April 01, 2022 - No. 22 In This Issue : Collins Aerospace To Retrofit Carbon Brakes On Avelo's Boeing 737s : AIR GREENLAND TO INTRODUCE ELECTRIC FLYING TAXIS FROM VERTICAL AEROSPACE : F&E Aviation Maintenance adding 250 jobs at CVG with $40M investment : The Safe Aircraft Maintenance Standards Act is Essential Reform : GE AESS to offer metal additive engine component repair Collins Aerospace To Retrofit Carbon Brakes On Avelo's Boeing 737s The move to carbon brakes will decrease maintenance times and increase cost savings for Avelo Airlines. Avelo Airlines has announced a deal with Collins Aerospace to retrofit its fleet of Boeing 737 aircraft with new wheels and state-of-the-art carbon brakes. All six of the airline’s Boeing 737 NG aircraft will undergo the retrofit. Gary Martin, Head of Technical Operations at Avelo Airlines, said, "Collins' world-class reputation and broad capabilities made them the right partner for Avelo. Delivering a reliable, on-time experience for our Customers is a top priority. Avelo's partnership with Collins ensures we will continue to live up to that commitment." What benefits will the new carbon brakes bring? Collins Aerospace’s 737 brake is made from carbon friction material, delivering an average 35% longer brake life compared to other carbon materials on the market. The new brakes also have an oxidation protection system. Such features allow for decreased maintenance times and increased cost savings. Brake Systems Avelo Airline's six Boeing 737s will be retrofitted with new wheels and carbon brakes. According to Collins Aerospace, over 3,000 Boeing 737 NG and Boeing 737 MAX aircraft worldwide have already been fitted with the carbon brakes. Panama’s Copa Airlines, for example, announced in August 2021 that it would be working with Collins Aerospace to retrofit its fleet of 65 Boeing 737 NG aircraft. Avelo Airlines and the Boeing 737 Newcomer Avelo Airlines began operations just last year, with its inaugural flight from Hollywood Burbank to Santa Rosa taking to the skies on April 21st. Today the airline boasts a fleet of six Boeing 737 aircraft, made up of three 147-seater Boeing 737-700 NGs and three 189-seater Boeing 737-800 NGs. Avelo Airlines’ Boeing 737-700 NGs are based at Tweed-New Haven Airport (HVN), serving the carrier’s East Coast route network. It is currently the only airline to operate scheduled flights at the Connecticut airport. Its Boeing 737-800 NGs, on the other hand, are based at Hollywood Burbank Airport (BUR) in California and serve the airline’s West Coast destinations. Expansion on the horizon Up to now, Avelo Airlines’ East Coast network has been focused primarily on Florida, with destinations including Orlando, West Palm Beach, and Fort Myers. But May will see considerable expansion, with the airline launching several new services from Tweed-New Haven Airport, including Chicago-Midway, Baltimore, and Nashville. The West Coast will also see expansion, with new routes from Hollywood Burbank to Boise and Spokane scheduled to begin in May. To support this growth, Avelo Airlines will take delivery of nine additional B737 NG aircraft this year, increasing its total fleet size to 15. https://simpleflying.com/collins-aerospace-retrofit-avelo-boeing-737-carbon-brakes/ AIR GREENLAND TO INTRODUCE ELECTRIC FLYING TAXIS FROM VERTICAL AEROSPACE Air Greenland is investing in emission-free eVTOL aircraft from Vertical Aerospace to help passengers travel by air with minimal impact to the environment. Jenny Southan reports Air Greenland, the flag-carrier for Greenland, will be bringing zero-emissions travel to the region to help tackle the issue of climate change thanks to a partnership with international aircraft leasing company Avolon. The idea is that Air Greenland will commit to purchasing or leasing a fleet of VX4 eVTOL (electric vertical take off and landing) aircraft, manufactured by Vertical Aerospace, from Avolon. (Virgin Atlantic is also planning to launch a fleet of flying taxis from vertical Aerospace.) Upon its introduction, the VX4 will be the most advanced and the safest eVTOL in the market and will be built to EASA safety certification standards – the most stringent global requirements and at the same level as commercial aircraft. The VX4 will be near silent when in flight and will have zero operating emissions, transporting four passengers and one pilot distances of over 100 miles at up to 200 miles per hour. According to a press statement, Avolon and Air Greenland will partner to form a Working Group to assess the opportunity to commercialise zero-emissions air travel to the region. It will also collaborate to identify local infrastructure and certification requirements for eVTOL aircraft. The size of Air Greenland’s VX4 fleet will be defined at the conclusion of the Working Group’s assessment of the scale of the market opportunity. Dómhnal Slattery, CEO of Avolon, says: “Since our initial order, we have seen airlines all over the world make a commitment to the zero emissions travel by selecting the VX4 aircraft as the first step in their decarbonisation journey. “The announcement with Air Greenland means we are taking zero-emissions travel to where climate change is having its most pronounced impact. We look forward to working with Air Greenland to bringing the zero-operating emission VX4 aircraft to where it matters the most.” Jacob Nitter Sørensen, CEO of Air Greenland, says: “The announcement marks the start of our long-term sustainability journey, and we are excited about bringing zero emissions travel to our region. “In Greenland, we see the effects of climate change every day and, as a company, we want to be at the forefront of the climate revolution. “The VX4 aircraft will have many uses for Air Greenland and, through our partnership with Avolon, we look forward to welcoming our first travellers onboard in the near future – flying our guests to Ilimanaq Lodge to show the visible impacts that climate change is having on our country and planet.” Stephen Fitzpatrick, CEO of Vertical Aerospace, says: “We are delighted that Air Greenland has chosen the VX4 to bring zero emissions air travel to the region. This partnership is a significant first step in introducing sustainable air mobility to Greenland.” In June 2021, Avolon ordered 500 VX4 eVTOL aircraft from Vertical, valued at US$2 billion. Since announcing that order, Avolon placed 250 VX4 aircraft with Gol and Grupo Comporte in Brazil, up to 100 aircraft with Japan Airlines in Japan, and a minimum of 100 aircraft with AirAsia. Avolon has now placed up to 90 per cent of its initial orderbook, underlining the demand for VX4 aircraft from the world’s leading airlines. Air Greenland is owned by the Greenland Government and has flight operations to total of 62 destinations internally in Greenland and to and from Denmark and Iceland. At the moment its fleet consists of fixed-wing aircraft Airbus A330-200 and 7 Dash 8-200 to transport passengers and cargo, a King Air for medical evacuations and 17 helicopters of various types, which meets the need for passenger transport, mineral exploration, heliskiing, sightseeing, scientific expeditions, Search and Rescue, and in the maintenance of vital telecommunications infrastructure. As a key player in aviation on the world’s largest island, Air Greenland aims to facilitate Greenland’s infrastructure in a sustainable way by investing in the green conversion. To support a sustainable development in the tourism industry and the economic growth to the benefit of the country, Air Greenland supports the development of sustainable destinations and goals in the subsidiaries Hotel Arctic and Greenland Travel. https://globetrender.com/2022/03/31/air-greenland-zero-emission-evtol-vertical-aerospace/ F&E Aviation Maintenance adding 250 jobs at CVG with $40M investment FRANKFORT, Ky. – F&E Aircraft Maintenance LLC, a provider of aircraft maintenance and engineering services, will locate a new three-bay hangar at the Cincinnati/Northern Kentucky International Airport, creating nearly 250 full-time positions, including at least 124 Kentucky-resident jobs, with a $40.2 million investment. “We continue to see existing Kentucky businesses grow and create quality jobs throughout the state, and FEAM AERO is the latest example of a company with a vision for the future in the commonwealth,” Gov. Andy Beshear said. “These well-paying positions will benefit well over 100 Kentucky families while also improving support for two of our major air hubs at CVG Airport.” F&E Aircraft Maintenance will construct a 150,000-s.f., three-bay hangar at CVG to house Boeing 767 aircraft, with work expected to begin in June of this year and completed by the end of 2023. The location will include 15,000 s.f. of back shop space, 5,000 s.f. of office space and 175,000 s.f. of ramp access. Jobs created at the new hangar will include aircraft mechanics and technicians, ground support equipment mechanics, administrative personnel and management positions. Leaders at the company, which currently employs 300 people at CVG, noted the new operation will provide ample aircraft maintenance capacity and resources for its growing airline customer base in support of cargo operations such as Amazon and DHL. Additionally, in concert with further initiatives currently in planning stages related to aircraft maintenance training, the new facility will provide viable employment opportunities for the next generation of aircraft mechanics throughout the region. “We are not only excited for the opportunity to continue growing our relationship with CVG airport, but we are also thrilled in continuing to exceed our customer expectations, delivering them more value at such a critical time in aviation,” said F&E Aircraft Maintenance owner and CEO Fred Murphy, “while at the same time staying true to our values in putting people at the heart of everything we do by investing and growing the FEAM team in the surrounding communities.” Founded in 1992, F&E Aircraft Maintenance is a leading provider of aircraft line maintenance services in the United States. The company operates maintenance bases at 36 locations in the U.S., United Kingdom and Europe, including two hangar facilities, and employs more than 1,300 technicians and engineers companywide. FEAM AERO aims to deliver more flight time and less downtime to customers with services that include line maintenance, technical training, global aircraft-on-ground support, technical support services and base maintenance. Candace McGraw, CEO of CVG Airport, said the company’s latest investment furthers efforts to grow the airport’s economic impact. “We congratulate FEAM on their success and business growth,” McGraw said. “They have been a terrific partner in which we share a vision to further develop needed infrastructure and services to support continued growth of cargo carriers at CVG. The airport’s current strategic plan outlines the transformational impact we can make for our region, and this project does just that through job creation and capacity building to grow and diversify cargo operations.” Boone County Judge/Executive Gary Moore congratulated FEAM AERO. “Aviation maintenance is a high-growth subcluster in our supply chain management and support services industry in Northern Kentucky,” said Judge/Executive Moore. “We welcome these new, high-paying jobs that will keep an increasing amount of air cargo moving in and out of CVG.” Northern Kentucky Tri-ED CEO Lee Crume noted FEAM AERO’s continued investment at CVG is a significant contributor to the strength of the aviation sector. “We have tremendous assets in the Amazon Air and DHL air cargo hubs at CVG driving significant growth in aviation maintenance with highly technical and high-paying jobs being created by FEAM AERO,” Crume said. “We are using our Target Industry Analysis to identify new manufacturing operations that support the expansion of companies like FEAM, so that components and parts are easily accessible in the region.” F&E Aircraft Maintenance’s investment and planned job creation furthers recent economic momentum in the commonwealth, as the state builds back stronger from the effects of the pandemic. https://www.lanereport.com/154189/2022/03/fe-aviation-maintenance-adding-250-jobs-at-cvg-with-40m-investment/ The Safe Aircraft Maintenance Standards Act is Essential Reform House Committee on Transportation and Infrastructure Chairman Peter DeFazio introduced The Safe Aircraft Maintenance Standards Act today, calling for unannounced FAA inspections of foreign repair stations, minimum qualifications for mechanics and others working on U.S.-registered aircraft at foreign repair stations, data gathering and analysis, and a conditional moratorium on FAA certification of new foreign repair stations among other essential safety reforms. "We applaud Chairman DeFazio's leadership on the issue of aviation safety and particularly as it relates to aircraft maintenance," stated AMFA National President Bret Oestreich. "As the carriers seek to accomplish more aircraft maintenance outside of the U.S., this bipartisan legislation is a huge step forward in ensuring that the flying public enjoys safe travel while leveling the playing field for U.S. workers and the companies that employ them." "Chairman DeFazio's bill goes straight to AMFA's motto that safety in the air begins with quality maintenance on the ground," noted Mr. Oestreich. "We are in support and thank the thirteen original cosponsors while urging other legislators to join as supporters." https://www.aviationpros.com/education-training/trade-associations-events/press-release/21262386/aircraft-mechanics-fraternal-association-amfa-the-safe-aircraft-maintenance-standards-act-is-essential-reform GE AESS to offer metal additive engine component repair GE Aviation Engine Services Singapore (GE AESS) first MRO approved to use metal AM for commercial jet engine component repair. As metal additive technology continues to gain momentum in the design and industrial production of new aerospace components, GE Aviation’s Loyang facility is the first maintenance, repair, and overhaul (MRO) facility worldwide that has been approved to use metal additive manufacturing (AM) for commercial jet engine component repairs. GE Aviation Engine Services Singapore (GE AESS) currently employs more than 1,700 employees in the city-state and accounts for more than 60 percent of GE Aviation’s global repair volume. GE Aviation continuously innovates in the MRO sector, and GE AESS recently announced that it is the first MRO facility in the world approved to perform metal additive repairs on jet engine components. 3D-printed parts are typically printed using STL files generated from CAD drawings. However, this works only for new-make production where the goal is to produce identical parts conforming to the blueprint. When repairing used parts, however, the repair must be customized for each individual part because each part wears differently during service. Additive technology in repairs also offers the possibility of embracing complexity, rather than shying away from it. Chen Keng Nam, executive manufacturing leader at GE AESS in Singapore, has also been involved in the metal additive roll-out. “This disruptive technology can be used for lots of applications, not only in aviation. When I see beyond the realm of repair into new-make, it’s mind-blowing to see the parts that we can design and print using additive. Now designers are making use of the ability to produce new designs that couldn't be imagined or manufactured before with traditional methods.” Iain Rodger, managing director at GE AESS, also sees the potential for metal additive technology in MRO. “In this part of the supply chain our customers truly value faster turn-around time, and that’s what we are achieving. Using our GE Additive Concept Laser M2 machines typically halves the amount of time it takes us to repair these aircraft parts.” Rodger says his teams are already using additive technology to repair parts in GE Aviation’s CF6 engines used on wide-body aircraft. The next goal is to include parts on the widely used CFM56 commercial aviation engine. One example is the repair of high-pressure compressor (HPC) blades that run at high speeds and tight clearances within aircraft engines. They face regular erosion and wear that, in time, demand continuous repair and replacement. Repairing these blade tips used to require a long process of cutting, welding and grinding to create the proper shape. GE Aviation has established an automated AM process to repair the HPC blade tips, saving time and costs associated with labor and machining. The team created image-analysis software that maps the shape of a used blade and creates customized instructions for the Concept Laser M2 machine to build a new tip with precise alignment and profile. The 3D-printed part is near-net shape and can be finished with minimal additional processing. “Productivity has increased with our employees able to repair twice as many parts in a day compared to the conventional repair process. Less equipment is also needed for post-processing, so the floor space required is reduced by one-third,” says Rodger. “We are currently assessing what we are going to do in turbine parts and other components beyond compressors. Day-to-day, working with customers, they will know that there's a difference as they will be seeing their parts return to them more quickly.” Beyond the much faster turn-around times possible with metal additive technology in aircraft part repairs, Rodger sees another significant win for GE Aviation, for customers, and for the aviation industry more broadly. “To me one of the significant advantages of additive is its sustainability. This is going to allow us to repair more parts and throw fewer parts into the bin, use less energy, generate less waste, and have a smaller footprint. Repair capability is a big part of the sustainability journey. As the industry expands and new technology is developed, that will only increase.” As part of its national high-tech strategy, Singapore’s Economic Development Board supported the initial development trials and training for the introduction of metal additive technology for aviation maintenance into the country. Shih Tung Ngiam, a senior engineering manager at GE AESS, was involved in the project from its inception. He acts as a bridge between the local team and the wider additive community across GE Aviation and GE Additive to industrialize the process. “While teams at the GE Aviation Additive Technology Center in Cincinnati and GE Additive Lichtenfels in Germany worked on developing printing parameters for the Concept Laser M2 machine, our team here in Singapore focused on the modifications needed to make the process robust and production-friendly in a high-volume repair process,” Ngiam explains. The Singapore team designed tooling to prepare and print parts efficiently and fine-tuned the repair process, including printing, pre- and post-processing, and inspection. Extensive trials and tests were conducted to ensure the quality and safety of the parts before the repair was substantiated. In 2020 Ngiam and the team also designed a pilot production line, including an automated powder recycling system, to streamline the repair operation. The COVID-19 pandemic disrupted the approach for a while; however, by 2021 the team in Loyang was ready to go live on its full-scale production line. “Additive gives us speed and productivity with less floor space required. We gave a lot of careful consideration to how best to integrate the M2s into the rest of the repair line. We completed an assessment of which parts of the repair we should leave alone, which ones could benefit from additive, and what other changes we needed to make to the repair process for it to make sense,” says Ngiam. The two big advantages that metal additive provides the site are speed and the near-net-shape product. This allows the team to increase productivity and reduce floor space required. The traditional methods for repairing HPC blades involves a lot of effort to weld the blade and then a lot of additional effort to remove the excess material. By using the Concept Laser M2 metal 3D printers, the repaired blade is very close to the final shape when it comes out of the machine, so it takes much less labor and equipment to achieve the finished profile. Given the critical nature of aerospace components, extensive analysis and testing are required before any repair can be approved, even more so when new technologies such as AM are involved. GE AESS worked closely with GE Aviation Engineering to produce parts for testing and to establish a robust quality-assurance process before the process could be approved. As the aerospace industry becomes more familiar with additive, the approval process can be streamlined. Back on the ground, as GE AESS starts to scale metal additive technology for aircraft part repairs, a real consideration is the talent that will be needed to implement ambitions. “Singapore’s universities and polytechnics are training a healthy number of students in AM, but the pool of experienced graduates is still quite small. As the industry matures and these graduates gain experience, we expect that Singapore’s pool of additive talent will grow accordingly,” says Chen Keng Nam. And this feeds into a blueprint for the future, where AM is a mainstay of the aircraft repair supply chain. “The great dream of additive is to print spare parts on demand without even needing to have an inventory. It’s true that it’s a few years away, but it will happen. But we must also recognize that change can take time, especially in our highly regulated industry, and we have to make efforts to prove that our new methods are as good, if not better, than what has gone before,” Ngiam concludes. https://www.aerospacemanufacturinganddesign.com/article/ge-aess-offer-metal-additive-engine-component-repair/ Curt Lewis