Category: Commercial

JPB Système Witnesses Significant Lead Time Reduction and Weight Saving Benefits From Continued Trials of Additive Manufacturing

JPB Système has reported positive results from its continued research into the benefits and application possibilities of additive manufacturing (AM) technology. In some trials, this has seen the France-based business cut overall lead times by 80% on some parts, and crucially, secure weight-savings of 30% – a fundamental objective for aerospace customers.

The company, which serves the likes of Safran, Pratt & Whitney, GE and Rolls-Royce, has been trialing industrial-grade metal binder jetting (MBJ) AM technology for several months as part of its ongoing objective to ensure greater efficiency and agility across its production operations.

The company says the results of the trials with MBJ technology to potentially produce flight-ready parts, are meeting expectations by delivering robust lighter-weight alternatives quicker, easier and more cost-effectively than traditional manufacturing methods such as machining and casting. Leveraging this AM technology, the company is also able to create highly complex products with new geometries, further streamlining production efficiencies by removing the need for assembly.

Reduced Lead Times Accelerate Time to Market

“As we anticipated, our trials of MBJ technology underscore how its versatility and ability to reduce time and costs offer huge benefits for us as a company and for our customers,” explains Jocelyn Vecchio, Director of Engineering and Innovation at JPB Système.

“Such production efficiencies are evidenced if we compare the technology to the typical method of producing parts via casting in a foundry,” he adds. “As well as having limitations insofar as the geometries achievable, this involves expensive tooling that can entail long lead times of around six months – even longer if geometries change and a new mold is required. In contrast, using MBJ additive manufacturing, we could produce the same part in about four weeks; that’s a decrease in time of more than 80%, which ultimately means we speed up delivery times to customers. The flexibility of this technology also means that, it doesn’t take any longer to produce 100 different parts than it would 100 identical parts.”

Another vital attribute for JPB Système is the technology’s ability to create parts that are much lighter than metal alternatives. Via solid yet hollow bodies and tough lattice structures, test parts developed by JPB Système match the durability of traditional metal variants but use much less material. This has seen the company enjoy weight savings of 30% in some cases.

“This is an important tick-in the-box for OEM customers and those further up the supply chain who are constantly seeking to reduce the overall weight of the aircraft,” adds JPB Système Research Engineer, Benjamin Sangouard. “A lighter aircraft means less fuel, which means less cost and reduced emissions, which is of course important from a sustainability perspective.”

Continues Benjamin, “The sustainability factor is further demonstrated by the on-demand manufacturing principle of AM that enables companies like us to produce what is needed, when it is needed, rather than traditional techniques that obligate long production runs just to ensure cost-effectiveness. This would give us greater flexibility and reduce the need to store large quantities of stock.”

Improved Design Possibilities

JPB Système also benefits from the way in which AM allows the company to leverage greater design freedom to produce complex products much more easily. This includes the consolidation of two parts into one, or products that accommodate one element inside another – something not typically achievable with conventional manufacturing techniques.

In one example, this allowed the team to produce an assembled multi-component functional system that offers multiple advantages by incorporating three components into one. Thanks to a reduced number of parts, the supply chain is simplified and assembly time is removed. Also, from a safety aspect, the eventuality of foreign object damage to the engine, while fundamentally an unlikely eventuality, is all but eliminated.

For Jocelyn Vecchio, this ability to leverage AM to develop more advanced products with fewer parts, could also increases JPB Système’s strategic competitiveness with new patents.

“So far, our exploration into the application possibilities of MBJ have proved very successful and offer significant potential in our quest to innovate our production processes to better meet the needs of our customers,” he concludes.

JPB Système is set to open a new start-of-the art facility in Villaroche, south of Paris in 2023, which is partly government funded through an initiative designed to accelerate industry growth and help manufacturing companies. The eventual integration of additive manufacturing technology, and other disruptive innovations that enable the Industry 4.0 concept, will underpin the new facility’s automated production lines once operational.

Cementex Announces Enhanced New Design of Double-Insulated Wrenches

Safety tool specialist Cementex announced a new design enhancement to its extensive line of industry-leading Double-Insulated Wrenches that they say provide the greatest possible safety of personnel in environments in and around energized equipment. Cementex open-end, box-end and geared wrenches will now feature a continuous outer layer of orange insulation to provide a smooth transition between the dual-layer and single-layer portions of each tool.

Beginning immediately, Cementex will be phasing out the yellow insulation layer on the working ends of the wrenches and will ensure that all kits will have the same style. All part numbers for tools and kits will remain the same.

This design advancement makes the work end of the wrenches even slimmer so that they are consistent with the insulation process that makes Cementex drivers the slimmest insulated tools available. The smooth transition and reduced overall size of the wrenches enables access into tighter locations and minimizes the likelihood of the outer layer being caught on sharp edges that could damage the tools’ insulation.

Cementex tools are manufactured in Burlington, NJ to the highest quality standards. The insulation is guaranteed to pass a 10,000 VAC proof test in accordance with applicable U.S. and international standards and all tools come with the Cementex Limited Lifetime Warranty.

Austrian Airlines and Spairliners extend E-Jet component support contract

Austrian Airlines and Spairliners have signed a long-term flight hour agreement to extend their business relationship for the component support of Austrian Airline’s E-Jet fleet. Austria’s leading airline currently operates 17 Embraer E195 aircraft. The contract includes access to Spairliners’ comprehensive component pool, repair services via their extensive maintenance network across the globe, logistics, as well as a dedicated on-site stock at Austrian Airline’s home base at Vienna Airport.

‘We are very pleased to be selected by Austrian Airlines as their preferred partner for component support of their E-Jet fleet. At Spairliners, we provide our customers with reliable, future-oriented solutions that are fully customized to their requirements at very competitive terms. The renewal of our contract proves that our commitment to provide the best possible support to Austrian Airlines during the pandemic, with scalable solutions to suit their needs, further strengthened our long-standing, successful relationship’, says Taco Stouten, head of Sales and Marketing at Spairliners.

‘Spairliners has proven to be a very reliable and competent partner to us, and we therefore continue to put our trust in them to provide full component support for our E-Jet fleet. We appreciate the flexible solutions and high level of collaboration they offered during the pandemic and look forward to working together with Spairliners in the future’, says Wolfgang Dielacher, head of Strategic Procurement Technics at Austrian Airlines.

Iraqi Airways Receives First GTF-Powered A220 Aircraft

Iraqi Airways has taken delivery of its first Airbus A220-300 aircraft, powered exclusively by Pratt & Whitney GTF engines. The airline ordered five such aircraft in 2013.

“We would like to welcome Iraqi Airways back to the Pratt & Whitney family,” said Rick Deurloo, chief commercial officer at Pratt & Whitney. “Our relationship with Iraqi Airways dates to their Boeing 707 fleet, which was powered by our JT3D engines. We look forward to supporting the airline’s growth with the world-class operating costs and environmental advantages that come with our revolutionary GTF engines.”   

The A220 offers significantly lower operating costs compared to previous generation aircraft. The engines deliver double-digit improvements in fuel and carbon emissions. They also provide a 75% reduction in noise footprint and produce NOx emissions 50% below the International Civil Aviation Organization (ICAO) CAEP/6 regulation.

Equair Chooses AFI KLM E&M for Component Support

The new Ecuadorian airline Equair has selected AFI KLM E&M – whose parent companies Air France and KLM trace their roots back to the dawn of aviation – to provide component support for its two Boeing 737 NGs. The multi-year contract includes maintenance, repairs, access to AFI KLM E&M’s spare parts pool, as well as the provision of an advanced stock (Main Base Kit) at the customer’s base at Mariscal Sucre International Airport (Quito, UIO).

Competitiveness, proximity, responsiveness

The services are provided under the 737 Component Services Program (CSP) jointly operated by Boeing and AFI KLM E&M. Through the CSP, the companies say Equair will benefit from the dual expertise of a leading aircraft manufacturer and an MRO-Airline with intimate knowledge of the needs and operational challenges of airlines.

Equair can also count on the scale of AFI KLM E&M’s worldwide network, as well as the long experience of its Amsterdam and Miami workshops on 737 components: their in-house repair capabilities cover the largest part of the component removals on the 737 fleet. Last but not least, the logistical support to Equair will be all the more efficient and responsive as KLM operates daily direct and indirect flights between Amsterdam, Miami and Quito.

The beginning of a valuable partnership

“It is important for us to start our operations with the highest level of quality,” Gabriela Sommerfeld, CEO from Equair commented. “This is why we have chosen a leading MRO solution, which guarantees the availability of parts and thus the availability of our fleet for the benefit of our customers.”

EVP KLM Engineering & Maintenance, Ton Dortmans added: “The creation of a new company is always good news, and we are very happy to welcome Equair among the global air transport family! We are also very honored by the trust they have placed in us to support their components. We are committed to provide the best service to contribute to the success of their operations and the growth of their fleet. This is the beginning of a long-term partnership between our companies, which may one day go beyond the MRO field.”

Delta TechOps MRO Reaches New Milestone with First Rolls-Royce Trent 1000 TEN Engine Service

Last week, Delta TechOps reports reaching a major milestone by completing the first shop visit & test of a Rolls-Royce Trent 1000 TEN engine at its Technical Operations Center in Atlanta. As a powerplant option for the Boeing 787 aircraft operators, the test marks the first production of this model through Delta TechOps’ maintenance facility.

During the shop visit, the engine was disassembled to replace High Pressure Turbine systems and blades, and several reliability improvement Service Bulletins were incorporated. To successfully pass the test, the engine had to meet multiple performance parameters such as thrust, balance and temperatures.

“The successful test of the Rolls-Royce Trent 1000 TEN engine is a great achievement for Delta TechOps, and we’re proud of our world-class team and our Rolls-Royce support partners for their hard work to further our engine programs,” said Mike McBride, Delta’s vice president – Maintenance Operations & Delta Material Services. “This is yet another step that advances our MRO offerings and capabilities, and TechOps will continue enhancing our next-generation engine types for our MRO customers worldwide.”

Prior to the engine visit, many departments within Delta TechOps worked with onsite support partners from Rolls-Royce to complete the first production of this model. In 2020, TechOps team members participated in virtual differences training on the Trent 7000 High Pressure system that reads across to the Trent 1000 TEN model.

“We are delighted to celebrate another key milestone in the engine overhaul capability for the Rolls-Royce Trent 1000 TEN, which adds to the existing portfolio of Trent products within Delta TechOps,” Paul Keenan, senior vice president – Service Delivery, Rolls-Royce said. “The whole programme delivery for this product, which has been during a challenging year due to the pandemic, is a testament to our collective teams’ determination, underpinned by a collaborative partnership focused on supporting our growing Trent fleet.”

Delta TechOps has serviced and repaired Rolls-Royce Trent 1000 Pack C engines for several years and the Trent 1000 TEN model was designed to increase fuel efficiency by improved intermediate pressure compressors. According to onsite Rolls-Royce support partners, the Trent 1000 TEN model possesses a two percent reduction in fuel burns compared to the Trent 1000 Pack C engine.

In October 2015, Delta and Rolls-Royce signed a formal agreement for Delta TechOps to become an Authorized Maintenance Center for Rolls-Royce engines – the Trent 1000, Trent 7000, Trent XWB and BR715. Since then, TechOps has made significant investments to further enhance maintenance capabilities, especially for next-generation engines that feature higher efficiency and less fuel burn. These major projects include the conversion of aircraft hangar bays into a new engine shop, development of a hot section repair shop, construction of the largest MRO test cell in the world and an additive manufacturing shop.

SMS for Small Aviation Organizations: A Brand New, Virtual Course, Offered On-Demand

TACG announced their newest course: SMS for Small Aviation Organizations. An SMS is not a “one size fits all” program. It is scalable to any size aviation organization. This course is targeted toward the smaller aviation organizations that may have limited resources to implement and sustain a functional SMS. This is a self-directed course that can be taken and accessed any time or place that’s convenient for your company and employees, TACG says. More information can be found at http://www.tacgworldwide.com.

Air India Latest Airline to Implement Groundbreaking Jet Engine Cleaning System, GE’s 360 Foam Wash

Following technology trials and aircraft maintenance technician training, Air India is the latest airline to adopt GE’s 360 Foam Wash to help maintain its GEnx-powered Boeing 787 fleet.

Air India previously received a technical license from GE Aviation to use GE’s patented 360 Foam Wash system on its GEnx-1B aircraft engines, and has now industrialized the innovative cleaning system into its maintenance process.

GE’s 360 Foam Wash is an alternative to the water wash method. It helps restore engine performance leading to reductions in fuel consumption. The process involves injecting a specially-formulated, proprietary solution that removes dust and dirt particles in the engine.

“Air India prides itself on our sustained commitment to adopt innovative technology, like GE’s 360 Foam Wash. This will have a significant positive impact on AI’s fuel efficiencies besides curbing the CO2 emission appreciably. In 2022, we expect to attain fuel savings of approximately 230,000 gallons and a reduction of more than 2,200 metric tonnes of CO2 on our fleet of 27 Boeing 787 aircraft, compared to water wash methods,” said Vinod Hejmadi, director Finance, Air India.          

During technology tests with its GEnx engines, the 360 Foam Wash solution allowed Air India to improve engine performance by reducing build-up of deposits in the engine, lowering engine exhaust temperatures, and improving engine compressor efficiency.

The system is self-contained, allowing it to be used inside maintenance hangars or outdoors. GE’s 360 Foam Wash is approved for use on multiple GE engine programs, including models of GE90, GEnx, CF34 and CF6.

Including Air India, seven airline customers have been awarded licenses for 360 Foam Wash.

“GE’s 360 Foam Wash is an example of GE Aviation’s innovative maintenance solutions to help keep our engine fleets flying with improved performance for our customers,” said Vikram Rai, South Asia and Indonesia country leader for GE Aviation. “Air India has always been at the forefront of technological developments, and we are delighted that they will be using 360 Foam Wash technology.”

Rossiya Airlines Awards Contract to VD Gulf for Heavy Checks on Four Boeing 747-400 Aircraft

VD Gulf, a VDT subgroup company and one of the largest independent MRO service providers in the Middle East, is delighted to announce that it has been awarded a contract to conduct heavy checks on four Boeing 747-400 aircraft operated by Rossiya Airlines.

The heavy checks (C-checks) will be conducted by VD Gulf’s highly skilled engineers in Sharjah, UAE, at VD Gulf’s ultra-modern hangar facility located adjacent to Sharjah International Airport.

The first of the four Rossiya Airlines aircraft covered by this agreement arrived in Sharjah in late November.

“VD Gulf highly values its long-standing relationship with Rossiya Airlines. This agreement underscores VD Gulf’s sector-leading capability to conduct heavy maintenance checks on Boeing 747 aircraft, and I would like to thank Rossiya Airlines for once again putting their confidence and trust in VD Gulf,” Ayrat Gilmutdinov, VD Gulf’s Director Commercial, said.

VD Gulf is an independent MRO services provider approved by multiple regulatory authorities offering unlimited maintenance services on Boeing 747-400/-8, 777, 737CL/NG, and Airbus A320ceo family/A320ceo family aircraft.

Rossiya Airlines JSC, part of the Aeroflot Group, is one of Russia’s oldest and largest airlines. The company is headquartered in St. Petersburg, Russia, and operates a fleet of more than 115 aircraft, including nine Boeing 747s and 10 Boeing 777s.

Jamco America Announces Extensive Testing Service Capabilities for Entire Product Design Cycle

Jamco America announced its extensive testing capabilities for a variety of industries including but not limited to: aerospace, automotive, space, defense, and marine product testing. With test facilities that include mechanical properties, static load, fire properties, ballistic, and environmental testing, as well as a complete, FAA-accepted dynamic test facility, Jamco America experts can help companies evaluate products at almost every stage in the design cycle.

Jamco America’s comprehensive dynamic test facility is one of only a small number of FAA-accepted facilities in the U.S. Equipped with an accelerator-type impact system; the facility is capable of testing products in highly specified acceleration profiles. It also includes extensive sensors and data acquisition technology to maximize information generated and processed from each testing profile.

The materials testing lab is ideal for earlier phases in the design process, when it is necessary to evaluate the mechanical properties of new materials, particularly metals and advanced composites. This test facility can evaluate the tensile strength, compression strength, and other key mechanical properties at room temperature and elevated temperature profiles.

Their extensive testing facilities also include fire properties testing, acoustic testing, static load testing, ballistic testing, and product cycle testing to evaluate the lifecycle of a component or assembly. Regardless of the phase of development a customer’s products are in, Jamco America experts can provide extensive testing data for optimizing product performance. In addition to decades of experience in the aerospace industry, individuals on the Jamco America testing team are experienced in product testing and other applications.