and delivered in 2003 for its forthcoming launched as a communications satellite to give coverage to South and Central America, and which will be managed by the Brazilian operator “Embratel”. In the second satellite, the participation of NOVALTI has included the design, development, processing and assembly of most of the microwave equipment in the payload in order to provide support for the 45 Ku, C and X transponders transported by STAR ONE C2 in its geostationary orbit. The services to be offered by this satellite after its launch in 2007, on the Ariane V platform, will be the broadcasting of television signals and local telephone communications, or between countries covered by the satellite, especially in Brazil and Mexico. ICO & P21 ICO & P21, in which NOVALTI delivered a number of different pieces of equipment and components for the new satellites of the American operator ICO (Intermediate Circular Orbit), as a result of the merger with Teledesic and whose main contractor is Loral. This satellite, under licence to FCC, will offer mobile communications services by satellite with ATC technology in the 2 GHz frequency band and in geostationary orbit. This satellite includes new component designs
Annual Report 2005, HEGAN.33
4- SUMMARY OF THE ACTIVITIES
4.5 SPACE
that allow the incorporation of the latest generation of voice and data communications, offering full coverage irrespective of the user’s position. Coverage will be limited exclusively to the United States. ASTRA 1M The ASTRA 1M satellite, for which NOVALTI, during the second half of 2005, began the design and development of the necessary equipment (filters, equalisers, multiplexers, etc.) to provide support to the more than 32 digital channels that will be managed during the lifetime of the satellite. The company NOVALTI has also manufactured, verified, coated and mounted the initial models, whose validation and final manufacture as flight equipment will be carried out in 2006. This satellite will replace the ASTRA 1H and will offer additional capacity to the already extensive fleet of ASTRA satellites. It will transport 32 Ku-band transponders for the main contractor EADS-Astrium. The aim is to cover the FSS and BSS frequency for the British and Irish markets (both in television broadcasting services, and in high bandwidth communications, including HDTV) as these are still experiencing problems of saturation in spite of the offer of the models ASTRA 1KR and ASTRA 1L, due to the growing demand for services in both markets. For the first time, 4 additional channels with limited life spans of five years will be included in order to test the new technologies that will cover the African market, while the remaining equipment will have a service life of 15 years. AMOS 3 At the end of 2005, NOVALTI began the design and development of the new equipment that AMOS 3 will carry in its payload and which will contain up to 15 transponders. The end user is the company Spacecom Satellite Communications who signed an agreement with Israel Aircraft Industries (IAI) to build a third satellite for the Israeli contractor. It is due to be launched in December 2007.
34.HEGAN, Annual Report 2005
Having replaced the AMOS 1 -in-service since 1996- this satellite will be used by a long list of SPACECOM customers (a Tel Aviv-based company). The satellite will be more sophisticated than its predecessors and will offer greater capacity. The new satellite includes 15 transponders in two frequencies managed by two antennas, whose broadcasting capacity can be controlled from earth. For this reason it has been necessary to apply new designs and technologies. The coverage of this new satellite will be Europe, Africa, the Middle East and part of the American continent, during its 11-year lifespan. SUPERBIRD 7 With regard to projects for Asian, throughout 2005, NOVALTI has designed, developed and manufactured mechanical components (filters and equalisers) for subsequent assembly by Alcatel Alenia Space of the 8 input multiplexer assemblies (IMUX) in Ku Band for the Japanese satellite SUPERBIRD 7, which will provide services for up to 56 channels (although its antennas can be reorientated to cover nearby areas, and can even cover Oceania). This will be a commercial satellite at the service of the Japanese market and will be managed by the supplier Space Communications Corp. (SCC) and will be the successor to the SUPERBIRD-C launched in 1996. It will weigh 5 tonnes at the time of launch and will go into geostationary orbit during the first quarter of 2008 and will have a total of 28 Ku band transponders. In order to comply with its customer’s requirements, NOVALTI has developed new technologies and designs that will allow the input signal to be sent on channels corresponding to different communications transponders, using the dielectric resonator filter technology. CHINASAT 9 Also on the Asiatic market, during the second half of 2005, NOVALTI developed and processed the filters and systems in “proto-flight” models for the Chinese satellite CHINASAT 9 (Zhongxing 9, ZX 9), which is equipped with 22 Ku Band transponders for satellite broadcasting services (BSS), and which include 18 channels for 36 M-Hz and four for 54 M-Hz. Once the flight models have been built, and after validation of the qualification models, which will be completed in 2006, NOVALTI’s components will be integrated into the rest of the satellite payload
ES OF ASSOCIATE COMPANIES
4.5 SPACE
which will weigh 4500 kilograms at the time of launch and which will have a 15-year life span. The satellite will be launched with the CZ-3B Chinese rocket (Long March) in 2008. In order to achieve this objective, the customer “China Satellite Communication Corporation (ChinaSat)” has requested the implementation of new designs in order to cater for the new generation of direct broadcast satellites, making this the first Chinese state company to offer the service to its domestic market. NOVALTI’s co-operation in the Chinese market strengthens its position after several years of successful experience: from SINOSAT 1 (1996) to APSTAR VI (2003). GALILEO Lastly, with reference to the GALILEO constellation, NOVALTI has continued development throughout 2005 of a number of different testing and verification components while it waits for the results from the recently launched GIOVE satellites, confirming the results or requiring modification. These vehicles were developed and manufactured in the past and are used to validate the system in orbit. Throughout 2006, the designs and manufactures corresponding to the qualification components of each subsystem based on the results obtained in the GIOVE vehicles, will intensify. During this second development stage, NOVALTI’s participation will take the form of a number of different designs, developments and BreadBoards corresponding to filters, transponders and the rest of the usual equipment. MICROSAT 1 Advanced Dynamic Stystems (ADS) is a private company engaged in the research, development, industrialisation and commercialisation of dynamic equipment and systems for terrestrial, naval and space applications. In 2005, it became member of the Cluster Association and collaborates with companies in the sector, technology centres and universities, offering engineering in the following areas: systems engineering, design and development of control systems, software development, testing, etc.
This company was created in 2004, promoted by a NEOTEC project of the CDTI which developed the definition stage of an Advanced Gyroscopic Actuator (AGA), for controlling the attitude of satellites. The company has a Technological Demonstrator of this actuator and it is working on the design and development of an engineering model for the INTA MICROSAT1 programme. In 2005, ADS won the Toribio Echevarria prize for technological innovation with its AGA project. This award, organised by SPRI, BIC BERRILAN, BASQUE GOVERNMENT and EIBAR TOWN HALL, is given to the best technological innovation project of a company in the Basque Country. Likewise, in 2005, ADS launched the SAGAS-150 project (System with Advanced Gyroscopic Actuator for satellites of the 150 kg class) the aim of which is to perform the design and development stage of the AGA 150, its integration as an attitude control device in the MICROSAT1 satellite (project led by INTA) and its later qualification in flight.
ADS
ROSETTA and others AEROTEAM also works in the space subsector by manufacturing tooling for one of the fibre parabolic antennas of the ROSETTA satellite probe. Industrias TEY is taking part in the heat treatment of parts and elements for space programmes such as ERS-1, EUTELSAT II, CRSS 264 and ARIANE 5 for EADS-Espacio.
Annual Report 2005, HEGAN.35
4- SUMMARY OF THE ACTIVITIES
4.6 R&D PROJECTS 4.6.1 AIRCRAFT AND SPACE ENGINEERING
CESAR, ADVICE, FRIENDCOPTER, TATEM, COCOMAT and ARTIMA During 2005, GAMESA AERONÁUTICA increased its presence in the second round of the 6th Framework Programme, taking part in the preparation and presentation of joint proposals with the main European manufacturers and research centres and for the main projects in the sector. GAMESA AERONÁUTICA continued to participate in integrated projects such as CESAR -Cost Effective Small AiRcraft-, and ADVICE -Autonomous Damage Detection and Vibration Control Systems-and continued to work and develop projects that had been won the previous year, FRIENDCOPTER -The environmentally FRIENDly heliCOPTER-, TATEM -Technologies And Techniques for nEw Maintenance concepts-, COCOMAT -Increasing safety and MATerial exploitation of COmposite airframe structures by accurate simulation of Collapse-and as leaders of the consortium in ARTIMA -Aircraft Reliability Through Intelligent Materials Application-. Currently, GAMESA AERONÁUTICA has two patents relating to ground effect vehicles and fire protection and 4 utility models for tooling and production and assembly processes. DART, TRISYD, NICE TRI and AWIATOR DART and TRISYD are two of the seven critical technology projects that aim to establish the bases for launching a demonstrator programme of the European TILT-ROTOR within the 6th Framework programme. DART, led by EurocopterFrance involves the design, manufacture and testing of an advanced rotor for implementation in a demonstrator aircraft TILT-ROTOR (aircraft driven by propellers that 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, led by AGUSTA, intends to develop the integrated operating system. SENER, engaged in detailed design and component calculation activities and SPASA, are the two HEGAN companies that are taking part in both programmes. In turn these programmes come within the IP Novel Innovative Competitive Effective Tilt Rotor Integrated Project, already approved and at the contract award stage, under the acronym NICE TRIP, in which SENER and GAMESA AERONÁUTICA are also taking part. AWIATOR -Aircraft WIng with Advanced Technology OpeRation- is a Technology Platform within the 5th Framework Programme of the European Union. The aim of this programme is to develop advanced technologies for the wings of commercial aircraft in order to reduce noise levels and turbulence and to improve the efficiency of combustion gases. This project has a budget of 18 million euros and the consortium comprises work teams from AIRBUS-Germany (leader), AIRBUS-France and AIRBUS-UK and more than 20 industrial partners from Europe and Israel. The project includes technology validation flight tests amounting to more than 100 hours of flight. These tests will be made in a A340, appropriately modified for this purpose. SENER has performed the design and validation of a number of different devices and mechanisms such
36.HEGAN, Annual Report 2005
as braking ailerons and modified flap edges, which are being tested successfully in flight in the A340. SPASA is also taking part in this project. SILENCER, BOSTOOLS, FULCODEM and HELINOVI The programme SILENCER Significantly Lower Community Exposure to Aircraft Noise-, is an R&D project of the TP6 technology platform “Low External Noise Aircraft” of the 5th Framework Programme, led by Snecma. Its partners include the main European engine manufacturers (Snecma, Rolls Royce, MTU) aircraft manufacturers (Airbus, Fokker, Dassault, Alenia), as well as three of HEGAN’s associate companies: SENER, SPASA and TECNALIA AEROSPACE. SENER has performed design and integration tasks for the circumferential acoustic divisors in the thrust reverser of the Rolls Royce TRENT 500 engine, as well as the complete design (acoustic, thermo-mechanical, etc.) of two gas exhaust cones for fitting to the Snecma CFM56-5B engine. SENER has led a consortium of HEGAN companies for the manufacture of these components: the two cones and circumferential divisors, in addition to acoustic validation test pieces. SENER’s work on the SILENCER was completed successfully and on time. It now only remains to perform engine tests to corroborate the expectations indicated during the design stage on the components finally manufactured. For its part, TECNALIA
ES OF ASSOCIATE COMPANIES
4.6 R&D PROJECTS
AEROSPACE is working on the manufacture of a new concept in noise reduction based on large cavities. Within the same field of R&D, SENER is developing a methodology of stochastic design for aerostructures, such as sandwich panels or monolithic structures, of great use in the optimisation of designs and weight reduction, together with a BOSTOOLS computer system that systematises the application of these methodologies and, at the same time, is compatible with MSC/PATRAN and MSC/NASTRAN -the most widely used commercial software in aeronautics. SENER is also conducting research into different alternatives for the replacement of conventional honeycomb nuclei and has defined very attractive solutions with regard to improving features and reducing cost and weight. In collaboration with AIRBUS-España, and through INGENIA, SENER is working on the FULCODEM -Full Composite Demostrator- project, which will develop a demonstrator for a S19 made completely of composite material. The aim of this project is to develop the first prototypes of the future A320. SENER has continued working on the HELINOVI project-Helicopter Noise and Vibration reduction, conducting analytical activities involving the estimation of excitations and noise reduction in helicopters.
ANTLE, VIVACE and DEEP ROUTER In the area of technological development, ITP has continued its activities in the fields of aerodynamics, materials and processes, seeking solutions in order to reduce consumption, noise, weight and cost. During 2005, the company approved its participation in four new European projects which means that the overall participation of ITP in the 6th Framework Cup programme now amounts to 11M€. As an extension to the EEFA project of the 5th Framework Programme of the EU, the ANTLE demonstrator engine, which includes a turbine and externals made by ITP, was tested at INTA’s facility. At the same time, tests have been conducted by Rolls Royce, and by CTA on the DT74 and PTB4 scale models, which demonstrates the development of basic technologies on an experimental basis. The results from the integrated project VIVACE, in which ITP is taking part, are very interesting. This project is being used to evaluate technologies that will enter service in 2020. The new life correlations deduced are very promising. ITP has dedicated considerable effort to design systems, including new phenomenology, such as flutter, and introducing considerable reductions in the design cycle. As a result of previous developments, ITP has concluded the qualifications stage of the DEEP ROUTER programme -electronic routing of tubes-, which is being used operationally on the routing of the Lift Fan of the motor for the JSF aircraft. POA, IPU-EF, IPU-DL, HISAC SENER continued its work on 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. The main European aeronautics companies such as Airbus, Alenia, Hispano-Suiza, Liebherr-Aeroespace, RollsRoyce, Snecma Moteurs, Thales and TRW are all involved in this project. SENER is taking part in the equipment integration, as well as in the test bed and its design. In the area of Image Processing for air reconnaissance, SENER is developing the following programmes: - IPU-EF: Adaptation of the IPU card (Image processing Unit) to the Litening ‘pod’, which is to be fitted to the Eurofigther aircraft, provided with reconnaissance capabilities. The Programme involves making an initial batch of 4 electronic cards. The direct customers are Zeo y Rafael, and the end customer are the British Air Forces.
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4- SUMMARY OF THE ACTIVITIE
4.6 R&D PROJECTS
- IPU-DL: Increase the features of the IPU card, based mainly on communications functions provided through Data Link (radio link). The Programme includes the preparation of an initial batch of 4 electronic cards, followed by a second batch of 16 cards. The direct customers are Zeo y Rafael, and the end customer is the Dutch Air Force. Another European R&D programme in which SENER is taking an active part is HISAC -Environmentally Friendly High Speed Aircraft. The aim of this programme is to evaluate the feasibility of a small size, environmentally friendly and economically feasible supersonic transport aircraft. The main problem of this aircraft derives from its incompatibility with environmental standards. These are linked to the noise generated, emissions (NOx, CO2, H2O, HCS), shock waves and high flying altitude, which will condition its feasibility. Dassault Aviation is coordinating the HISAC, formed by a consortium of 37 companies from 13 countries, including Russia, and has an overall budget of 26Mâ‚Ź (14Mâ‚Ź subsidised by the European Community). SENER is the only Spanish company taking part in this project and is involved in two work packages: variable cycle engine technologies, in which the design will be developed from the mechanical viewpoint, capable of varying the engine cycle according to requirements, and on the other hand, the nozzle noise reduction technologies, in which SENER will undertake, in collaboration with Volvo Aero, the design of a mixer-ejector for the reduction of the noise of exhaust gases. -enlace de radio-. OMUX Throughout 2005, NOVALTI has completed a number of tasks pertaining to several research projects in progress, and has met all the targets originally set. In OMUX, NOVALTI has continued work on the design, modifications and BreadBoards corresponding to a number of different pieces of equipment and systems in order to define those that will be used definitively in future generations of satellites, thereby bringing the three-year project which began in 2003 to a successful conclusion. These new component designs of Ku-band multiplexers with a technology not used by any manufacturer at this time, represent a huge leap forward technologically and are already being offered for new equipment in order to apply these immediately as soon as the customer/ end user requests this. MULFUN, HEGATEK, AISHA The need to reduce costs in the aerospace industry was the starting point for the MULFUN project -Multifunctional Structures. The aim of this programme, in which TECNALIA AEROSPACE is taking part, is to design structural elements that can perform multiple functions in order to obtain light, advanced and totally integrated equipment. With the proposed MFS housings, a 40% reduction in the total mass and a 50% reduction in the volume occupied by electronic housings is expected, both in aircraft and spaceship equipment. The main innovations
38.HEGAN, Annual Report 2005
consist of an integrated electronic housing made of composite material, a passive thermal dissipater system based on the use of high thermal conductivity carbon, an active thermal system based on fluid circuits inside foam, a novel multifunctional design approach and the integration of flexible electronic systems in composite structures. CTA continues working on the STREP project within the 6th Framework Programme, AISHA, led by METALogic, which aims to develop an intelligent structure methodology (embedded damage detection systems) based on Lamb waves. Within the SEOP line of safety in air operation and avionics, it is interesting to note the activities of the HEGATEK Strategic Project, within the ETORTEK 2005 project passed by the Basque Government. CTA is leading this project, which focuses on the development of high-level knowhow, technology, protection and use of results in the avionics sector. EUVE and the Electronics and Telecommunications Department of the Bilbao Engineering School are also taking part in this project.
TIES OF ASSOCIATE COMPANIES
4.6 R&D PROJECTS
4.6.2 PROCESSES AND MATERIALS
SENER and TECNALIA AEROSPACE are taking part in NEWTIRAL, a project included within the 5th Framework Programme of the European Union, the main objective of which was to assess manufacturing processes of compound matrix metallic materials (titanium) with applications in the aeronautics sector, such as landing gear elements and pistons, to reduce weight while maintaining the same characteristics. The consortium coordinated by SENER included TECNALIA AEROSPACE, the University of Bordeaux, QINETIQ, SETTAS, BODYCOTE, DONCASTERS, CESA, EADS CCR and INASCO. The European NEWTIRAL project was completed. TECNALIA AEROSPACE has developed a new strengthened titanium alloy that allows enhanced mechanical and tribological properties of a conventional type 6-4 titanium alloy. SPASA is taking part in a number of different projects such as the project to develop new tools for machining the Inconel 78 alloy with minimum lubrication, INCOMEC, financed by the Basque Government and led by Kenametal, or the project that aims to optimise the production processes of monolithic parts by implementing chatter prediction models, mixed cooling systems and on-line tension releasing treatments, AEROBAKI, also financed by the Basque Government and led by SPASA, in which another associate member, ASTORKIA, is also taking part. MAFFIX is another project, this time financed by the EU, which develops completely flexible, reconfigurable and reusable fastening tools, capable of securing any kind of component irrespective of its material form and rigidity during the performance of different machining operations in which SPASA is taking part. RENAMILL ITP has completed RENAMILL, a project developed over recent years in collaboration with several companies and centres of the Basque Network of Technology Centres for the development of hard metal milling tools with nanostructured coatings. PRODUCTION TECHNOLOGIES Within the field of reduction technologies, the development and innovation activities of ITP are generally linked to processes, geometries and specific materials. Some of their major developments during 2005 include machining and inspection and special processes. The first of these areas includes the implementation of robotised edge finishing processes, deburring with vibrating drums and three-dimensional measurement with continuous sensing. With regard to the second, special processes, ITP has performed feasibility studies for the use of laser welding and brazing on different parts as an alternative to current processes, and plasma and electron beam welding processes have been developed for large size components with complex geometries. Continues improvements have been made in chemical milling and electrochemical processes by means of mask feasibility studies without COV emissions, the automation of operations and the study of systems for electrolyte evaporation.
REPAIR TECHNOLOGY In the field of repairs, ITP has continued to develop new technologies for the repair of engine components in accordance with a strategy of making repairs instead of replacements, which represents the main line of technological innovation in independent repair centres. In 2005, characterisations were made of the Wide Gap Brazing process in the repair of hot zone parts on Hastelloy X and Inconel. In turn, certain repair technologies, developed under production conditions in previous years have been employed to carry out specific repairs, approval for which has been obtained either through the manufacturer -OEM-, or through the FAA -DER. Examples include the repair of blade seals by means of automatic TIG welding, the application of heat barriers -TBCin turbine distributors, etc. Another project in this field relating to new structures, in which SPASA is taking part and which is led by CTM, is the “Technical and environmental feasibility study of structural adhesives in aluminium foam joints of structural components in the manufacturer of aircraft�, in which CTA is also taking part. NANOMATERIALS AND OTHER MATERIALS TECNALIA AEROSPACE is a pioneer in Spain in the development of nanomaterials for space and biomedical applications, which it started to develop more than six years ago. This HEGAN associate is working on the development
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4- SUMMARY OF THE ACTIVITIES
4.6 R&D PROJECTS
of the following technologies: surface treatments and functionalisations, nanocoatings, polymer-based nanocomposites, ceramics or metal matrices, synthesis, purification and functionalisation of carbon nanotubes by CVD and the agglomeration of ceramic nanoparticles by chemical hydrothermic methods. Lastly, in the area of materials, ITP groups its research projects in three areas: improve the methodology for calculating the life of turbine disks, simulation of welding processes and new materials with greater potential at high temperatures, or lighter materials for current temperatures. AHEAD, HERA and AEROSFIN FATRONIK as taking part in and leads several R&D programs with practical applications in aeronautics sector. In 2005, the European AHEAD project led by FATRONIK, came to an end after three years of development and with a budget of 5.7 million euros. The aim of this project was to develop technologies that AEROSFIN allow the configuration of flexible, scalable automation systems for the manufacture of aeronautical elements. Within the framework of this project, FATRONIK has developed and patented an autonomous climbing robot for the automatic drilling of aeronautical assemblies such as wings or fuselages. This robot would be used to automate the assembly of aluminium or carbon fibre wings and fuselages, as these products require a large number of bolts and rivets, and today does not allow a high degree of automation The climbing robot is a flexible, sturdy, and relatively economical solution as it allows the automation of certain operations, with the following main advantages: reduce the initial investment in machinery, provide multipurpose and flexible production systems, and increase their degree of automation in production. Until now, FATRONIK has performed several industrial developments based on parallel kinematics, the most
40.HEGAN, Annual Report 2005
recent of which is a high-speed 5-axis machining centre for aeronautical drilling and milling operations. The machine incorporates the Hermes module, a single parallel kinematic module with three degrees of freedom, developed and patented by FATRONIK, mounted on two serial axes (X and Y) to adapt the volume of work of the machine to the type of parts to be produced. The novel feature of the system is the implementation of the Hermes parallel kinematic module in this machining centre, which generates a single, original configuration, the main characteristics of which are its high load capacity, its rigidity, its dynamic features as well as its low manufacturing cost compared to the cost of a conventional kinematic solution for the same features. In spite of the numerous research projects carried out, the application of parallel kinematics in industry is very limited. FATRONIK is a pioneer in the use of this technology and its application to different industrial processes. This machine has been designed for aeronautical drilling and milling operations, but its specific characteristics, such as its load capacity and rigidity, offer the chance to perform other kinds of operations, such as friction welding. FATRONIK is leading the cross border collaboration project for the aeronautical sector AEROSFIN, within the European Interreg III A project. The aim of this project is the development and application of new technologies and aeronautical production techniques. Within the framework of AEROSFIN, FATRONIK organised a demon-
FATRONIK
ES OF ASSOCIATE COMPANIES
4.6 R&D PROJECTS
stration of the new production techniques and technologies applicable to aeronautical production with the aim of conveying its experience to companies in the sector and to the other partners in the project. The latter were able to see these new manufacturing technologies or improvements in existing ones, applicable to their own production systems, such as: Friction Stir Welding, machining of low rigidity parts, aeronautical drilling, plasma assisted machining, Incremental Sheet Forming and polishing. NOESIS, FESTIP, IMPRESS, HORTIA and OPTISPRAY SENER is taking part in a new project within the 6th Framework Programme of the European Commission, -NOESIS-, for the development of composite material with carbon nanotubes that provides the material with sensorial capacity and the ability to operate alone, for aeronautical applications. In this project, led by INASCO, a number of important European research centres, such as CNRS and the University of Hamburg are taking part, as well as aeronautical industries such as IAI. SENER will perform mesoscopic modelling processes and methodologies with these carbon nanotubes. TECNALIA AEROSPACE has developed products such as light alloys based on g-TiAl, for the FESTIP; shaping work, characterisation and protection of the high temperature titanium alloys of the HORTIA project (completed in 2005) which was designed to reduce the noise in helicopter engines, or the activities of the IMPRESS project, co-financed by the ESA in which IONTECH is also taking part through the development of special coating applications by means of the Thermal Spraying of aviation engine components. In the OPTISPRAY project, which has also ended, TECANLIA has developed a simulation model for the spray forming process for the replacement of the forging process and the characterisation of the material obtained. EXPERT, FLPP and SMART TPS The efforts made by TECNALIA AEROSPACE to develop strengthened intermetallic alloys (Ti2AlNb/SiC), will be the basis for its participation in programmes such as EXPERT (experimental re-entry capsule) or the FLPP -Future Launcher Preparatory Program. The consolidation of the integration capacity of subsystems, the development of new technologies such as nanomaterials or applications with dual uses, are some of the guidelines that TECNALIA AEROSPACE applied throughout 2005 and for the coming years. The thermal protection systems -TPS- of reusable space vehicles -RLV-, are fundamental systems for the safety of aircraft in which light materials with very high thermomechanical features are combined with accurate design, allowing the aircraft to withstand extreme operating conditions, especially during the re-entry stage into the earth’s atmosphere, during which speeds of over 30,000 km/h and temperatures of over 1700ºC are reached . Likewise, over recent years TECNALIA AEROSPACE has specialised in
the development of new materials and thermal protection systems. An example of this is the company’s participation in projects such as SMART TPS, financed by the ESA in which, with the collaboration of EADS ST and CENTROSPAZIO, new concepts of TPS are being developed, bringing about improvements in the operability and reliability of future shuttlecraft.
TECNALIA AEROSPACE
WAVE GUIDES WAVE GUIDES is another of the projects in which NOVALTI has worked throughout 2005, for which the original objectives have been met. In this recently initiated project, NOVALTI is developing a new technology for the uniform coating of inaccessible internal tubes. The project is based on the “Tubular Reactor” technique developed in the field of polymers, but applied for the first time to metallic coatings on aluminium. The automatic aim of this project is to apply this coating to “Wave Guides” for satellite payloads. This methodology reduces the environ-
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4- SUMMARY OF THE ACTIVITIES
4.6 R&D PROJECTS 4.6.3 TESTS
mental impact of the process and ensures an adequate and uniform distribution of the layer even on those areas which not easily accessible, either because of their complex geometry or because they have a very narrow section which limits the access from auxiliary anodes.
Fluid dynamic tests From the aerodynamic viewpoint, ITP has concentrated on defining a test bed for a representative turbine step of the Trent 1000 technology, in order to reduce uncertainties relating to the efficiency of the turbine. These tests will continue until next year to verify the improvements in this technology. The research has also been oriented towards obtaining a more realistic simulation of the turbine, including multistage effects, uncharacteristic behaviour, the effect of cavities, seals, surface finish, etc. The CTA unit, engaged in the performance of fluid dynamic tests and located in Zamudio, has made progress during 2005 in this concept of a PTB4 experimental turbine prototype for ITP, not only as a vehicle to validate the technology applied in TRENT1000, but as a basic model used as the starting point for a number of different industrial applications in the future. The configuration by CTA of a stage with the rotor as slipstream generator, together with an assembly mechanism that allows the rig to be opened and the implementation of a fast and simple part changing system, allow the performance of additional tests within a minimum timeframe, but especially with the maximum assurance that the results will be compared accurately. Moreover, compared to other configurations, this rig allows experimental assessment of the non stationarity of the fluid field in an engine environment, which is essential for understanding the fluid dynamics of the turbine and in order to characterise its performance. This novel concept of this rig allows numerous experiments to be conducted based on the PTB4. Any of these tests would have meant, according to conventional philosophy, the preparation of a completely new rig with the consequent repercussions on delivery dates and costs. For ITP, a major development from the viewpoint of experimental infrastructures are the activities to modify the no. 5 engine testing cell in Ajalvir, as well as the completion of the civil works on the Open Air Testbed which, for basic aeroacoustic verifications, are being developed at the Mor贸n de la Frontera airbase.
CTA
42.HEGAN, Annual Report 2005
ES OF ASSOCIATE COMPANIES
4.6 R&D PROJECTS
AGA, HALT tests and advanced instrumentation CTA continues to participate in the new generation gyroscopic actuator project (AGA), for the satellite control system and fine adjustment of the single axis test bed, in addition to manufacturing, in 2005, an adimensional chamber to study behaviour in the presence of fire in aircraft cabins, which will be used for simulations and Virtual Testing in cooperation with EUVE and the GIDAI group of the University of Cantabria. Likewise, the company has begun to develop a test bed for studying the electrostatic behaviour of textile materials and carpets used in aircraft. With regard to new testing methods, CTA has begun to work on the development of a HALT testing methodology on aeronautical components. The aim is to reduce delivery dates and the costs required in development and certifying tests. Work has concentrated mainly on hydraulic components. Throughout 2005, CTA has studied the feasibility of automating an inspection technique by means of infrared thermography in composite aeronautical materials, applicable to inspection and assembly lines. Lastly, in the field of testing, CTA has initiated a new project to research new thermographic techniques such as the thermoinductive and ultrasonic TI (including vibrothermography). With this project CTA will complete the set of TI techniques the company offers the aeronautics industry. In 2005, with the help of the Provincial Council of Bizkaia, CTA put its Fluid Dynamic Testing Institute into motion, with two technological development projects. These projects form part of two strategic lines of research in turbomachinery: aeroelastic phenomena in turbines and refrigeration technologies. The use of rapid response probes initiated by the CTA unit in Zamudio the year before, ceased in 2005, resolving problems relating to parameters that affect the quality of the measurements obtained, such as feed conditions, sensor temperature or hysteresis. CTA has also designed a new closed cycle and variable density calibration tunnel which will provide CTA’s Zamudio facility with the capability to calibrate fluid dynamic instrumentation under a wide range of operating conditions. 4.6.4 R&D TOOLS
OTRI, ECARE+, SCRATCH A major development in 2005 was the setting up of CTA’s Research Results Transfer Bureau registered by the Permanente Commission of the Interministerial Science and Technology Commission. The main aim of this Bureau is to manage and promote the protection, dissemination and transfer of technology and the results of research obtained by this sector technology centre HEGAN is responsible for ECARE+ at a state level, as mentioned in chapter 3 of this report. Lastly, we should mention that TECNALIA AEROSPACE is the state coordinator of the European SCRATCH project to support SMEs for their participation in European projects under the 6th Framework Programme.
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5- STATISTI 5.1 SALES [M€]
5.2 EMPLOYMENT
44.HEGAN, Annual Report 2005
STICS 2005 5.3 EXPORTS [M€]
5.4 INVESTMENTS IN R&D [M€]
Annual Report 2005, HEGAN.45
6- SPECIALIST AREAS AND MA
46.HEGAN, Annual Report 2005
MAIN AEROSPACE CUSTOMERS
STRUCTURES AIRBUS: A300-310-318-319-320-321-330-340-350-380-400M-MRTT, BOEING: 737 747LCF 787, BOMBARDIER: CRJ 700-900 C-Series, DORNIER: DO728, EADS: C101-212-295 CN235 TBM700, EMBRAER: ERJ135-140-145 EMB170-175-190-195 Legacy, SINO-SWERINGEN: SJ30, SIKORSKY: S92, EUROCOPTER: Tigre, DASSULT: Falcon 7X.
ENGINES EPI: TP400, EUROJET: EJ200, GENERAL ELECTRIC: CF700 CT7 F404-414 LM2500 J79 T700 GE90, HONEYWELL: TF50 AS907 T53-55 Garrett TPE331-731 AS900, MTRI: MTR390-Enhanced, PRATT & WHITNEY: PT6 T3 F135 JT8STD-200 GP7000, ROLLSROYCE: TAY BR 710 TRENT-MT50 TRENT-MT30 BR 715 RB211 TRENT500-700-800-900-1000 V2500, ROLLS-ROYCE NORTH AMERICA: A250 A601K T63 M250, SNECMA: ATAR 9K PLUS- 09C-09K50 CFM 56, TURBOMECA: MAKILA.
SYSTEMS AND EQUIPMENT BARDIER, EADS-CASA, EUROFIGHTER, EUROCOPTER, SIKORSKY, MESSIER-DOWTY, MARTIN-BAKER, EADS-CESA, LATECOERE, LIEBHERR, DIEHL-BGT, ROLLS-ROYCE, HONEYWELL, BAE Systems.
SPACE ESA / NASA: GALILEO, HERMES, HUBBLE, SOHO, ULISSES, HERSCHEL-PLANCK, CLUSTER, EGNOS, ENVISAT, EUREKA, HIPPARCOS, INTEGRAL, ISEE-B, ISS-COLUMBUS; ISS-CRV, ROSETTA, SPACELAB, XMM-NEWTON, AURORA, CX-OLEV, ARTEMIS, METOP, MSG, OTHERS: ARIANESPACE, ASTRIUM, GE 1i and GE 2i, HELIOS I-II, HISPASAT 1C-1D, METEOSAT, MINISAT, NETLANDER, OLYMPUS, SPOT-4, SYRACUSE III, YAMAL 200, ARABSAT 4A-B, GALAXY 17, KOREASAT 5, SUPERBIRD 7, CHINASAT 9, MICROSAT 1.
7- ACKNOWLEDGEMENTS
We should like to end this report by expressing our sincere thanks to those persons who have made this publication possible and for the professionalism of HEGAN’s management team. The involvement shown by our associate companies and the support and collaboration of all the agencies that form part of this cluster association, members, governments, universities, technology centres and non member companies, represent an invaluable tool without which our work would be much harder. While in 2004 we said that the year for us had been a point of inflection, 2005 has represented the beginning of a new stage in which all the aforementioned agents have shown, with an ever-increasing level of involvement, the great appreciation that they feel towards this Association. The satisfaction of working on a daily basis with such good professionals is a stimulus which we wish to repay with our modest contribution to the increasingly fruitful development of the entire Basque Aerospace Cluster and, consequently, of society as a whole. Once again, many thanks for your invaluable, constant and essential support. JosÊ Juez Director Gerente
48.HEGAN, Annual Report 2005