GKN Technology:

Leading the way toward more efficient aircraft

Ashley Brooks - Manuela Cassissa - Susanna Halls | 17th July 2014

GKN Technology
Making things fly

GKN Technology: Leading the way toward more efficient aircraft

2

GKN PLC: Delivering to our markets

We have four operating divisions: GKN Driveline and GKN
Powder Metallurgy that focus on the automotive market; GKN
Aerospace, and GKN Land Systems. Every division is a market
leader, each outperforming its markets, giving unrivalled expertise
and experience in delivering cutting-edge technology and
engineering to our global customers:

GKN Aerospace
A leading first tier supplier to the
global aviation industry focussing on
aerostructures, engine systems and
products and specialty products.

GKN Driveline
A world leading supplier of
automotive driveline systems
and solutions, including
all-wheel drive.

2013 - Sales by division

104m
Other
1%

899m
Land
Systems
12%

GKN Powder Metallurgy

The worlds largest manufacturer of
sintered components,
predominantly to the automotive
sector.

3,416m
Driveline
45%

2,243m

Aerospace
30%

GKN Land Systems

A leading supplier of technologydifferentiated power management
solutions and services to the
agricultural, construction, industrial
and mining sectors.

Powder
Metallurgy
12%

932m

GKN Aerospace
$3.5 billion Global Aerospace company, 35 sites in 9 countries, 11,700 people
Market leaders in airframe structures, engine components and transparencies
Increasing investment in technology and focus on deployment
Growing global footprint as part of drive for increasing competitiveness

GKN Aerospace World class Product Portfolio

Aerostructures Global #3

Engine structures

45% of Sales 2013

50% of Sales 2013

Wing

Fuselage

Nacelle and
Pylon

Global #2

Engine Systems and Services

Engine structures

Engine rotatives

Special
products

Global
#1/2
5% of Sales 2013
Transparencies
and Protection
Systems

J-UCAS Fuselage

A380 Fixed Trailing Edge

B747-8 Exhaust
B787 Anti-icing System

A350XWB Rear Spar

CH53K Aft Fuselage

A400M Engine Intake

V22 Fuel Tanks

A330 Flap Skins

B787 Floor Grid

B767 Winglet

HondaJet Fuselage

B787 Cabin Windows

B787 Inner Core Cowl

Full Engine MRO and support

Ariane 5 Exhaust nozzle

F35 Canopy

A Broad Customer Base

Military 27%

Civil 73%

2013 Sales

Targeted Innovation Technology

Engine
Statics

Engine
Rotatives

Future Wing
Technologies

Advanced
Fuselage

Composite Technology
Metallic Technology
Supporting Technology

Nacelle,
Pylon &
Exhaust

Transparencies Protection
& Coatings
Systems

The Challenge
Contemporary aviation objectives

GKN Technology: Leading the way toward more efficient aircraft

8

The Industry Drivers

Fuel cost
Operating costs
Emissions
Aircraft noise
Passenger volume and travel trends

Source: http://mashable.com/2014/03/14/visualization-air-traffic/

Industry Response
Improve engine
efficiency

REDUCE FUEL
CONSUMPTION

Optimise
missions

Reduce
drag

Remove
bleed air
systems

Engine
technology

Reduce
weight

More Electric
architectures

Reduce systems /
wiring weight

Increase use
of composites

Low-drag
surfaces

Reduce
power
consumption

Composite
manufacturing
technology

Systems
integration with
composites

Advanced
Manufacturing

10

Advanced
aircraft
designs

Technology Focus at GKN Aerospace Luton

Improve engine
efficiency

REDUCE FUEL
CONSUMPTION

Optimise
missions

Reduce
drag

Remove
bleed air
systems

Engine
technology

Reduce
weight

More Electric
architectures

Reduce systems /
wiring weight

Increase use
of composites

Low-drag
surfaces

Reduce
power
consumption

Composite
manufacturing
technology

Systems
integration with
composites

Advanced
Manufacturing

11

Advanced
aircraft
designs

GKN Aerospace Luton Products

Images: Various sources please see the end of presentation

12

Aircraft Icing
Why ice protection systems are important

GKN Technology: Leading the way toward more efficient aircraft

13

Aircraft Icing Effects

Disturbs airflow: increases drag, reduces lift and results in unpredictable handling
Increases weight and changes weight distribution: unwanted vibrations and trim
adjustments
Engine issues: ice accretion can reduce thrust and cause blockage
Ice accretion is partly determined by surface geometry leading edges most at risk

14

Icing Conditions

Ice accretion on surfaces is proportional to amount of

supercooled liquid water present
Largest droplets are found just below 0C
Certain cloud types (tall) present highest risk

15

Icing-Related Accidents

16

Types of Aircraft Ice

Protection

GKN Technology: Leading the way toward more efficient aircraft

17

Avoidance of Icing Conditions

Aircraft without IPS (Ice
Protection Systems) must
avoid icing conditions if
possible
E.g. Dont fly in poor
weather
E.g. Find the shortest route
through a weather front or
divert away

Descend/ascend is
sometimes best way out

Modern commercial/military aircraft need IPS to maintain practical operational

capability

18

IPS (Ice Protection Systems)

Switched on once ice

accretion is detected

Actuates the
surface in order to
loosen/shed ice

Pneumatic
Expulsive
Electric

De-Ice
IPS

Heated
Hot gas

Anti-Ice
Switched on once
icing conditions
are detected
Elevates surface
temperature so that
ice is melted or shed

Passive
Coatings
Make the surface
icephobic

19

Hot gas or bleed air

systems are common on
existing large aircraft
Wing leading edges
Engine intakes and
splitters/guide vanes

Pneumatic expulsive
systems (inflatable
boots) are common on
smaller aircraft with small
power budgets
De-icing/anti-icing
chemicals are commonly
applied when aircraft are
on ground in cold
climates

Traditional Wing Leading Edge and Engine De-Icing

Traditional architecture for large jet aircraft is for hot gas (bleed
air) to be used for wing anti-ice
Valves control flow of bleed air from the engines along the wing
Network of piccolo tubes distribute heat evenly
Spent gas is exhausted through holes on wing underside

Reduces engine efficiency

Exhausted gas contains wasted energy
Also generates drag and noise
Limited control of temperatures

Typical Bleed-Air De-Icing Arrangement

20

Electro-Thermal Ice Protection

Need for fuel, noise and efficiency savings is driving industry to adopt electric ice
protection to a greater extent
Pneumatic

Electric

Hot gas

CHALLENGES

Coatings

Significantly increases
aircraft electric power
demand
Requires aircraft with more
electric architecture

Expulsive

De-Ice
IPS

Heated
Anti-Ice
Passive

21

ADVANTAGES
Reduces energy waste
Precise heat distribution
Hybrid anti-ice/de-ice
Eliminates a source of drag
and noise (bleed air
exhausts)

A More Electric Aircraft Architecture

Standard aircraft
A mix of electrical, pneumatic
and hydraulic power demand

More electric aircraft

Emissions reduction
Fuel savings
More efficient
More versatile
Lighter structure
Aircraft Diagrams. Source: Courtesy of GKN Aerospace.

22

Boeing 787 GKN Wing Ice Protection System (WIPS)

First large commercial airliner to adopt this type of technology

Supports a significant step change to an electric aircraft architecture in order to achieve
fuel savings

Images Source: Courtesy of GKN Aerospace.

23

Heating a Composite Wing

Thermal environment of a lightweight structure

GKN Technology: Leading the way toward more efficient aircraft

24

Heated Aircraft Surfaces Thermal Environment

Aluminum Leading Edge

Carbon/Epoxy Composite

Heat transfer from surface to moving air

Desired surface temperature e.g. 60C

Desired surface temperature e.g. 60C

Material limit e.g. 500C

Good thermal conductor

Structure heats up less for given

surface temperature

Large amount of material thermal

headroom

Material limit typically <180C

25

Poor thermal conductor

Structure heats up to greater extent

Tight on thermal limits of material

Heated Composite Components Design Aims

We need to:

Carbon/Epoxy Composite

Avoid overheating the composite

Maximise efficient heat transfer to

the surface

Desired surface temperature e.g. 60C

Therefore we need:

Careful selection of polymer

matrix materials
Heat source as close to the
surface as possible

Material limit typically <180C

Robust and accurate control over

the heat source
Extremely difficult to achieve with
air bleed/hot gas systems

26

Heated Composite Components Design Aims

We need to:

Electro-Thermal Heating

Avoid overheating the composite

Maximise efficient heat transfer to

the surface

Electric heaters are a good choice

because we can:
Deliver a precise amount of power
Vary the amount of power
delivered to different areas of the
surface or structure
Occupy a very thin layer with the
heater
Get heat source very close to the
surface

Therefore we need:

Careful selection of polymer

matrix materials
Heat source as close to the
surface as possible

Robust and accurate control over

the heat source
Extremely difficult to achieve with
air bleed/hot gas systems

27

GKN Aerospace Heater Mat

Technology
Integrated within composite structures

28

GKN Aerospace Heater Mats

Unique application of
thermal spray
Automated process
Controlled electrical
properties for desired
heat output on a local
scale

Thermal spray
conductors
Film
adhesive

Applied directly to
complex shape
components
Heater encapsulated
within composite
material
Structural or passive

Erosion
protection thin
metal

Bell V-22 Osprey Engine

Intake

Compatible with
multiple types of
composites
manufacturing
processes

Film adhesive
(if needed)

GRP basecoat and

topcoat dielectric
composite layers

AW101 Main Rotor Blade

Images Source: Courtesy of GKN Aerospace.

29

Small and large

components

Coatings

More than just aesthetic appeal..

GKN Technology: Leading the way toward more efficient aircraft

30

An Introduction to Functional Coatings

Functional coatings are found everywhere on modern technology. They can serve a variety of purposes,
be it to protect a surface from damage through scratches or transitioning to different colours depending
on light intensity levels or just to improve their appeal. Functional coatings can be used to add value to a
product by increasing the products longevity or giving the product a desirable characteristic.

Functional Coating Examples:

Waterproofing
Self-cleaning
Damage protection
UV Protection
Scratch resistance
Non-stick

[3]

[2]

[4]

31

[1]

An Introduction to Coatings in Aerospace

Coating / Paint Example Locations:
Fuselage
Cabin Windows
Cockpit Windows
Aft of Leading Edges

Paint Systems:
Protection from
Erosion,
Airline Insignias,
Aesthetic Appeal

Images Source: Courtesy of GKN Aerospace.

32

Functional Aerospace Coatings

Icephobic Coatings:
Reduction in ice accretion,
Reduction in power requirement for
IPS,
Could be placed in areas with no
active IPS

Images Source: Courtesy of GKN Aerospace.

33

Functional Aerospace Coatings

Low Drag Coatings:
Could be located anywhere where
drag performance is a factor.
Reduction in fuel consumption.
Aids laminar wing concepts.

Images Source: Courtesy of GKN Aerospace.

34

Functional Aerospace Coatings

Composite Damage Detection:
Could be located anywhere at risk of impact
damage; hail, ground support equipment
and runway debris
Increase in confidence of visual inspection
processes, potential reduction in tolerance
requirements leading to lighter aircraft.

Images Source: Courtesy of GKN Aerospace.

35

GKN Aerospace Functional Coatings Technology

Images
Source:
Courtesy
of GKN
Aerospace
.

36

Functional Coatings Technology Example: Anti-Ice

What are Anti-Ice Surfaces?:
Anti-ice surfaces are surfaces that shed ice or reduce likelihood of ice accretion
Such surfaces can be classed as; non-stick, non-build, thermal transfer, or a combination
Images Source: Courtesy of GKN Aerospace
thereof

Non-Stick
Ability of ice to adhere is vastly
reduced

Non-Build
Ice crystal growth is disrupted
preventing growth of ice layer

Coatings subjected to icing conditions

and electro-expulsive tests.

Pictorial representation of non-build

surface structure .

37

Thermal Transfer
Surface can be heated or
transfer heat energy from a
heating source

Anti-Ice Coating Technology

Benefits of Anti-Ice Coating Technology:
Reductions in the power requirements of the ice protection system used:
electro-thermal, electro-mechanical or bleed air

It can also be useful on parts where ice protection systems cannot be utilised, yet are still at
risk from ice accretion

Applications for the Technology:

Wings (leading edge and areas aft of leading edge)
Engine components (fan blades, spinners, splitters and guide vanes)
Images Source: Courtesy of GKN Aerospace

Technology Development Approaches:

GKN Aerospace is in the process of developing icing / ice adhesion test equipment and a
predictive model, expanding the understanding of how ice accretes and sheds from
different surfaces. These also act as tools to enable rapid development and testing of novel
coating solutions.

38

Functional Coatings Technology: Low Drag

What are Low Drag Coatings?:
Low drag coatings are surfaces which assist with reduction in drag (increased time to
turbulence) of the structure to which they are applied
This can be achieved by appropriate structure, chemistry, uniformity and cleanliness
Images Source: Courtesy of GKN Aerospace

Power
coated
composite
still
showing
fibre
texture
Surface profiles of super smooth
and structured coatings

Primered
then
topcoated
aluminium
panel

An example of the spray

application process

39

Low Drag Coating Technology

Benefits of the Technology:
Assist with enabling laminar concepts to be met when combined with appropriate structures
Can reduce fuel consumption by a significant (measureable) amount. Even 1% fuel saving
would be a great benefit

Applications for the Technology:

Any aircraft surface where turbulent flow is a significant risk, examples include engine fan
Images Source: Courtesy of GKN Aerospace
blades, wings and winglets

Technology Development
Approaches:
GKN Aerospace is studying the
effects of various factors that are
thought to affect drag performance of
surfaces, with the intent of
generating a predictive model to
guide development
Also GKN Aerospace has developed
substrate preparation and application
processes which will enable desired
characteristics to be achieved

40

Functional Coatings Technology:

Composite Impact Damage Detection Coatings
What are Composite Impact Damage Detection Coatings?:
These are smart coatings which when applied to a composite surface will provide an
indication/ signature of an impact event identifying the surface area impacted and the
associated energy transferred
This is achieved by the addition of microcapsules of various strength levels to already aircraft
certified paints. The microcapsules contain unique dyes, the signatures of which can be
Images Source: Courtesy of GKN Aerospace
detected utilising suitable light source inspection equipment
Before Impact Event

After Impact Event

Microscope photographs of microcapsules as made (not dispersed into

a paint system)

41

Exposed to
UV Light

Composite Impact Damage Detection Coatings

Images Source: Courtesy of GKN Aerospace.

Benefits of the Technology:

There are a variety of scenarios
where impacts to aircraft occur,
some of which may cause
damage to the underlying
composite such that a repair will
be required and others such
that the part would need to be
replaced
In many incidents damage
which causes a structural risk
can be very difficult to see
based on standard visual
inspection

Examples of potential impact damage sources

This technology therefore, could reduce the risk of aircraft flying with structural damage and
enhance the efficiency and accuracy of the inspection process
In the long term, such technology may also enhance the understanding of the behaviour of
composite structures and enable further weight reduction through reducing the number of
plies in a composite part

42

Composite Impact Damage Detection Coatings

Applications for the Technology:
Any composite part of an aircraft that is susceptible to an impact event, such as fan blades, radomes
and doors or even wing skins

Images Source: Courtesy of GKN Aerospace

Technology Development Approaches:

Microcapsules of various wall thicknesses and
chemistries synthesised with simultaneous
incorporation of fluorescent dyes, signatures of
which appears in response to incident light with
wavelengths outside of the visible spectrum.
Evaluation of impact performance with regards
to intensity and wavelength of fluorescence
emitted.

Photograph of signal
under UV light exposure.

43

Coating Technology Summary

Coatings are able to provide more than just aesthetic appeal
By incorporation of functionality, coatings can assist with achieving:
reduced power requirements of aircraft, such as reduced energy consumption from ice
protection systems
increased confidence in composite technology, through the use of damage detection
microcapsules

reduced fuel consumption by the development of low drag coatings for composites and
metallic surfaces

Images Source: Courtesy of GKN Aerospace.

44

Development Focus

GKN Technology: Leading the way toward more efficient aircraft

45

The Development Process

Interact with customers

Interact with suppliers

Develop new concepts
Test new technologies

Create marketable ideas

Improve current products

Source (clip): http://www.gkn.com/aerospace/technologyandinnovation/Pages/coatings1.aspx/

46

Developing New Solutions

Developing new technologies
Developing a concept

Creating a strategy
Funding
Filling the market gap
Evaluating demand

Testing the idea

Preliminary tests
Rapid prototypes

Testing for certification

Repeatability
Reliability
Manufacturability
Source: Microsoft Office Clipart

47

The Development Process: International Teamwork

Testing
standards

Testing houses
Engineering
Institutions

CATAPULT
centres

Environmental
Agencies

GKN Sites
Worldwide

Government
Institutions

Universities
Source: Microsoft Office Clip Art Images

48

GKN Aerospace Luton Development Focus

Integration of highly functional components and assemblies
Integration with morphing leading edge technology
Application for GKN Aerospace flexible heater mat technology
Challenge: fatigue and damage tolerance of surrounding structure
vs flexibility

Combination of ice protection and acoustic liner technology

in the same complex component
GKN Aerospace Clean Sky scoop intake is on display at
Farnborough Innovation Zone, Hall 4 Stand 4/IZ/B10

Integration of advanced coatings e.g.

Composite structures which indicate damage events

Drag reduction coatings
Self-cleaning coatings
Icephobic coatings

Development of highly accurate, smooth and stable

structures for ultra low drag flight
All of the above?
Images Source: Courtesy of GKN Aerospace

49

GKN Aerospace Luton Development Focus

Reduced power demand of ice protection systems

Improve thermal heat transfer in the right direction

through the structure
New materials manufacturing processes

Combine electric heating with passive techniques

such as icephobic coatings
Improve the use of ice detection to further optimise
power usage
Current instruments measure ice or no ice in the wrong
place on the aircraft (fuselage)
GKN has developed and flight tested an optical ice
detector which fits inside any aerodynamic surface
Measures ice thickness, and could measure type of ice
also
Images Source: Courtesy of GKN Aerospace

50

GKN Luton Development Focus

Manufacturing costs and capacity

Recent programmes (Boeing 787, A350 XWB) have

indicated a higher rate environment for aerospace
manufacturing
Advanced technology is only exploitable if it can be
manufactured cost-effectively
Various technology strands being integrated into
GKN Aerospaces next generation of ice protection
heater mats:
Selection of composite processes
Avoid long autoclave cycles, step change in process
times
Relax/remove out-life and storage controls for materials
Automation e.g. robotic lay-up, element application and
roll-to-roll manufacturing
Modular assemblies with common components across
multiple design configurations
Images Source: Courtesy of GKN Aerospace

51

Conclusions
Advanced technology is needed by the aviation industry in order for it to respond to the
industry drivers
Within GKN Aerospace, and by collaboration with partners, suppliers and customers, new
technology is being developed and matured to meet these needs
At GKN Aerospace Luton, the development and manufacture of new ice protection
systems and novel functional coatings represent niche technologies with which have far
reaching benefits to the overall aircraft
These technologies can provide complete technological solutions to complex problems, to
achieve this we work closely with all levels of the supply chain
New ice protection systems and niche functional coatings are a part of the wide array of
technology strands currently being developed across the global GKN Aerospace
organisation

52

Thank you
Thank you for listening

Any Questions?

Manuela Cassissa

Susanna Halls

Ashley Brooks

IPS Development Engineer

Coatings Projects Lead

IPS Lead Project Engineer

(manuela.cassissa@gknaerospace.com)

(susanna.halls@gknaerospace.com)

(ashley.brooks@gknaerospace.com)

53

References
Slide 12: Heater mat. http://www.compositesworld.com/articles/787-integrates-new-composite-wing-deicing-system
Slide 12: Aircraft. Source: http://www.gkn.com/aerospace/products-and-capabilities/Pages/default.aspx
Slide 12 Cockpit window: http://www.gkn.com/aerospace/products-and-capabilities/transparencies/windshield-cockpit-windows/Pages/default.aspx
Slide 12: Cabin window: http://www.gkn.com/aerospace/products-and-capabilities/transparencies/passenger-cabin-windows/Pages/default.aspx
Slide 12: Scoop and NACA duct. Source: Courtesy of GKN aerospace.
Slide 14: Image source: AOPA Air Safety Foundation Air Safety Advisor SA11, Weather No. 1 (2008)
Slide 14: Image source: http://www.woodardfamily.com/nonplane/airbusice.htm
Slide 15: Source: Hazardous Weather Phenomena Airframe Icing Bureau of Meteorology, Commonwealth of Australia, Feb 2013
Slide 18: Image source: AOPA Air Safety Foundation Air Safety Advisor SA11, Weather No. 1 (2008)

Slide 31:[1] http://www.creativematch.com/news/hi-tech-launch-revolutionary-new/96558/

Slide 31: [2] http://www.angusmcphie.co.uk/pages/tints.htm
Slide 31: [3] http://www.european-coatings.com/Raw-Materials-Technologies/Applications/Automotive/Photodegradation-of-multilayer-automotivecoatings-tracked-in-detail
Slide 31: [4] http://www.vtt.fi/service/oled_and_photovoltaics.jsp?lang=en
Slide 50: Source (top image): AMT Airframe Handbook, Chapter 15, Federal Aviation Authority

54