MTI, NASA partner to 3D print rocket engine parts

Engineers from Metal Technology (MTI) are collaborating with scientists from NASA’s Johnson Space Center (JSC) to develop the next generation of rocket engines.

Multiple NASA business units are working on projects to leverage digital manufacturing methods, including 3D metal printing. Conformal regenerative cooling channels and other geometry not constrained by traditional manufacturing techniques could increase performance and/or reduce weight. Total part count-reduction could improve cost and reliability.

MTI engineers have produced components for NASA JSC out of Inconel 718 alloy, a material robust enough to withstand extreme heat and corrosive environments without losing rigidity or becoming brittle.

“The project provided amazing collaboration between the NASA and MTI development teams, and the results were excellent,” says Gary Cosmer, CEO of MTI.

The joint collaboration yielded components that withstand temperatures well above the melting point of the material. This would be impossible without engineered cooling, one of the benefits derived from 3D printing. Recirculating gases are channeled throughout the component by channels built into the component, one layer at a time.

MTI also has produced forgings for the Orion capsule, which will travel on NASA’s Space Launch System designed for missions to Mars and beyond. www.mtialbany.com

Cirrus Aircraft delivers strong 2015 performance

Cirrus Aircraft shipments in 2015 exceeded 300 for the second year in a row as the Cirrus SR22 maintained its position as the best-selling airplane in its segment for the 13th consecutive year. New unit deliveries for 2015 totaled 301 while the global Cirrus fleet surpassed 6,200 total SR aircraft and amassed more than 7 million flight hours. In addition to new SR series deliveries, the Vision Jet program continued progress toward first customer deliveries in 2016.

“2015 was a strong year for the enterprise, both for new aircraft deliveries and for the investments we made for the future,” says Todd Simmons, president of customer experience at Cirrus.

The Vision Jet program continues toward first customer delivery as progress continues on systems testing and integration of the Cirrus Airframe Parachute System.

“Just as important as new aircraft deliveries in 2015, major milestones were also achieved in the Vision Jet program while we broke ground on the Vision Center – our new Customer Experience center in Knoxville, Tennessee,” Simmons adds.

Significant milestones were accomplished in 2015, including FAR Subpart B flight characteristics testing, flight load static testing, ultimate load, and parachute testing. Cirrus also unveiled the Perspective Touch by Garmin flight deck and opened new facilities in Duluth, Minnesota, for Vision Jet production. With more than 550 orders, certification is planned for the first half of 2016 with deliveries set to begin shortly thereafter. www.cirrusaircraft.com

Eco-friendly corrosion-inhibiting aerospace sealant qualified

Engineers from PPG’s aerospace business have completed qualification of three grades of its non-chromate, corrosion-inhibiting sealant that provides commercial, general aviation, and military aircraft manufacturers and maintenance, repair, and overhaul (MRO) shops with faster cure to reduce application cycle time and for save costs.

Since the initial launch of PRC PR-2870 aerospace sealant in Class B for most-common extrusion application, PPG has qualified additional viscosities for application by brush (Class A) and roller (Class C). A replacement option for PRO-SEAL 870 sealant, PR-2870 sealant uses PPG technologies to inhibit corrosion on metal in aerodynamic smoothing, structural surface sealing, fay sealing, and pressure fuselage sealing.

Bill Keller, PPG global segment manager for aerospace sealants, says PPG is the first manufacturer to offer a fully qualified chromate-free corrosion-inhibiting aerospace sealant in all three classes.

“PR-2870 sealant has received exceptional marketplace acceptance because of its light weight and process benefits as a viable alternative for chromated sealants, with several commercial and general aviation customers qualifying it,” Keller states. www.ppgaerospace.com

Norwegian places $2.7B Rolls-Royce order

Rolls-Royce has won a $2.7 billion order from Norwegian for Trent 1000 engines and TotalCare long-term service support for 19 Boeing 787 Dreamliner aircraft. The order also includes TotalCare for the Trent 1000 engines that will power 11 previously-announced leased Boeing 787s yet to enter service.

Rolls-Royce will provide TotalCare comprehensive availability service solution for all 30 aircraft and this will also cover eight Norwegian 787s already in service.

The airline also has options for 10 further aircraft which, if confirmed, will be powered by the Trent 1000. www.rolls-royce.com

GKN Aerospace to supply engine shafts for CJ1000

A contract with AVIC Commercial Aircraft Engine Co. Ltd. (ACAE) of China has GKN Aerospace supplying low pressure turbine (LPT) shafts for the new CJ1000 high-bypass turbofan jet engine – being developed to power Chinese commercial jet airliners. The LPT shafts will be delivered within 12 months for use in the engine test and development program. They will be manufactured at the GKN Aerospace facility in Norway.

Neil McManus, senior vice president Asia, GKN Aerospace says, “This contract represents a milestone first agreement with ACAE of China for our engine systems operation and further strengthens our relationship with the Chinese aerospace industry.”

The GKN Aerospace engine systems business has delivered more than 10,000 LPT cases to the major prime manufacturers of commercial and military aero-engines worldwide. www.gkn.com