GKN overview The global technology partner to the aerospace industry
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GKN AEROSPACE OVERVIEW
GKN plc: Tier 1 Supplier to the major Automotive and Aerospace OE manufacturers
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GKN AEROSPACE OVERVIEW
GKN Aerospace: the global technology partner to the industry
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GKN AEROSPACE OVERVIEW
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GKN AEROSPACE OVERVIEW
The leading global Tier 1 aircraft supplier
Mexico
4 locations
China
2 locations
Landing Gear
Electrical and Wiring
Services
Aerostructures
Office locations
USA
24 locations
Netherlands
7 locations 2 1 1 3
2 2
1 1
India
2 locations 1 1
Romania
2 locations 2
Turkey
1 location 1
Belgium
1 location
Canada
1 location
1
Singapore
1 location
Thailand
1 location
United Kingdom
7 locations
1 3 3
Sweden
3 locations 1
Norway
1 location
1
Germany
1 location 1
Engine Systems
Transparencies
and Special Products
12 2 7 1 2
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1
1
2016 sales
£3.42 billion
Number of employees
17,950
Number of manufacturing
locations
52 in 14 countries
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GKN AEROSPACE OVERVIEW
Leadership in our chosen technologies
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[DOCUMENT NAME]
GKN Aerospace Filton & Western Approach
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GKN AEROSPACE OVERVIEW
GKN Aerospace Filton
Customers
Airbus
Dassault
Triumph
BAE Systems
Programmes: Large Civil: Airbus A320 family, A330, A380, A350XWB, Boeing 787
Military Transport: A400M
Business Jet: Dassault Falcon 5X
Military Fast Jet: Joint Strike Fighter
Investment:
> £40M capital investment since 2009
Approx £25M projected over next 3 yrs
Filton Engineering Centre established
− Over 200 design and engineering specialists
People:
Safety
Employee engagement
Education and Community support
Apprenticeship programmes
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GKN AEROSPACE OVERVIEW
GKN Aerospace - Filton Overview
>1,500 employees > £350M Sales
12 Value Streams
Wing Assembly Wing Systems Components
• Major structural assembly
• Metallic and Composite
• Automated and robotic assembly
• Full system capability – hydraulic,
pneumatic, fuel, anti-ice
• Electron beam welding, automated
robotic welding and assembly
• Large structural and complex parts –
max 6m x 2m
• Hard and soft metal capability
Business Support Capability
• Design - build capability
• Filton Engineering Centre
• Independent quality approvals
• Metrology and conformance engineering
• Additional capabilities through GKN network
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[DOCUMENT NAME]
GKN Western Approach
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GKN AEROSPACE OVERVIEW
GKN Aerospace - Western Approach Overview
GKN’s Centre of Excellence for major
composite primary structure components
Approx £235M invested in new state-of-the-art
composite structures manufacturing and assembly facility
near Avonmouth, Bristol.
Over 30,000m2 of floor space
First Advanced Fibre Placement spar manufacture
– largest composite part in GKN
First Fixed Trailing Edge automated moving assembly
system
Fully integrated product teams working closely with
customer and supply chain
Programmes
A350 XWB Spar manufacture and Fixed Trailing Edge
Assembly
A400M Spar manufacture
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GKN AEROSPACE OVERVIEW
Outer Spar
Mid Spar Inner Spar
A350 Fixed Trailing Edge
3 Spars total over 27m in length with an accuracy of +/- 0.3mm
Total weight of spar carbon is 1230kg/aircraft
FTE assembly weighs 1800kg
The FTE is 7% of total wing weight and supports 10x its own weight
First “large Scale” assembly operation undertaken by GKN
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[DOCUMENT NAME]
GKN Additive Manufacturing Jan 2018
Updated 06 March 2017
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GKN AEROSPACE OVERVIEW
Unrivalled materials, process and manufacturing expertise
Widest range of AM parts flying on seven major platforms
Further components undergone certification trials and awaiting clearance
Significant new investment in large scale deposition now underway
Global ecosystem of excellence centres and AM partnerships
Comprehensive suite of technologies: fine-blown to large-scale
Tier 1 with widest range of capabilities in AM design and manufacture
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GKN AEROSPACE OVERVIEW
[Document Name]
Bristol,
UK
Trollhättan,
Sweden
Oak Ridge
Laboratory, USA
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Radevormwald,
Germany
Cinnaminson,
USA
Process Development
Design and Manufacturing
Powder Manufacture and
Development
AM partnerships in 6
countries
Bonn,
Germany
Global Reach
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GKN AEROSPACE OVERVIEW
GKN AM Strategic Positioning & Differentiation
Vertically integrated: Combining Powder Capability, Process Knowledge, Product Expertise
Global scale: Demonstrated ability to industrialise technology globally
End market access: Leader in Aerospace & Automotive supply chain
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GKN AEROSPACE OVERVIEW
Capable to develop Ti alloy, Al, & Ni
powders optimised for AM
Water & Gas atomising processes
Full technical support
GKN Powder Metallurgy
Titanium Powders for Powder Bed AM
JV with TLS
Production facilities in place in US
Full certified quality management
system
GKN Hoeganaes (Ancor brand)
2nd largest global supplier
25% market share
c. 300,000 tonnes per year
Fe based powder
Global industrial base
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GKN AEROSPACE OVERVIEW
GKN’s Diverse Range of AM Process Capability
LASER
(WIRE)
PICTURE
DESCRIPTION
DEPOSITION POWDER BED
DESIGNATED ICON
TWI
GKN Aerospace
TWI
GKN Aerospace
FINE SCALE DEPOSITION
• Lower material throughput deposition systems
• Focus on Ti and Ni alloys
•Add-ons and features
• High value component repair and modification
• Broad range of medium-size engine and structures components; fabrications
POWDER BED
• Lowest material thru-put
• Ti, Ni and steel alloys
• Nearest-net
• Intricate complex hi-value components
• Low material thru-put
• Ti6-4
• Highly net-shape
• Small – medium prismatics
LARGE SCALE DEPOSITION
• High material throughput deposition systems
• Focus on Ti Large-scale pre-forms
• Initial cost-driven introduction
• Applications including large aero structure components
L L L EB L
APPLICATIONS
Deposition of wire fused using laser
beam in a chamber to produce part
Laser beam selectively fuses
powder on a bed in a chamber to produce
part
Electron beam selectively fuses
powder on a bed in a chamber to produce
part
Deposition of wire fused using laser beam or plasma in a chamber to produce part
Deposition of powder fused using laser and
local shielding to produce part
POLYMER
POLYMER
L
Laser beam selectively fuses powder on a bed
in a chamber to produce part
Deposition of extruded polymer which solidifies in place to previous
layers
•Material thru-put can be high
• Wide range of thermoplastics
• Highly net-shape
• Tooling, RP, components
•Medium throughput
• Nylon
• Highly net-shape
• Tooling, RP, components
Powder / binder system requiring
down-stream consolidation
B
• Higher material throughput than other powder bed
• Ti6-4, Fe
• Not fully dense
• Used for casting moulds
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GKN AEROSPACE OVERVIEW
GKN’s Diverse Range of AM Process Capability
LASER
(WIRE)
PICTURE
DEPOSITION POWDER BED
DESIGNATED ICON
FINE SCALE DEPOSITION POWDER BED LARGE SCALE DEPOSITION
L L L EB L
POLYMER
POLYMER
L B
Radevormwald
Bonn
Trollhatten
Bristol
Oakridge
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GKN AEROSPACE OVERVIEW
AM at GKN – Already in Production
Free Form Deposition (Out Box) Powder Bed (In box) Powder
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GKN AEROSPACE OVERVIEW
Widest capabilities of any Tier 1
Fuselage, wing,
nacelle & pylon
Inflight opening
doors and
empennage
(tails)
Static & rotating
structures
Titanium engine
inlet parts
Transparencies
Ice protection
systems
Flotation devices
Fuel tanks
AEROSTRUCTURES ENGINE SYSTEMS SPECIAL PRODUCTS
Helicopter
landing gear
Composite
load carrying
landing gear
components
(drag brace)
Availability
services, MRO,
conversion and
completion for
mature and
legacy aircraft
WIRING INTER-
CONNECT SYSTEMS LANDING GEAR GLOBAL SERVICES
GLOBAL NO. 2 GLOBAL NO. 2 GLOBAL NO. 1 GLOBAL NO. 3 GLOBAL BRAND
Electrical Wiring
Interconnection
Systems (EWIS)
for aircraft &
aircraft engines
GLOBAL BRAND
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GKN AEROSPACE OVERVIEW
AM Successes - Aerostructures
Papendrecht
Bristol
Isle of Wight
EBM – Proof of concept metal leading edge
EBM, LPB, FDM – Tooling, Jigs, Guides, Proof of
concept parts, Airbus Catcher Bracket,
LPB – Proof of concept Topology Optimisation.
Lattice and Foam development for functional and
structural applications.
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GKN AEROSPACE OVERVIEW
AM Successes – Engine Systems
Trollhättan
Significant opportunities on Engine & Space Components
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GKN AEROSPACE OVERVIEW
AM Successes – Special Products
Kings Norton
Portsmouth
Luton
FDM - Dornier Seat Start Window
Frame
SLS, LPB, EBM – Ice tunnel trailing edge, Acoustic Liner
flight trial, Optical Ice Detection equipment housing Flight trial
LPB, EBM – Floatation manifold
demonstration and development
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[DOCUMENT NAME]
Powder Bed
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
LASER
(POWDER)
LASER
(WIRE)
DEPOSITION POWDER BED
DESIGNATED ICON
FINE SCALE DEPOSITION TROLLHATTAN
POWDER BED FILTON
L L L EB L
LARGE SCALE DEPOSITION ST LOUIS
Example Applications – Powder Bed
Titanium and Nickel
On case-by-case basis can demonstrate significant savings on near-net replacement
Part integration and structural optimization can lead to higher performance and further cost reductions
Functional systems for Acoustic liners or embedded Anti-ice
In Production
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
The Bristol Centre is a substantial R&D capability
focused on powder bed
12 machines across a variety of AM technologies
Electron Beam Melting
Laser Powder Bed
Polymer / Indirect AM (FDM & SLS)
Dedicated Materials Laboratory
In-house Metrology
Working closely with site based conventional
manufacturing techniques
Production cell for series manufacture of Titanium
components using EBM
GKN Additive Manufacturing Centre, UK
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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[DOCUMENT NAME]
Powder Deposition
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
LASER
(POWDER)
LASER
(WIRE)
DEPOSITION POWDER BED
DESIGNATED ICON
FINE SCALE DEPOSITION TROLLHATTAN
POWDER BED FILTON
L L L EB L
LARGE SCALE DEPOSITION ST LOUIS
Example Applications – Powder Deposition
Feature deposition
Modification
Repair
Thermal distortion management/modeling
Ti and Ni capability
In production
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
Laser Powder Deposition application
Modification of a civil jet engine super alloy structure
Production equipment installed at GKN AES in
Trollhättan, Sweden
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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[DOCUMENT NAME]
Laser Wire Deposition
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
Wire Deposition Roadmap
Generation 1 Generation 2 Generation 3
En
gin
es
Air
fra
me
Generation 1 Generation 2 Generation 3
Next Generation
Optimized
Structures
Functionally
Graded
Properties
Net Shape Builds
Proof of Concept
Generation 4
Increased Complexity, Increased Criticality, Reduced Buy:Fly, Increased Process & Property Control
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GKN AEROSPACE OVERVIEW
Equipment – wire fed into melt pool propagated by a laser
beam – enabling accurate near-net deposition of feedstock
LASER
(POWDER)
LASER
(WIRE)
DEPOSITION POWDER BED
DESIGNATED ICON
FINE SCALE DEPOSITION TROLLHATTAN
POWDER BED FILTON
L L L EB L
LARGE SCALE DEPOSITION ST LOUIS
Laser Wire Deposition
Qualified process in GKN AES for bosses and grow-outs
Use in Space systems
Ti and Ni capability
In Production
Deposition of a boss or grow-out
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
LASER
(POWDER)
LASER
(WIRE)
DEPOSITION POWDER BED
DESIGNATED ICON
FINE SCALE DEPOSITION TROLLHATTAN
POWDER BED FILTON
L L L EB L
LARGE SCALE DEPOSITION ST LOUIS
Laser Wire Deposition
Process Development for non round structures
Big and heavy –
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
AM Laser wire (free form fabrication) capability in Ti6Al4V
Total weight per box is 18 kg
Buy to fly ratio 1.1:1 shown
The information in this presentation is proprietary and confidential
and shall not be disclosed to or used by a third party unless
specifically authorised by the relevant GKN plc group company
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GKN AEROSPACE OVERVIEW
Summary
AM is a strategic priority for GKN Group
− Already in qualified production in multiple materials, processes and applications
GKN is uniquely positioned as a potential AM partner
− Vertically integrated: Powder to Part
− Multiple AM processes in production
− Established AM network
− Global industrial footprint
− Key end market applications in multiple sectors