Polish Aero Engine Industry Presentation - NEWAC€¦ · · 2012-07-06Polish Aero Engine Industry...

Polish Aero Engine Industry Presentation

European Engine Technology Workshop

Warsaw, 2-3 June 2009

1-Jun-09Robert Haligowski 2This document and the information contained are property of the companies that are presentedand shall not be copied or disclosed to any third party without prior written authorization.

Polish Aeronutical Technology Platform

ACARESRA 2020 – 350 technologies

PATPNSRA – 150 technologies

Academia &Institutes

78 technologies

12 Aircraft Avionics,

Systems & Equipmenttechnologies

Industry28 technologies


Systems & Equipmenttechnologies

44 technologies


Systems &Equipment

technologies

PATP


GENERAL COMPANY INFORMATION

Company activity

• Founded in 1937, WSK "PZL - Rzeszów"has become one of the leading players in theCentral Europe aerospace industry. It wasstate owned for over 60 years and joined theUnited Technologies corporation family in2002. WSK "PZL - Rzeszów employs morethan 4‘000 workers in one facility located inthe city of Rzeszów, on the Wisłok riverbank. Company facilities - head office,manufacturing, engineering, service centers,customer support, finance and procurementgroups.

WSK is involved in the following activities:

• manufacturing

• overhaul and post-sale services

• special order services

• design and research


MAIN AREA OF R&T

Design

Optimization of mechanical systems,structural components, externals

Manufacturing

Cost reduction & efficiency improvement

• Process modeling

• Forming, joining, casting

• High performance machining /newmaterials/

• New NDT technologies

Maintenance & overhaul


NATIONAL/EU PROJECT PARTICIPATION

Material Laboratory, Technical University of Rzeszow

– 6 M €, Ministry of Science

Key national project „Modern materials for AerospaceIndustry”

– 22 M € of EU Structural Funds

– 7 Technical Universities, 340 scientists

Strategic project „Single crystal and DS.”

– 5 M €, Ministry of Science

– 4 technical Universities and WSK

Strategic project „Thermal barriers”

– 3.5 M €, Ministry of Science

– 8 Technical Universities and WSK

New technology support, Ministry of Science

– 10 on going WSK projects, 2.5 M € / year

– Top 10 Technical Universities

FP6 & FP7 projects:

– 5 on going WSK projects, 0.5 M € / year


COLLABORATION IN FUTURE FP

Area of interest:

FEM/CFD analysis, CAD DesignOptimization of engine sub-systems

Modeling of welding / forming /castingfor aerospace materials

High performance machining -machine/fixture/part/processinteraction

Laser supported manufacturing ofaerospace components for cost &environmental foot print reduction

Non conventional machining

Automation of assembly

Casting technology

Coating technology

Surface layer technology (eg. Shotpeening, induction hardening)

NDT technologyDR TECHNOLOGIES

FORMING TECHNOLOGIESJOINING TECHNOLOGIES

IH TECHNOLOGIES

LBM TECHNOLOGIES EDM TECHNOLOGIES

INFORMATION TECHNOLOGY

COATING TECHNOLOGIES

MODELING TECHNOLOGIES



AvioPolska sp. z o.o. is a part of AVIO international industrial group, a leader in the aerospaceindustry. The company launched its operation in 2001 in Bielsko-Biała.

Currently we manufacture Rotor Blades oflow-pressure turbines for the engines:CFM56,GE90-115K,PW308,T700Development and implementation underway Stator vanes of low-pressure turbines forthe new Genx-2B engine.

0

20

40

60Mio€

YEAR

REVENUES

Revenues 0 1 4 9 15 19,5 27,9 40 50,5

2001 2002 2003 2004 2005 2006 2007 2008 2009


MAIN AREA OF R&T

AvioPolska focuses its activity on manufacturing carried out in the Manufacturing Center and R&Dactivity pursued by its own Research and Development Center. In 2006 also the Office of Sales andMarketing was open in Warsaw.

MANUFATURING CENTERIncapsulation and decapsulation,Decontamination,Hardfacing by welding (stellite surfacing,manual or automated),Grinding,Milling,Barrel finishing,Marking,Heat treatment – ageing, diffusion,aluminizing, soldering, thermal etching,Fluorescent Penetrant InspectionSurface strengthening - ball peening,Measure inspection - CMM

RESEARCH and DEVELOPMENT CENTERFEM analyses -TurbinesFEM analyses - GearsHeat flow/CFD (FEM)Non-linearity/fatigue (FEM)CAD designing


NATIONAL / EU PROJECT PARTICIPATION

1. Avio Polska is a Member of Polish Aeronutical Technology Platform

2. GEnX-2B – internal program in cooperation with ATH in Bielsko-Biala

3. AITEB-II Project in 6 Frame Program in collaboration Avio Group with IMP PANGdynia

4. TIMECOP A.E. - Innovative methods of combustion process modeling in aircraftengines. Project in 6 FP in collaboration Avio Group with PolitechnikaCzęstochowska


COLLABORATION IN FUTURE FP1. Avio Polska as a part of Avio Group is a associate member of JTI “Clean Sky” in group

“Sustainable and Green Engines”

New polish initiatives:

1. Cooperation with Politechnika Warszawska i Wojskowa Akademia Techniczna to establish

in Poland Cold Flow Turbine Test Facilities

2. Cooperation with Politechnika Slaska for aluminization and laser welding process

3. Collaboration with Politechnika Śląska e Politechnika Rzeszowska (Research and

Development Laboratory for Aerospace Materials) for new TBC process.

4. Cooperation with Politechnika Warszawska for material characterization

5. Avio Polska participation in Slaskie Centrum Naukowo Technologiczne Przemyslu

Lotniczego in cooperation with Silesian Aviation Claster, Glowny Instytut Gornictwa,

politechnika Slaska, Akademia Techniczno – Humanistyczna, Instytut Lotnictwa



Company of Safran Group

Starting from August 2001


MAJOR PRODUCTION DEPARTMENTS

• Gears

• Housings

• Structural components

• Engine components

Today’s compagny crew: 354 people

Active member of the Aviation Valley

Hispano Suiza


ENGINES and APPLICATIONS:

ENGINES: APPLICATION:CFM56-2 DC8 & KC135CFM56-3 B737-300, -400, -500CFM56-5 A319, A320, A321CFM56-7 B737-700

GP7000 A380

TRENT 500 A340-500/600TRENT 700 A330TRENT 800 B777

BR715 B717-200BR710GV GULSTREAM 500 family et Baé Nimrod 2000BR710GX Bombardier G5000 et Global Express

CF34-8 EMBRAER 170AS 907 Bombardier Challenger 300

CTS800 Helicopter Westland LynxArriel Ecureuil, Dauphin, EC130, EC145, EC155BArrius Augusta A109, EC135Makila AS332 Super Puma, EC725


MAIN AREA OF R&T

• INCONEL grinding

• Titanium machining

• Gearbox housing machining (lenght < 1600 mm)

• Highly automatic production line for aluminium and titanium parts

• Gears and spline grinding

• Special processes: LPC, Shoot peening, Black oxide, Plasma spray coating,

• polymerization of silicone rubber coatings

• NDT: FPI, MPI, Nital Etching,

• Metalurgical laboratory

• CMM control


GENERAL COMPANY INFORMATIONPratt & Whitney Kaliszsince 1992 is part of theUnited Technology Corporation

Total area 335,000 sq/ft

100% subsidiaryof Pratt & Whitney Canada

Employment 1700

2200 P/N

17 product families (Line)

Customers:

PWC, PWEH, Sikorsky, Hamilton Sundstrand, SPWAEC

97% of the production is exported to Pratt & Whitney Canada, a worldwide leader in manufacturingturboprop, turbofan and turboshaft engines for business aircraft, local transportation andhelicopters.


PWK as a Center of Excellence for:PWK as a Center of Excellence for:Gears, Stators and ShaftsGears, Stators and Shafts

Gears and bevel gears

Stators

Pump housings

Tool Department

Carriers

Tubes

Shafts


MAIN AREA OF R&T

Brazing of Stators

SuperfinishingMinimum roughness – maximum durability

Deburring by water jet

High performance machining



Laser cuttingof inconel, steel and Al alloy

Contour induction hardening of gears

Neutral atmosphere in Heat Treatment- elimination of thin copper plating

NDT - eddy curent testing



Area of interest:

- Modeling of welding for aerospace materials

- High performance machining -

machine/device/part/process interaction tests

- Laser supported manufacturing of aerospace

components for cost & environmental foot print

reduction

- Optimisation of mechanical systems



The basic activity:• products for hydraulic and fuel systems for aircraft andhelicopters of general and special applications.•industrial hydraulics products,Major customers: Honeywell, Hamilton Sundstrand,Textron, Goodrich in the field of manufacture ofassemblies and production of special machiningprocesses, heat treatment, chemical processes, EDM,NDT, all of them meeting the requirements for theNADCAP accreditation.

We carry out R&D works. We offer maintenance, repairsand overhauls; spare parts and service. We guaranteethe top quality of our products and services, confirmed bythe following certificates: ISO 9001:2000, AS 9100,PART 21, PART 145.We win the confidence of our Clients through the highquality and reliability of the manufactured products, theunique organizational culture, shaped over the course of60 years of our activities in the aerospace industry.

LeadershipMr. Adam Mlynczak, CEO & Managing DirectorMr. Andrzej Czopek, Member of the Board

Development and Engineering DirectorMr. Ryszard Jaron, Marketing Director - Proxy

Financials (PLN):Turnover 2008 total 51,8M

EmployeesTotal: 590 peopleGeneral preparation of manufacture,R&D (Engineering and Design Departments) - 61 peopleEngineers – University grade, BSc and MSc - 74 peopleOther university background - 30 people


MAIN AREA OF R&TFuel control systems of turbo-jet, turbo-propeller,turbo-shaft and piston engines

Fuel control pumps Propeller speed governors Turbine synchronizers Equalizers, barostats Fuel distributors Carburettors, fuel blend regulators Valves

Hydraulic systems for aircraft and helicopters Hydraulic feed and adjustment blocks Primary and auxiliary pumps Hydraulic cylinders Synchronizers Hydraulic actuators Distributors

Electronic systems to control the operation of fuel controland hydraulic actuating units

Electronic system to control the operation of a turbo-shaft and a turbo-jet engine Diagnostic unit for the ground service of an aircraft engine Aircraft engine start-up controller FADEC type full-range microprocessor aircraft engine control system



PZL-Wrocław sp. z o.o.

FADEC (Full Authority Digital Engine Control) for PZL-10WM engine

participation in the upgrading programme of the PZL-Sokół helicopter

to the Głuszec version

participation in the production programme of the SW-4 helicopter

Servovalves for aviation industry – for the military and commercial application

(submitted development project – in the course of opinion-providing by the MoS&HE)

High-pressure high-output gear pumps

Military

programms

Industry



Products for the supply of aircraft engines

Servovalves

Products for hydraulic systems

for aircraft and helicopters

(F-16, Black Hawk and others)



Founded in the year 2000 as Polishowned private limited company

ULTRATECH activity

Machining of high precision aviation parts

FPI approved by Boeing and Nadcap

Machining, polishing and shot peening ofblades for steam turbines, gas turbines andjet engines

Aviation deburring

Electrochemical Etch marking of aviation parts

Assembly

Design of special production tools

Research programs (FP6 – MagForming)

ULTRATECH – other main information:Since April 2007 approval by German TÜV Nord - Quality system is based on aviation EN9100 (AS9100)DSQAR status in Goodrich - first in Poland and one of the few companies in Europe and AsiaApproved supplier - Goodrich, WSK Rzeszów (UTC), General Electric, British Aerospace, PZL Mielec (nowSikorsky Aircraft), MOOG, Selex Galileo, Hutchinson, Honeywell, Liebherr and EATONSupplier of Polish Army (machining of military products – blades for polish jet trainer)Sole supplier in the world for over 60 different items for Boeing 737 (landing gear components)

Staff (70 persons now):Managers: 3Designers, process planners: 12Commerce : 2Quality department: 6Company administration: 1Direct workers: 46


MAIN AREA OF R&T

Main goal to support area of excellence:

• HPM machining

• Light & Ni based alloys

• Manufacturing cost reductiontechnologies

• Green production technologies

• Modeling of manufacturing processesbased on CAD/CAM capabilities



MagForming - Development of NewMagnesium Forming technologies for theAeronautics Industry

MagForming WP list:

* Large scale forging

* Small / medium scale forging

* SPF (super plastic forming)

* Deep draw

* Roll bending

* Pad / rubber forming

* Creep forming

ULTRATECH develops forging die for makingthis demonstrator

(magnesium window frame for Airbus A340)



Design of highly automated,Design of highly automated,hydraulic & pneumatic actuatedhydraulic & pneumatic actuatedmachining fixturesmachining fixtures


1-Jun-09Robert Haligowski 28


WZL-4 S.A.

MILITARY AIRCRAFT WORKS No 4 Stock Corporation is the Polish leader of military aero-engines with 58 years experience on the Polish military market, located in Warsaw and has facilitydedicated for the engine maintenance repair and overhaul activity for the Polish Air Force needs.

Aircraft & helicopter engines:· AŁ-21F3 (Su-22 fighter-bomber)· RD-33 (MiG-29 fighter)· GTD-350 (Mi-2 helicopter)· TW2-117A/AG (Mi-8 helicopter)

Starter engines:· TS-21· AI-9(W)

Small turbine engines for non-aviation application:· DG4M-1· GTD-5(M)· 2PW8-1· 9156-3

Additional WZL-4 S.A.perform regulating tests of engines:· CFM-56-3 (Boeing 737 passenger plain)· F100-PW-229 (F-16 fighter)

Types of engines maintained by WZL-4 S.A.




WZL-4 S.A.

FUTURE

WZL-4 S.A. are going to support PAF and Polish Navy in MR&O and services in line of thefollowing types of aircraft engines:

- PW 127G powered CASA 295 M Transport Aircraft- T700 powered Kaman helicopter- LM 2500 turbo engine propulsion for Gawron Corvette.

Moreover, WZL-4 S.A. have capabilities to cooperate in MR&O on commercial market and be areliable partner for Polish PW100 engine operators like PLL “LOT” and in the near future Centraland Eastern European customers:

- PW124B powered ATR 72 passenger plain- PW127E powered ATR 42 passenger plain- CFM-56M powered Boeing 737 passenger plain




WZL-4 S.A.

Building and exploitation of the “Cold Flow Turbine Test Facility” (CFTTF) for research and testingamong others prototypes of turbines of the aircraft engines as well as testing of demonstrators of thetechnologies in structure of the aircraft engines taken advantage constructed within the „FrameProgram Research of the European Union”.

COLD FLOW TURBINE TEST FACILITY (CFTTF)

„POLONIA AERO” Sp. z o o.

Members:

-Military Aircraft Works No 4 Stock Corporation- Avio S.p.A

-Warsaw Military of Technology (WAT)


Contacts:

Robert Haligowski - Technology Management Office; EU R&T Director

WSK "PZL-Rzeszow" S.A.

Hetmanska 120; 35-078 Rzeszow; Poland

Tel. +48 17 866 7388, Mobil. +48 606 44 22 99,

e-mail: [email protected]

www.wskrz.com

Łukasz Komendera – Quality Office; Head of Special ProcessDepartment

Avio Polska Sp. z o.o.

Grażyńskiego 141; 43-300 Bielsko-Biała; Poland

Tel. +48 33 813 5543, Mobil. +48 784 025 911,


www.aviopolska.pl

Hispano-Suiza

HISPANO-SUIZA Polska Sp. z o.o.

ul. Partyzantów 29; 39-120 Sędziszów Małopolski, Polska

Telefon: +48 17 22 22 100

Fax: +48 17 22 22 101


Jacek Kaszyński – Technology Development Manager

Pratt & Whitney Kalisz

Elektryczna 4a, 62-800 KaliszTel: +48 62 7669 479

Fax:+48 62 7669 362

[email protected]

PZL Hydral

Marketing Department

tel. +48 (0) 71 / 324 51 15

fax + 48(0) 71 / 325 25 65

e-mail : [email protected] www.pzl-wroclaw.com.pl

WZL4

Księcia Bolesława St. 1/3, 01- 452 Warsaw 42

Tel. switchboard: (022) 685-23-01, 685-23-05

Central office: tel/fax: (022) 836-45-21


http://www.wzl4.mil.pl

Ultratech

Contact person: Marek Bujny - Vice-President

E-mail: m. [email protected]

Mobile: +48 608 536 285

www.ultratech.pl

Buck-up information


Additional information:

22%

5% 5%

11%

15%

18%

3.3%3.0%

2.8%

2.0%

1.2%1.0% 0.9%

0%

5%

10%

14%

19%

24%

2002 2003 2004 2005 2006 2007 2008

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

Efficiency growth - base '02

SRR % sales

EFFICIENCY & QUALITY

209

209

2002 2003 2004 2005 2006 2007 2008

77

43%

99

53%

176

59%

130

70%

226

75%

230

91%

Non Aerospace

100%

302CAGR 2002-2008: 38%

($ millions US)

SALES

CUSTOMER SATISFACTION

6,36,2

4,34,5 4,6 4,7

5,8

2002 2003 2004 2005 2006 2007 2008



0

15 000

30 000

45 000

60 000

75 000

90 000

105 000

120 000

135 000

150 000

Sales hrs 79 450 81 454 92 300 98 419 118 500 132 000 132 000 132 000 132 000

Prod. Hrs 80 158 81 768 92 300 113 600 118 500 132 000 132 000 132 000 132 000

2004 2005 2006 2007 2008 2009 2010 2011 2012

Avio Poland

0

10

20

30

40

50

60

70

80

90

Mio€

EBITDA

REVENUES

EBITDA 1.9 1.3 1.7 5.8 9.0 10.9 15.6 15.8 15.3

REVENUES 0 1 4 9 15 19.5 27.9 40.0 50.5 80 81.3 80.8

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

0

50 000

100 000

150 000

200 000

250 000

300 000

350 000

Components 143 600 213 000 194 800 206 649 271 000 261 700 284 400 269 600 267 300

Prod. Hrs 64 000 100 000 132 000 193 673 240 000 237 000 305 000 296 000 281 000

2004 2005 2006 2007 2008 2009 2010 2011 2012



• National Labor Inspectorate Award – 1stplace in Poland in category:

• ‘’Employer – organizer of safe work’’ – 2007

• Mori Seiki award at EMO 2007 InternationalMachining Exhibition– 2nd place in category:‘’Innovative development of machiningprocess in aerospace industry’’

• 1st place in classification of Pratt & Whitneycompanies – number of working hourswithout lost time accident at work (over 11700 000 hrs)

• The Arthur E.Smith Award – presented to Pratt& Whitney Canada and Pratt & Whitney globaloperations and sourcing teams for benchmarkachievement in efficient, productive and costeffective operations in Poland, May 2008

Aerospace Technology Platform

CIRP Associate Membership

The International Academy

for Production Engineering

The Centre of Advanced Technology

"AERONET - Aviation Valley"

Aviation Valley Association



PZL Wroclaw is accredited to and holds:

• AS 9100 Aerospace Standard,

• NADCAP Special Processes and

• ISO 9001:2000 quality standards.

Process Date of firstaccreditation

Heat treatment 24/07/2006

Chemical processing: anodizing in sulphuric andchromic acid, conversion/phosphate coatings

08/12/2006

NDT: PT 21/11/2006

NDT: MT 20/10/2007

EDM: wire and plunge 13/11/2007

SPECIAL PROCESSES QUALIFIED BY NADCAP

CERTIFICATES

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