Current technology projects

The Midlands Aerospace Alliance is running six projects under its Aerospace Technology Exploitation Programme in 2011-12, funded by Advantage West Midlands and the European Regional Development Fund.

Novel materials for springs Project: Aerospring Lead: G&O Springs Partners: Alloy Wire, Reliable Spring Manufacturing, Institute of Spring Technology (research provider), Aero Engine Controls (customer), BAE Systems (customer) Three SMEs – including two regional competitors – have been brought together with the Institute of Spring Technology (IST) to manufacture springs in novel materials such as titanium and various nickel alloys. Data gathered will enable accurate fatigue predictions for springs produced from any of the materials covered.

	New design methods for tyres Project: ATFEM Aircraft Tyres Finite Element Modelling Lead: Dunlop Aircraft Tyres Partners: University of Birmingham (research provider), Airbus (customer) The ATFEM project is a good example of the innovative results that can be achieved with close industrial cooperation. Airbus, the customer, regularly provides input to Dunlop and the research team on the required direction for the FE modeling work and its future directions, enhancing the value of the collaborative effort. So far, modelling has been validated by work on an existing tyre and is set to move on to predictions for new tyres in future aircraft programmes.

Using surfaces as coolers Project: TASC Technology Advancement of Surface Coolers Lead: HS Marston Aerospace Ltd Partners: Advanced Chemical Etching, University of Wolverhampton (research provider), Rolls-Royce (customer) The TASC project led by HS Marston, to model a novel surface cooler to increase the effectiveness of engine thermal management, follows on from developments in diffusion bonding carried out under an ATEP 1 grant. To date a test rig has been built and commissioned and sample test results correlated with computer-generated models. Working with Rolls-Royce as customer ensures that test data is truly representative.

	Coatings without hazardous elements Project: Chrome Free Ipcote Lead: Indestructible Paint Partners: Ashton & Moore, Clean Burner Systems, Messier-Dowty (customer), Rolls-Royce (customer) Removing the hazardous elements from protective engine-surface coatings is the objective of the Chrome-free Ipcote project led by Indestructible Paint (IP). All funded partners are SMEs and are learning new technology development capabilities and project management skills as the project develops with the technical support of ceramics institute CERAM. As well as finding a substitute for the hexavalent chrome in current Ipcote coatings, the project team will require data to support the customer accreditation process and the many end-user accreditations.

Ceramics in aircraft brakes Project: Endurance Braking Lead: Meggitt Aircraft Braking Systems Partners: James Kent Ceramic Materials, CERAM (research provider), Embraer (end user), BAE Systems (end user) In Endurance Braking – a project with wide application in aerospace – SME James Kent and Meggitt Aircraft Braking Systems have been sharing knowledge to try and find an optimum material solution for the friction required at high temperatures. Thermal modelling has started and is being correlated to early test data on new carbon test pieces.

	Manufacturing techniques for novel aluminium alloy Project: A20X Aluminium Alloy Lead: Aeromet, Worcester Partners: Grainger & Worrall, University of Birmingham (research provider), London & Scandinavian Metals, Aero Engine Controls (customer) The Aeromet-led project to develop a novel aluminium alloy A20X with considerable increases in strength characteristics has advanced to the successful casting of a 3,000kg batch of the alloy using production continuous casting equipment. Product demonstrator trials have commenced following chemical, metallographic analysis and mechanical testing of this latest ingot. Simulation modelling of the casting process is also under way, while structural analysis and machining trials will test the extremes of the alloy capability.

ERDF partfunded ADV