Day 1: Wednesday, September 10, 2014  


Wednesday, September 10, 2014
  • 8:00 – 9:00: Registration and Coffee
  • 9:00 – 9:15: Welcome Address
  • 9:15 – 10:05: Keynote Presentation
  • 10:05 – 12:00: Conference Sessions
  • 12:00 – 1:30: Lunch and Keynote Address
  • 1:30 – 5:30: Conference Sessions
  • 6:00 – 8:00: Networking Reception at the House of Blues
Thursday, September 11, 2014
  • 8:00 – 9:00: Registration and Coffee
  • 9:00 – 9:15: Welcome and Conference Details
  • 9:15 – 10:05: Keynote Presentation
  • 10:20 – 12:00: Conference Sessions
  • 12:00 – 1:30: Lunch and Keynote Address
  • 1:30 – 4:15 Conference Sessions
  • 4:15 – 5:30: Questions & Cocktails
8:00-9:00 Registration and Coffee
9:00-9:15 Welcome Address
Adrian Allen, Commerical Director, The AMRC
9:15-10:05 Keynote: The Future of Advanced Aerospace Composite Materials (view abstract)
Dr. Greg Hyslop, Vice President and General Manager, Chief Engineer, Boeing Research & Technology

Strong, lightweight and adaptable composite materials have become the material of choice for a wide range of products – from golf clubs to automobiles to aircraft.  The combination of a rapidly expanding world wide commercial fleet along with the breakthrough performance capabilities that composites bring to both commercial and military aerospace products has resulted in the overall tremendous growth in the application of composite materials in aerospace.  For example, while composite materials accounted for approximately 10 percent of the structural weight of the Boeing 777, this percentage has grown to over 50 percent of the Boeing 787.  The future of advance aerospace composites will continue on this dual focus on both optimizing composite material systems for quality and cost as well as on specialized and multifunctional performance applications. Focusing technology investments on future needs translates into extreme affordability in development, production, operations and support; breakthrough performance to meet the customer needs; enduring sustainability and being environmentally responsible.

10:05-10:30 New Uses for High Speed Electro Erosion (HSEE) (view abstract)
Scott Walker, President, Mitsui Seiki

Join Mr. Scott Walker, President of Mitsui Seiki USA, as he relays valuable information about the machine tool requirement to apply HSEE successfully and efficiently to titanium aerospace structures, jet engine components, and power generation parts. Thermal events are more intense and widespread than conventional EDM processes and are controlled by the applied potential and current, the electrolyte, and the distance between the tool electrode and workpiece. Each thermal event erodes some of the workpiece resulting in bulk material removal. Under most conditions the contact forces between the electrode and the workpiece surfaces are negligible enabling the use of slender electrodes or light duty machines. End milling, peripheral machining, and shaped electrode profile machining have been studied. In this seminar, machining results will be shared for nickel based superalloy and titanium alloy rough machining. In each case material removal rates 2-3 times the conventional analog for similar size tooling was achieved.

10:30-10:45 Coffee Break
10:45-11:10 Harnessing New Technology and Opportunities
Bill Smith, Director of Technology Development, Spirit Aerosystems
11:10-11:35 Super Plastic Forming for Aerospace (view abstract)
Andries Buitenhuis, Chief Engineer, Fokker Aerostructures

Over the last 25 years, Fokker Aerostructures has applied thermoplastic materials for a wide range of aircraft structure applications with increasing complexity and structural significance. Starting with nonstructural applications like the Fokker 50 Main Landing Gear door and Fokker 100 bagage floor panels, via control surface ribs and the Airbus A340 / A380 ‘J-Nose’ wing fixed leading edges, to completely thermoplastic induction welded elevators and rudders currently in service on the Gulfstream G650. The next step to horizontal stabilizers is currently in progress, including some applications on helicopters. The presentation will focus on some of the unique properties of thermoplastics like the improved damage tolerance / impact resistance and through-the thickness strength as well as on the novel production and assembly techniques enabled by thermoplastics like press-forming, ultrasonic or resistance welding, co-consolidation and induction welding. Certification aspects will be covered as well.

11:35-12:00 The Impact of New Trends in Machining Technology and the Effect on the Manufacturing of Aerospace Components (view abstract)
Michael Standridge, Aerospace Industry Specialist, Sandvik Coromant

Machining the materials designed into complex aerospace components can be challenging and expensive. Making the proper investments into manufacturing to assure increased capacity and more efficient processes is critical for success. Trending technological advancements in exotic materials such as metal matrix- ceramic composites coupled with the use of new manufacturing methods, such as additive manufacturing, laser assisted machining, and cryogenic coolant systems will impact machining methodology and cutting tool technology, but in what way exactly? What are the pros and cons of investment into these new technologies and what will the effect be on the current way we machine aerospace components.

12:00-1:30 Lunch and Keynote Address: Why Materials and Manufacturing Matter. A Test Pilot’s Perceptive
Ricardo Traven, Chief Test Pilot - F/A-18 Programs, Boeing Test and Evaluation
1:30-1:55 Measurement Systems to Automate Aerospace Inspection and Assembly Processes (view abstract)
Lester Glover, VP Key Account Business Development, Hexagon Metrology, Inc.

With the significant increases in demand for aircraft, the aerospace industry is increasingly turning to automation to improve efficiency in all areas of production. Application of automated measurement technologies to aerospace quality and assembly workflows are being used with increasing frequency.  This presentation will discuss methods to improve productivity of inspection by using robotic carriers for automated inspection systems.  Also discussed are techniques to employ a metrology device for improvement of the absolute accuracy of a robotic system, for high precision guidance of large scale fixtureless assembly applications.  Real world case studies and concept systems demonstrating the application to real-world aerospace production processes and the resulting improvement in productivity and efficiency will be presented.

1:55-2:20 Future of Aerospace Manufacturing - ‘Breaking the Code’ (view abstract)
Colin Sirett, Head of Research & Technology Business Development, R&T National Representative, Airbus

In the last 10 years the global demand for air travel has increased by 45%. This growth spanned a period where we have seen the attack on the World Trade Centre, SARS outbreak and Financial Crisis. The Air Travel market has shown itself to be quite resilient in times of adversity, so much so that the forecast is for todays’ demand to double in the next 20 years.  Such growth cannot be unconstrained and the industry must demonstrate an environmental and social responsibility.  As with all industries that contribute towards the man-made CO2, aerospace and aviation must reduce its environmental footprint. But, as the price of oil has escalated, this has created a symbiotic relationship between reducing emissions and the airlines cost of operation. By burning less fuel there is both a reduction in emissions and cost.  ‘Breaking the Code’, is how can we reduce the cost of operation for the airlines, and at the same time enable all parties in the supply chain to generate ‘double digit’ returns for their stakeholders.

We must,

  • Use less material in the production of aircraft.
  • Apply lighter materials.
  • Reduce the cost of machining, and forming
2:20-2:45 The Evolution and Practical Application of STEP-NC (view abstract)
Jim Kosmala, Vice President of Engineering and Technology, Okuma
David Odendahl, Associate Technical Fellow , The Boeing Company

Boeing and Okuma will share their experiences in technology leadership with a new implementation of the STEP-NC ISO standard. Commercially available implementations, such as STEP Explorer, act as a universal CAM translator, similar in some ways to what MTConnect does for data transfer. This allows end users to leverage multiple tooling suppliers using a variety of CAM packages that provide optimized cutting paths resulting in reduced cycle times and increased tool life by taking advantage of the latest in tooling technology. These optimized tool paths can be incorporated into one STEP-NC file that retains process knowledge, not just the axis motion of G-code, for:

  1. Portability or transfer of operations from one plant to another
  2. Process retention, i.e., storing the process for future manufacturing use
  3. Evaluating suppliers and solutions.

Attendees will walk away with a better understanding of STEP-NC, its evolution and role in the programming environment, and its practical applications.


2:45-3:00 Coffee Break
3:00-3:25 Residual Stress in Inconel 718 (view abstract)
Dr. James Hughes, The AMRC

Nickel-based, Heat Resistant Super Alloys are used extensively in the hot sections of gas turbine engines for critical components, due to their high strength and thermal resistance. Unfortunately, the attractive properties of these alloys can affect tool life and cause metallurgical damage of the workpiece during machining. Control of material surface condition and residual stresses is therefore key during the finish machining of critical components to ensure the predicted service life is met. In James’ presentation he will review the relationship between developing tool wear and workpiece residual stress.

3:25-3:50 Advances in Metrology Assisted Manufacturing (view abstract)
Tarquin Adams, Group Communications Manager, Renishaw

Metrology remains fundamental to aircraft production as aerospace manufacturing operations demand increased capability, extra global production capacity, and shorter times for development and introduction of new products and processes. The introduction of new materials and manufacturing methods requires validation of processes and parts. Tightly toleranced features often necessitate rigorous inspection of production parts for quality assurance.

The presentation will show how new developments in metrology enable significant enhancements to the control of machining processes, robust and versatile shop floor gauging and radical reduction of inspection cycle times. Amongst other things, it will demonstrate the use of on-machine contact scanning to achieve exceptional accuracy in turned diameters and a solution for rapid inspection of cooling holes found in engine combustor casings and nozzle guide vanes. It will also show automated alignment of blade parts during both manufacturing and inspection cycles and include a look ahead at Renishaw’s involvement in additive manufacturing for aerospace applications.

3:50-4:10 The Billion Dollar Solution (view abstract)
Nadia Alberti, Alberti Umberto

Nadia will discuss and present novel approaches to overcoming the challenges surrounding hole accuracy and rate in the ever expanding aircraft production/assembly environment.

4:10-4:20 Coffee Break
4:20-4:40 Business Innovation: From Bushveld to Aerospace (view abstract)
Rich Ward, President, WARDJet, Inc.

There are unlimited opportunities for innovation and success for those willing to think outside of the box. Learn how Richard Ward went from constructing unconventional ‘roll-crete' dams between mountains in Africa, to moving to the U.S. and building a global waterjet company out of his home garage. Today, WARDJet is in a 220,000 square foot facility and Richard’s machines are the preferred cutting means in a host of leading aerospace companies worldwide.  Richard’s inspiring message and practical knowledge will encourage you to reach beyond your comfort zone to see new opportunities.

4:40-5:05 The Reality and Challenge of Machining Complex Monolithic Aerostructures (view abstract)
Mark Wilson, Head of Manufacturing Research and Development, BAE Systems

Aerospace Machining of Airframe details has progressed considerably in the last 30 years allowing great strides to be made in the design and manufacture of lightweight and highly accurate airframes. As we continue to push the boundaries we are continually presented with challenges to overcome from reducing cost, right 1st time quality, reducing lead times & environmental legislation. We will look at how far we have come and what the current challenges are that need to be addressed for large unitised parts.

5:05-5:30 Friction Stir Welding – A Perspective on the State-of-the-Art and Technology Challenges
Tracy Nelson, PhD, Mechanical Engineeing, Brigham Young University
6:00-8:00 Networking Reception at The House of Blues

Day 2: Thursday, September 11, 2014

8:00-9:00 Registration and Coffee
9:00-9:15 Welcome and Conference Details
Don Kline, Vice President, Gardner Business Media
9:15-10:05 Keynote Address: Driving Success through Intellectual Property Collaboration (view abstract)
Peter Hoffman, Vice President, Intellectual Property Management, The Boeing Company

Innovation often occurs in isolated pockets across the aerospace value chain and in many cases the value this innovation can bring a company is limited by its resources and capabilities.  To fully leverage a new idea, most businesses must partner with others in the value chain.   Executed properly, these partnerships can lead to value creation for all.  However, poorly planned and ineffective execution can lead to misunderstandings, confusion and value erosion from unnecessary contractual and legal churn.  Addressing the intellectual property terms and operating principles of a collaborative relationship up front and using IP discipline as the relationship grows are keys to all parties ending up in the win column.  This presentation will address the key elements of structuring a win-win collaborative relationship with a particular focus on structuring intellectual property terms for successful and sustainable value chain partnerships.

10:05-10:20 Coffee Break
10:20-10:45 Powder Metallurgy Options for Aerospace Applications (view abstract)
Tim Armstrong, Vice President – Research and Product Commercializ, Carpenter Technology Corp.

Over the past fifty years, powder metallurgy has evolved from a laboratory curiosity into an important materials technology.  The adoption of sophisticated superalloy compositions was limited by nature; that is, many compositions could not be processed by conventional cast/wrought techniques due to segregation during solidification.  The development of metallic powder technology took place on a variety of fronts; alloy development, melting, atomizing, handling, consolidation, engineering design criteria, and materials characterization have required an enormous effort.  At the present time, there are high volume, standard products and processes in place to produce even the most demanding rotating engine parts from powder.  The continued expansion of powder metallurgy technology in aerospace applications will require significant commitments to process and product development. This paper will explore the potentials for additive manufacturing as an emerging process and titanium powder as an emerging new product.

10:45-11:10 Innovative Technologies for the Aerospace Industry (view abstract)
Michael Kirbach, Director of the Aerospace Excellence Center, DMG MORI

Aerospace is driven by technology and long-term growth. To be competitive in this manufacturing arena only innovative and reliable technology can ensure competitiveness for long lasting success. Manufacturing technologies with state-of-the-art machine tools, capable and reliable processes, tuning opportunities with Ultrasonic support can add real value to manufacturing companies. Additive Manufacturing in combination with subtractive machining opens new opportunities in terms of the idea, design, sourcing of material and manufacturing for the entire process chain.

11:10-11:35 Engine Performance Driving Manufacturing Excellence (view abstract)
Bob Fagan, Chief Technology Officer, Commonwealth Center for Advanced Manufacturing

A number of factors lead to unique challenges in the manufacturing of aircraft gas turbine engines. Most importantly is the continuous drive to reduce fuel burn of modern commercial aircraft and the performance of advanced military aircraft while preserving and improving the safety of the integrated aircraft / propulsion system. At the same time, both commercial and military aircraft are being challenged to reduce their impact on the environment. Additional challenges include the manufacturing of low volume high value parts, the use of high temperature material systems, the requirement for weight optimized design, and the regulatory requirements for the manufacture of critical propulsion parts. Recently, there has been a world-wide focus on advanced manufacturing technologies that is leading to a renaissance in the manufacturing economy, particularly in the United States and Western Europe. Two significant thrusts include a group of technologies gathered under the monikers of digital or smart manufacturing and the continuing development and evolution of additive manufacturing. Both of these technology thrusts have had and will continue to have a significant impact on the manufacture of aircraft gas turbine engines. This presentation focuses on both the push of advanced manufacturing technologies into the gas turbine industry as well as the technology pull to support the specific needs of the industry.  The challenges and solutions specific to aircraft engines are addressed.

11:35-12:00 Cost Effective Machining of Titanium (view abstract)
Mark Larson, Manager of Titanium Process Development, Makino

Many factors need to be considered when machining titanium for a profit.  Great tool life can improve profitability, but if achieving great tool life a lengthy run time, the overhead cost of the machine and an operator for that machine can be much higher than the tool savings.  So how do you calculate the balance point, the breakeven point between machine operation cost, labor cost, tooling cost and tool change costs.  How can these costs be controlled, calculated and evaluated for the ‘best solution’?  This presentation will discuss conservative and aggressive cutting conditions and the impact to tool life, tool cost and machine productivity using a mathematical method to find the lowest production cost at the optimum productivity level.

12:00-1:30 Keynote Lunch: What's Driving us Forward? Landing Gear - Past, Present and Future (view abstract)
Chris Wilson, Managing Director and Vice President Production, Messier-Dowty Limited

Chris will look to the future and give an insight into what will drive development of new landing gear systems and discuss the manufacturing challenges these will provide.

1:30-1:55 Combining Additive and Subtractive Technologies for Practical Production of Complex Components Including Robotic Cells (view abstract)
Brett Hopkins, North America Professional Service Bus. Dev. Mgr., Delcam

Much has been made of the potential for additive manufacturing to replace more traditional manufacturing methods. However, for many applications, additive manufacturing is unable to generate components with the required accuracy or consistency. In many cases, additive manufacturing can only produce a near-net shape, similar to the traditional casting and forging processes. These components will then require a subtractive operation to produce the final part. Delcam has developed a range of adaptive machining processes for the machining of near-net parts, such as forgings and castings, to produce a series of identical parts from a set of similar, but not identical, near-net shapes. This presentation will show how this adaptive approach can be applied to components produced by additive manufacturing.

1:55-2:20 Shaping the Future: Additive Manufacturing at GE Aviation (view abstract)
Greg Morris, Additive Technologies Leader, NPI Value Stream, GE Aviation

This presentation will look at some of the additive activities that GE Aviation is working on with additive technologies, including a case study of additive metal components in a real test environment.

2:20-2:45 Advanced Aerospace Manufacturing Today (view abstract)
Rick Schultz, Aerospace Program Manager, FANUC America - CNC
Chris Blanchette, National Account Manager for Distribution Sales, FANUC America - Robotics

Advanced aerospace manufacturing today encompasses cost efficient integrated automated solutions with robots, motion control and machine tools.  Application examples presented will include automated paint operations, automated assembly applications and efficiency improvements using advanced motion technologies that will dramatically improve aerospace manufacturing processes.

2:45-3:00 Coffee Break
3:00-3:25 Hole Generation in Airframe Structure (view abstract)
Rich Garrick, President, Precorp, Inc.

Aerospace is becoming a fast growing industry. The demand for commercial aircraft is ever increasing. As demand has increased, there has been a push to take airframe technology and assembly to the next level. This has forced industry to look at new materials, new processes and new cutting tools. Precorp has been actively involved in air frame assembly since the introduction of carbon fiber reinforced plastics (CFRP) in to airframe. Many new cutting tool geometries have been matched to the many new processes to support the growth of the airframe area. In the last year with the increase rate of single aisle commercial aircraft there has been a refocus on the automation of metallic stack drilling as well as continued efforts in CFRP metallic stack applications. Many challenges arise as these advanced materials are assembled using automated processes, specifically in the hole generation. This presentation identifies those challenges and demonstrates how cutting tool technology has resolved them.

3:25-3:50 Identifying and Managing Chatter (view abstract)
Dr. Gareth Morgan, Advanced Manufacturing Limited
Jerry Halley, CHIEF ENGINEER, Tech Manufacturing, LLC

Understanding spectral response, while still not universally applied, is well understood for high speed machining.  This presentation reviews its application to low-speed, hard-metal applications and at high-speed in aluminum.  Specific examples are covered as well as how to use this tool for preventive maintenance as well as to take guesswork out of the process.

3:50-4:15 Environmental Impact of Manufacturing Processes (view abstract)
Dr. Sergio Durante, Executive Vice President, Diad Group
Dr. Nicola Ridgway, Research Manager, TEKS

At a time when environmental sustainability is attracting increasing attention in manufacturing, this presentation will discuss the use of Gabi and Simapro software to calculate the carbon footprint of manufacturing processes. After presenting a brief overview of the software, the presentation will include case-study examples of how the environmental impact of various processes can be compared.

4:15-5:30 Questions and Cocktails with Industry Experts

Global Presenters


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