Aerospace

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ISO 9001 : 2008 Registered

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WEBER MANUFACTURING TECHNOLOGIES INC.

Precision Tooling for Aerospace Composites

Tom Schmitz

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OverviewFounded in 1962, Weber Manufacturing Technologies Inc. is a leading manufacturer ofprecision tooling for Automotive, Aerospace, and Home/Building Products.

Located in Midland, Ontario, Weber is a privately held Canadian company. Weber offers highquality tooling in steel, invar and aluminum, and precision CNC machined aluminum parts.

Over the last 20 years, Weber has offered nickel shell tooling using the Nickel VaporDeposition (NVD) process. This process is also used for capturing fine surface detail, such asleather and wood grains, and authentically replicating them into hard tools.

140 employees, 135,000 sq. ft. facility

Certified ISO 9001:2008

Canadian Controlled Goods Program registered (Satisfies US-ITAR requirement)

On-site CAD Design capable (UGS, CATIA V5R20)

Modern simultaneous 5-Axis CNC machining centers

Full complement of CNC contour mills, gun-drills, vertical mills, and EDM machines

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Weber offers a range of materials to meet your Tooling requirements

• Invar

• Steel

• Aluminum

• NVD Nickel Shells

• High density foam

• Reinforced epoxy

• Welded fixture construction

TOOLING MATERIALS

Welded Invar 36 tool

Aluminum and Nickel: tools and parts

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• Examples of aluminum or steel matched molds for press molding of interior Aerospace panels

• Ask for the Weber presentation on high pressure SMC tooling or Automotive interior tooling

AEROSPACE APPLICATIONS

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• Nickel tools for high temp Polyamides in F414 engine

• Process at ~300 Celsius (600F)


LAY-UP TOOLING

• Nickel Lay up tools for Black Hawk UH60M

• Weber is a Boeing Approved Tool Supplier

• Nickel tools for B787 leading edge of vertical stabilizer

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TOOLING PACKAGE - BOEING 787300 tools = Lay-up Mold’s, Trim & Drill Fixture’s and Hot Drape Form Tools

(Invar, REN Board and Aluminum)

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KEY MARKET AREAS

TOOLING PACKAGE – HONDA JET

Over 150 Lay-up Mold’s and Trim & Drill Fixture’s (Invar, and Aluminum)

Full design in Catia V5 - from customer part model file – to tool and fixture drawing packages

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FIXTURES and MODELS – DIAMOND JET• Aluminum / REN bond tools, fixtures and prototypes

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• Aluminum prototypes for

• Production assembly fixtures for windscreen

• Welded and machined 407 bonding fixture

• ‘Soft’ Master models

FIXTURES and MODELS – BELL HELICOPTER

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MACHINING FIXTURES

220 Inches

Aerospace Machining Fixture With Vacuum Holding

A2C2 Double Vane Machine Fixture

A2C2 Doublet Bond Fixture

A2C2 Single Vane Machine Fixture

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Machined Aerospace Components

Various Aluminum Components Machined for the Aerospace Industry By Utilizing One Of Our Many 5 Axis CNC Machines

B787 wing components in machined aluminum

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AUTOCLAVE PACKAGESBoeing 717• 24 Lay-up Mold’s in NVD Nickel

• 6 - 8mm thick nickel shells mounted onto steel weldment with adjustable

push/pulls

Bell Helicopter

• 407 Fuselage

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Example of INVAR lay up tool for deep part

CAD design for welding 5 pre-shaped sheets together on frame

Close up of INVAR surface finish quality

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Bell 429

Completed nose cone tool and frame

+120 other tools


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NVD Nickel Lay up tool for high temp Polyimides >300 Celsius (600F process)

Nickel Shell Application

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•No welding of the shell to the frame.

•Perimeter standoffs are pre-machined as round counter-bored blanks and placed on deposition mandrel.

•The shell is placed on the welded frame and screwed into position.

Nickel Shell Design

•Encapsulations for tooling holes

•Encapsulations for vacuum through the shell

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Shell Design - View through side cutout window

NVD Shell

Frame

Push Pull Support

Spot Welded Studs

Vacuum Line

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IP LOWER DRIVER MOLD (M-CLASS)

MIDDLE CONSOLE MOLD (R-CLASS)

FRONT ARMREST MOLD (A-CLASS)

Rate tools in NVD Nickel from 1 Mandrel

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PRESS TOOLING Pratt and Whitney PW4168

• Acoustic Panel SectionsInnovative Weber tool design Multiple parts and steel tools

• Tools mold-in >3700 holesinto the part

• Inspection fixture and preform toolsalso supplied by Weber

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RTM PROCESS – PRATT & WHITNEYPratt F117-PW-100 engine for C-17

•Jet fan splitter•Large round multi-piece tooling •Updated manufacturing process•Reverse engineering to confirm existing drawings•Integrated Oil heated design to eliminate ovens

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RTM PROCESS – PRATT & WHITNEYPratt F117-PW-100 engine for C-17

•Jet fan spinners•Round multi-piece tooling •Updated manufacturing process•Reverse engineering to confirm existing drawings•Integrated Oil heated design to eliminate ovens

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www.webermfg.caRTM PROCESS

• closing an RTM tool with integral cooling lines

OUT OF AUTOCLAVESee separate presentation


www.webermfg.caISO 9001 : 2000 Registered

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NVD OPERATIONS


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• World’s only commercial Nickel Vapor Deposition facility

• Modern, computer controlled plant, built in 2000

• 400,000 lbs annual Ni deposition capacity

• NVD nickel is 99.98% pure

• 1.74m X 3m shell size capacity

• Speed is 0.25mm per hour, 6mm in 1 day.

• Superior process to Electroformed Nickel

NVD NICKEL PRODUCTION FACILITY

Chemically convert nickel to solid shapes

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- NVD shell tooling - high strength and lightweight- Flexible tool design options including:

• Undercut geometry• Encapsulated features for mounting and

location, injection, ejection, shear edges, mechanisms, etc

• Welded shell construction for very large parts- For Multiple Molds, Replicate Cavities:

• Are identical

• Cost less than alternative machining

• Are easy to replace if damaged

• Replacement timing is weeks

NVD SHELL TOOLING FEATURES

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NVD SHELL BASED TOOLING OFFERS…

• Conformal Heating/Cooling -> Faster cycle time• Uniform nickel shell wall thickness -> Improved thermal distribution • Mold release -> Fine grain structure • Mold durability -> 34 – 38 Rc hardness• Weldability –> allows for repairs or joining of multiple shells• Fast Process (0.25 mm/hr) -> ¼” in 1 day !• Reusable mandrel for duplicate shells -> Repeatable accuracy • Short duplicate shell delivery times -> ~ 2-4 weeks• Significant cost savings for duplicate shells • CNC Machined Metallic Mandrels -> Accurate shells, greater part quality• NVD Shells are virtually stress free -> Accurate shells

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Material P20 Tool Steel Aluminum Invar NVD Nickel

Densitylb / in3 0.282 0.098 0.293 0.322

kg / m3 7800 2720 8130 8910

YieldStrength

psi 143000 7980 40000 61400

MPa 990 55 276 411

Stiffnesspsi 30 x 106 10 x 106 21 x 106 17 x 106

GPa 205 70 145 114

ThermalExpansion

in / inoF 7.0 x 10-6 12.9 x 10-6 0.7 x 10-6 7.2 x 10-6

mm / mmoC 12.6 x 10-6 23.6 x 10-6 1.3 x 10-6 13.1 x 10-6

ThermalConductivity

BtuinFt2hroF 201 1452 73 610

W / moC 29 210 11 88

Hardness Brinell 270-480 20-160 120-180 330-380

MATERIAL PROPERTIES

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NVD NICKEL VS ELECTROFORMED SHELL

1. 25mm per 2000 hr deposition rate2. Shell thickness is not uniform 3. Inherent residual stresses4. Cavities made simultaneously from different

mandrels5. Problematic variation from cavity to cavity6. Replace damaged shell in 16-30 weeks7. Cannot do hollow8. Sulfates contamination from electroplating

bath = difficult welding + de-lamination risk

1. 25mm per 100 hr deposition rate2. Uniform thickness & temperature 3. Negligible residual stress 4. Cavities made sequentially from the same

mandrel 5. Little variation from cavity to cavity6. Replace damaged shell in 3 weeks7. Hollow deposition possible in many cases8. 0.999 pure Ni – weldable and no de-

lamination9. No environmental impact (closed system)

Other ApplicationsFor NVD Nickel Shells


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• Weber has produced NVD Nickel Leading Edges for stationary engine vanes

• Outer air surface is created from accurately machined, reusable female metallic master

AEROSPACE COMPONENTS

Examples of Nickel leading edge or erosion strips

0.25mm (0.010”) thickness

NICKEL PART APPLICATIONS

DESIGN & MANUFACTURING


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• Extensive CAD/CAM capabilities• 10 workstations running:

• UG-NX, IDEAS, Catia • Innovative designers are working with customers to

contribute to processes and provide tooling solutions. • Our team manages all information and supports the

machining, assembly and CMM teams.• Strict revision control on all documents and designs.• Part of the Weber focus of building relationships and

responding to customer needs.• CAD data transfer in: 1. STEP, IGES and VDA (BI-DIRECTIONAL) 2. IDEAS NX5 (NATIVE) 3. CATIA V5R20 (NATIVE) 4. UNIGRAPHICS NX6 and NX7.5 (NATIVE ) 5. SOLID-EDGE V20 (NATIVE)

TOOL DESIGN

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PROGRAM MANAGEMENT• On Time deliveries are paramount at Weber.• Manufacturing schedules reviews conducted weekly.• Progress reports are sent to customers bi-weekly.• In House transportation within North America.• Global customs expertise - We export and import responsibly.

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CERTIFICATIONS

• Quality standard is ISO 9001:2008 • Registered with Canadian Controlled Goods Program - Registration No. 22921• CWB W47.1, W59 Welding certificates

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Manufacturing and Mold MakingDepartments

• Weber has a large number of Machining, Fabrication and Assembly bays to suit all the shapes and sizes of your tooling

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Equipment Highlights

• State of the art machining.

• Hypermill 5- Axis software.

• 590 in/min max cutting speed with 8,000-10,000 RPM.

• Machining aerospace parts

Five 5-Axis Deckel Maho Machining Centers

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Ingersoll Master Mill

• 5-Axis simultaneous capable.

• 5 different cutting head attachments. 4,000 -10,000 RPM. All automatically loaded and unloaded.

• Large work envelope

• X-236 inches

• Y-137 inches

• Z-40 inches

• Table capable of taking 88,000 pound block.

• Utilizes HyperMill/PowerMill Machining Software.

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Droop & Rein Copy Mill

• Large load capability -66,000 pounds.

• Twin Spindle –simultaneous mirror image machining capability. Excellent for roughing.

• Large machining envelope

• X- 138 Inches

• Y- 117 Inches

• Z- 33 Inches

• Cutting Software –Powermill.

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CNC GUNDRILLS


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ASSEMBLY BAY SET UP FOR MULTIPLE MOLD BUILDS

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• Tryout Presses

• Wemhoner 3250 ton

• Fully rebuilt in 2005/6

• Steam and Oil Heating capability

• Full vacuum system for molding Class “A” SMC panels

• Ott 500 ton

• Steam and Oil Heating Capability

• Vacuum system

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• 2 Computer Controlled CMM’s• Certification of Models, Tooling Aids, Molds,

Steel & Finished Parts to Math Data• Diffracto Class-A Surface Quality Verification • Certificate of Conformance• Detailed Inspection Reports issued to Customer

QUALITY ASSURANCE

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•REN or epoxy models•Manufacturing of patterns for casting of aluminum face sheet or mandrels

•Aluminum castings can include cast-in-place heating/cooling lines if required

IN HOUSE PATTERN SHOP

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Customers from around the world choose Weber to take advantage of:

1. EXPERIENCE - Over 45 years of mold-making experience producing a wide range of large, class A, custom mold solutions in P20 steel, NVD Nickel, Invar and Aluminum.

2. INNOVATION – Design knowledge gained from experience in various competitive markets is continually applied for new engineering developments.

3. CAPACITY & CAPABILITY – Large, fully integrated Mold Design and Manufacturing Shop can handle large tools, and manage large, multiple tool programs efficiently, and professionally.

4. NVD NICKEL SHELLS – A unique mold making material, NVD nickel shell tooling provides an alternative for rapid, accurate, high quality composite production. Class A surfaces and conformal heating & cooling designs support shorter cycle times and uniform mold face temperatures.

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COMPOSITE CUSTOMERS

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16566 Highway 12P.O. Box 399Midland, ON L4R 4L1 CANADA

DirectMobile:Email:

(705) 527-2976(705) [email protected]

Tel:Fax:Web Page:

(705) 527-2930 [Main](705) 526-3818http://www.webermfg.ca Direct:

MobileEmail:

SALES OFFICES

GERMANYThomas HelleEuropean Sales Agent

Tel:Mobile:Email:

+49 (0) 7021 978 558+49 (0) 171 637 [email protected]

HEAD OFFICE

Tom SchmitzBusiness Manager

(705) 527-2956(705) 527-2154tom [email protected]

Robert SheppardVice President

Greg LeidigU.S. Sales Agent

Mobile:Email:

(416) [email protected] STATES of AMERICA