July12, 2023 - No. 029 In This Issue : Airbus A380 Faces New Issues Related to Wing-Spar Cracking : Airbus to Provide Free SAF for First Delivery Flight : Emirates A380 has blocked the Runway at London Gatwick : Revolutionary Design, Unmatched Performance: Inside the X-55 Carbon Comet by Lockheed Martin : Boeing sees 5G, drone inspectors and augmented reality training key to future aircraft maintenance : NASA X-59 QueSST aircraft moves Closer to Runway at Lockheed Martin Skunk Works facility for ground testing : World’s Largest Rubber Band Airplane : Airbus to handle some A380 repairs after wing-spar cracking Airbus A380 Faces New Issues Related to Wing-Spar Cracking Airbus revealed that it would provide special bonuses to workers involved in the project, starting from September and retroactively covering the period since the end of last year. BY BHAVYA VELANI July 10, 2023 PARIS- Two years after the final Airbus A380 jetliner rolled out of its Toulouse factory, the aviation giant is preparing to bring some of these superjumbos back for wing-spar cracking inspections at their birthplace. Despite the plant’s transformation to accommodate smaller aircraft, Airbus is dedicating part of its colossal assembly hall to inspecting and potentially repairing A380s, particularly those belonging to Emirates (EK), its largest customer. Airbus A380 Reported Wing-Spar Cracking Airbus began constructing a specialized “A380 Emirates” inspection facility within the Jean-Luc Lagardere building in December to address the issue. The project is expected to continue until the third quarter of 2024, as stated by the Force Ouvriere union. In a notice, Airbus revealed that it would provide special bonuses to workers involved in the project, starting from September and retroactively covering the period since the end of last year. An Airbus spokesperson confirmed their support for the inspections, stating, “We are supporting inspections on some aircraft in Toulouse.” Emirates, the affected airline, assured that the inspection and repair program would have minimal impact on its operations. The process is based on specified time limits determined by the installation of each wing, and the airline anticipates collaborating closely with Airbus and its maintenance and repair partners to meet the requirements. While most of the tasks will take place at Emirates Airlines Engineering Centre, Airbus will offer additional assistance in Toulouse. Ground Time and Operational Profit The duration of the inspections and repairs will vary depending on the findings, but it is estimated to average around 60 days per jet. Emirates President Tim Clark recently stated that “the first aircraft is already undergoing repairs. He expressed confidence that the issue would have “very little impact on our operating profit.” The Jean-Luc Lagardere site opened in 2004, is renowned as the world’s second-largest building in terms of usable space. Despite the shift in focus toward smaller aircraft, it remains one of the few industrial plants with sufficient height to accommodate A380s. Additionally, there is a shortage of third-party repair capacity for these large aircraft. Airbus and Boeing have been modifying sections of their iconic factory buildings as the industry adapts to the changing demands of air travel, emphasizing smaller models over discontinued four-engined jumbo jets. Transitioning to Smaller Jets Airbus data released on Friday revealed that orders for the A321neo, a single-aisle aircraft, have exceeded 5,000 units, making it the company’s best-selling model. This shift toward smaller, more in-demand aircraft reflects the changing landscape of the aviation industry. In conclusion, Airbus is undertaking inspections and potential repairs of A380s in its Toulouse factory due to wing-spar cracking issues. The inspections, specifically on Emirates’ A380s, are taking place in a dedicated facility within the Jean-Luc Lagardere building. Despite the transition to smaller aircraft, Airbus is committed to addressing the concerns surrounding the A380s. Collaboration between Airbus, Emirates, and maintenance partners aims to minimize operational impact. Airbus to Provide Free SAF for First Delivery Flight From July 2023, free Sustainable Aviation Fuel provided for Airbus Toulouse and Hamburg deliveries, joining China and the US BY BHAVYA VELANI July 10, 2023 Note: Important photos and graphics in the original article. TOULOUSE- Promoting Sustainable Aviation Fuel (SAF) as a crucial tool for decarbonising the aviation industry, Airbus is taking bold steps to lead the way. The company has set a goal to achieve 10% pure SAF in its own operations’ fuel mix by 2023. This includes ferry flights to its home base. Subsequently, to support this initiative, Airbus offers up to 5% pure SAF, free of charge, to customers receiving aircraft in Toulouse and Hamburg. Airbus Free SAF Ferry Flights As a leader in the aviation industry, Airbus is actively advocating for adopting Sustainable Aviation Fuel (SAF) to reduce carbon emissions effectively. Further, the company believes that concrete actions are necessary for its operations and while supporting its customers. Subsequently, Airbus has already committed to using 10% pure SAF in its commercial aircraft and helicopter internal operations this year. Building upon this commitment, the company is now extending an offer of up to 5% pure SAF, free of charge, to customers departing from the Toulouse and Hamburg delivery centres. The inaugural beneficiary of this offer was IndiGo (6E), whose new A320neo took off from Toulouse on 3 July. The validation of Airbus’ Science-Based Targets initiative (SBTi) in January 2023 emphasized the importance of actively promoting the adoption of SAF to meet carbon emission reduction targets. As part of this effort, customers ferrying aircraft from Tianjin, China, and Mobile, Alabama, to their home bases can already select varying concentrations of SAF. Airbus’ delivery teams now offer 5% pure SAF to all customers departing from Toulouse. Further, the same offer expanding to customers in Hamburg starting in September. Airbus has secured 6,805 hectolitres (HL) of SAF to achieve its objectives with different blend ratios ranging from 30% to 49%. This significant allocation will result in approximately 18,000 HL or 475,500 US gallons of blended SAF for 2023 alone. For instance, IndiGo (6E) Airlines has already capitalized on this opportunity by dispatching an A320neo from Toulouse (TLS) to Delhi (DEL) in early July. Paving the Way for the Future Airbus’ commitment to promoting SAF extends well beyond the current year. Further, the company is actively working to secure SAF supplies for future ferry flights departing from all its delivery centres. Julien Manhes, Airbus’ head of SAF and fuel efficiency, affirms, “Naturally, Airbus’ ambition goes beyond 2023. We’re working to secure SAF supplies into next year and beyond for ferry flights departing all our delivery centres. We’re sending a strong signal to our customers, the fuel ecosystem, and the wider sector: SAF has arrived.” In a recent development, Airbus announced a partnership with LanzaJet to support the construction of SAF facilities. These facilities will utilize LanzaJet’s proprietary Alcohol-to-Jet (ATJ) technology pathway to accelerate the certification and adoption of 100% drop-in SAF. Further enabling existing aircraft to operate without fossil fuels. This partnership is another significant step towards investigating and supporting the certification of 100% drop-in SAF. Subsequently, following Airbus’ collaboration with renewables producer Neste last year. The collective efforts aim to expedite the transition to sustainable aviation fuels. Additionally, Airbus remains fully engaged in boosting SAF production on a global scale. Unveiling Sustainable Aviation Fuel Sustainable Aviation Fuel (SAF) is an approved aviation fuel that blends up to 50% synthetic components derived from waste products with kerosene. The synthetic component significantly reduces carbon emissions by approximately 80% throughout its lifecycle compared to conventional jet fuel. Further, all Airbus aircraft, including military aircraft and helicopters, can already operate with a 50% SAF blend. Looking ahead, Airbus aims to make its entire product portfolio compatible with 100% SAF usage by 2030, acting as a catalyst for a global uptake of 10% SAF by the same year. Emirates A380 has blocked the Runway at London Gatwick Exclusive BY BHAVYA VELANI July 12, 2023 Note: Important photos and graphics in the original article. LONDON- Middle East carrier, Emirates (EK) Airbus A380 flight EK9 from Dubai (DXB) to London Gatwick (LGW) has blocked the runway at the airport. Further, departures and arrival at the airport are halted. The flight operated by Airbus A380-842, registered as A6-EUN, faced some kind of problems. First, it made a go-around; later, it landed at LGW but stopped on the runway. Emirates A380 Halted Gatwick Operations The firefighting team is assisting the aircraft and nearby the aircraft, probably some engine or landing gear system issues. Subsequently, the aircraft expected to arrive at Gatwick are seen circling nearby the airport. This includes Ryanair (FR), Vueling (VY), Norwegian (DY), and various other carriers. UPDATE 1: Emirates have declared a full emergency at London Gatwick amid nose wheel steering failure due to a hydraulic leak. Following this, firefighting vehicles surrounded the aircraft to prevent fire. UPDATE 2: Emirates has cleared the runway, and operations have resumed. The ATC is giving departure first, and arrivals are expected soon. Revolutionary Design, Unmatched Performance: Inside the X-55 Carbon Comet by Lockheed Martin by SOFREP Jun 21, 2023 The X-55 was a technology demonstrator for the use of advanced composite materials in an aircraft fuselage. (Source: Alan Wilson/Wikimedia Commons) The Carbon Comet The Lockheed Martin X-55 Carbon Comet is an advanced composite cargo aircraft that’s out of this world! This cutting-edge aircraft was designed to demonstrate the use of high-tech composite materials, and it’s been making waves in the aviation industry ever since. Alright, troops, gather around because we’re about to take a closer look at Lockheed Martin’s X-55 Carbon Comet – a mean, lean, flying machine that’s taking the aviation industry by storm. First of all, let’s talk about what makes this bird special. The X-55 is built with advanced composite materials, drastically reducing its weight while maintaining strength and durability. It can fly faster, higher, and farther than traditional metal aircraft. Thanks to the Composites Affordability Initiative introduced by the US Air Force Research Laboratory back in the mid-1990s, we’re finally seeing the potential of composites being fully realized. The X-55’s innovative design was made possible through the Composites Affordability Initiative (CAI), a bold approach by the US Air Force Research Laboratory (AFRL) to create advancements in the design and manufacturing of composites. The CAI aimed to make advanced composites more accessible and affordable to the aviation industry, which hesitated to adopt these materials at the time. The X-55’s composite structure also offers greater resistance to corrosion, fatigue, and damage, making it more reliable and low-maintenance. These features are critical in the demanding environments where the X-55 operates, such as reconnaissance missions, intelligence gathering, and other military operations. So how does the X-55 stack up against other aircraft in its class? Well, let’s take a look at the MQ-9 Reaper, for example. While the Reaper is a formidable platform in its own right, it’s also considerably heavier and slower than the X-55. With a maximum speed of 260 knots and a flight time of around 14 hours, it’s just not as agile or versatile as its composite cousin. Plus, the X-55’s stealthy design means it can fly undetected in hostile airspace, which is a definite advantage in a combat situation. Comparison to Lightning and Blackbird Of course, we can only talk about Lockheed Martin by mentioning their other famous products, like the F-35 Lightning II and the SR-71 Blackbird. Both of these aircraft represent the pinnacle of military technology in their respective eras, but they also highlight how far we’ve come with composite materials. The F-35 uses composites extensively in its design, which gives it a lower radar signature and greater maneuverability than older metal fighters. Meanwhile, the SR-71 was famous for its titanium construction, which allowed it to fly at incredibly high speeds without melting. But even the mighty Blackbird would have been even more impressive if it had been made with the kind of advanced composites we have today. Lockheed Martin Advanced Capabilities The X-55 is a twinjet transport aircraft that features a unique design, with its fuselage being replaced aft of the port side forward entrance door. It was originally based on the Dornier 328JET but has since been modified to make use of advanced composite materials. These materials are lightweight yet incredibly strong, allowing for greater speed and agility than traditional aircraft designs. But what really sets the X-55 apart from other planes is its impressive engineering feats. For example, did you know that it can take off and land in just 2,000 feet? That’s less than half the length of a standard runway! Plus, it can reach speeds up to 500 mph and has a range of nearly 1,500 miles. Talk about impressive! Lockheed Martin’s X-55 Carbon Comet represents a significant milestone in the application of advanced composites technology in modern aircraft design. Its unparalleled performance and durability have made it a top contender in the UAS industry, setting the standard for future designs. The AFRL’s Composites Affordability Initiative has played a crucial role in creating this game-changing technology and has paved the way for future advancements in the field. So read on to learn more about this more aircraft, check out our book list here! Boeing sees 5G, drone inspectors and augmented reality training key to future aircraft maintenance... Boeing officials recently demonstrated two separate efforts with the Air Force focused on aircraft mission and training readiness. By JASPREET GILL on June 29, 2023 at 11:30 AM Virtual mixed reality through Boeing’s ATOM technology and wearable devices allows customers to see three-dimensional interactive views of the aircraft. (Boeing) WASHINGTON — In the eyes of defense contracting giant Boeing, the future of aircraft mission and training readiness will rely on automation enabled by 5G connectivity to ensure planes spend less time in hangers for repairs and more time in the air. Right now, the company is evaluating how routine maintenance on its aircraft can be completed faster and more accurately with the help of autonomous technologies that can assist human operators, who themselves may have been trained using augmented reality. At the heart of the effort are two parallel programs: Autonomous Aircraft Inspection (AAI), which uses drones to assist with maintenance, and a Microsoft Hololens-enabled AR training initiative dubbed Augmented Training Operations Maintenance (ATOM). Beyond their own operations, during a demonstration at the company’s Arlington, Va., headquarters Tuesday, company officials made their case for the potential for both programs to aid the US Air Force and keep more American planes air-worthy. Boeing’s ATOM technology connects field representatives with customers globally to resolve issues quickly (Boeing). Autonomous Aircraft Inspection: A Digital Toolbox For Technicians Thousands of miles away, at Joint Base Pearl Harbor-Hickam in Hawaii, the Air Force has already tested how drones can help with maintenance readiness for its C-17 aircraft through Boeing’s AAI program. The idea, with which the Air Force has been experimenting for years, is to essentially digitize inspection workflow by using a drone, this one made by autonomous aviation systems company Near Earth Autonomy using Boeing software, to help technicians conduct routine maintenance checks — things like identifying corrosion and missing rivets. “Our goal here is to empower the warfighter with a digital toolbox, per se, of different capabilities that are [original equipment manufacturer] backed, so they never have to worry about concurrency, they never have to worry about… is this the right… module on the aircraft where this particular sustainment or training tool is being applied,” Scott Belanger, team leader for next generation product support for Boeing Global Services, told reporters. With AAI, an airman picks what part of the aircraft will be inspected and the drone collects photos, which are delivered back to the airman on the ground, Alli Locher, senior product manager at Near Earth Autonomy, explained. So far, five drones have been approved and three drones have been funded by DoD, Belanger said. “The other key here with 5G that’s really important is it’s great having photos, but one of the major problems that we’ve seen all across the industry is… there’s a lack of labor right now and a lack of resources available to have the right knowledge in place to actually be able to assess damage,” Locher said. “You might not have the person physically there. So how do you share resources, how do you share photos and make sure that you can collaborate effectively?” That’s where the cloud comes into the play. Photos from the drones, which are owned by the Air Force, are stored in a cloud environment and analyzed, making the data accessible from anywhere. That’s particularly useful if a defect is detected, and technicians in different places can collaborate and come up with a plan on how to tackle the problem. Still, the technician essentially has the final say on what data is stored up into the cloud, Belanger said, minimizing automated false alarms. “In other words, there’s not a scenario where the drone and the associated damage detection software is just going to flow damage straight to the cloud without the human technician concurring,” he added. The system is currently only trained for C-17s, but it can be applicable across the entire aircraft fleet, Locher said. It’s just a matter of loading the models into the Boeing software. C-5 aircraft, for instance, were recently loaded into the system, she added. Belanger admitted AAI isn’t perfect, but claims it’s been proven to be more accurate than just a human working alone. He estimated the accuracy level at about 78 percent. Using drones can also drastically reduce the time it takes to perform, cutting pre-flight inspections from four hours to just 30 minutes, Locher said. The system isn’t meant to completely replace a human operator, either. Belanger said there is a “safety observer” who can take control of the drone if there is a problem. Belanger added the process to train operators is about eight hours, and eight people have been trained so far at Joint Base Pearl Harbor-Hickam. “So we’re not trying to replace the human inspection, we’re trying to inform it,” he said. “We’re trying to upskill that human inspection, so when they do go on the [C-17] tail, they’re not guessing. They know exactly what to bring, they know exactly what to expect. And in the end, they’re going to get the aircraft out of the hangar, back to the crews, back into the fight much, much faster.” Augmented Training Operations Maintenance In a separate effort, Boeing says airmen at Joint Base Pearl Harbor-Hickam are being equipped with a Microsoft Hololens headset that allows them to use augmented reality for training, also using 5G for high-speed connectivity. Boeing has partnered with Chicago-based Enduvo, which builds C-17 training modules that are uploaded into the hololens. (A spokesperson for Boeing told Breaking Defense on Wednesday that the modules aren’t limited to just the Microsoft Hololens and can be used in any other AR/VR headset.) Van Holland, a manager on the Boeing Global Services team, demonstrated to reporters how the process works via live video feed at the base from a point of view of the headset he was wearing. While running the application, Holland brought up his hand in front of him, bringing up a digital 3D rendering of an aircraft part and a display menu of different options built into the application. “One of the things that’s great about this is all these sorts of capabilities are things that I want simultaneously,” Holland said. Belanger said ATOM was particularly useful during the COVID-19 pandemic. “We have eight international C-17 partners, and they bring their aircraft back to the United States for recurring modifications and maintenance,” he said. “Well, during COVID the Australians couldn’t bring their aircraft back here,” Belanger continued. “So what did [Holland] and his team do? They boxed up some of these ATOM goggles [and] sent them to the Australians. And while they were not able to do everything, they were able to do some pretty serious maintenance right there in Australia with secure reach back and the ability to dial in Boeing engineers everyday to walk through some pretty complex maintenance actions.” He added that the company wants to expand the ATOM project to the Navy at Whidbey Island, Wash. Although AAI and ATOM are technically separate programs, the hope is that in the future they will work together in some capacity. Both efforts are still in the early stages of development. “I can easily see one day where the information collected using the drones can be sent back to the headset,” Locher said. NASA X-59 QueSST aircraft moves Closer to Runway at Lockheed Martin Skunk Works facility for ground testing The series of images in this article shows NASA’s X-59 as it sits on the flight line — the space between the hangar and the runway — at Lockheed Martin Skunk Works in Palmdale, California, on Jun. 19, 2023. The QueSST (Quiet SuperSonic Technology) for quiet supersonic commercial flight over land moves on to the next stage for NASA Aeronautics‘ X-59. The aircraft moved to the space between the hangar and the runway which marks the start of a series of ground tests to ensure the X-59 is safe to fly. Lockheed Martin says on its Facebook Page; ‘We moved the innovative aircraft to a run stall on the flight line for further ground testing, including vibration testing. Technicians check out the X-59 aircraft as it sits near the runway at Lockheed Martin Skunk Works in Palmdale, California, on Jun. 19, 2023. ‘It is aiming to quiet the sonic boom and is one step closer to shaping the future of supersonic commercial flight travel.’ According to a NASA news release, this series of images shows NASA’s X-59 as it sits on the flight line — the space between the hangar and the runway — at Lockheed Martin Skunk Works in Palmdale, California, on Jun. 19, 2023. The move from its construction site to the flight line is one of many milestones that prepare the X-59 for its first and subsequent flights. Next up, the team will conduct significant ground tests to ensure the aircraft is safe to fly. The X-59 aircraft—the centerpiece of NASA’s QueSST mission—is designed to demonstrate the ability to fly supersonic, or faster than Mach 1, while reducing the loud sonic boom to a quiet sonic thump. NASA’s X-59 aircraft is parked near the runway at Lockheed Martin Skunk Works in Palmdale, California, on Jun. 19, 2023. This is where the X-59 will be housed during ground and initial flight tests. The X-59 technology will be demonstrated when the X-plane flies over communities starting in 2024 when NASA will fly it over several communities to gather data on human responses to the sound generated during supersonic flight. NASA will deliver that data set to US and international regulators to possibly enable commercial supersonic flight over land. This breakthrough would open the door to an entirely new global market for aircraft manufacturers, enabling passengers to travel anywhere in the world in half the time it takes today. World’s Largest Rubber Band Airplane By Editorial Staff Published: July 9, 2023 Updated: July 10, 2023 You Tube of Massive 16 Rubber band airplane. Given modern materials, tools and techniques, you would think it would be a sure thing to scale up the standard rubber-band-powered airplane we all flew as kids and have something with a truly awesome wingspan. As this video from the Think Flight channel shows, it’s not easy at all. And finding a rubber band large enough is the least of the problems. Airbus to handle some A380 repairs after wing-spar cracking Reuters July 7, 202312:20 PM CDT Updated 4 days ago PARIS, July 7 (Reuters) - Two years after the world's largest jetliner rolled out of its Toulouse factory for the last time, Airbus is preparing to bring some A380 superjumbos back to their birthplace for wing inspections even as it re-dedicates the plant to smaller jets. A380 production stopped in 2021 and part of the giant Jean-Luc Lagardere assembly hall has been redeployed as an assembly line for the single-aisle A321neo, to be inaugurated on Monday. But elsewhere in the colossal plant, Airbus is preparing to welcome back some A380s from the largest customer, Emirates, for inspection and possible repairs after accelerated cracking was detected in some wing spars of jets stored during the pandemic. Work on a dedicated "A380 Emirates" inspection facility in the building began in December and the project is due to run until third quarter 2024, according to Force Ouvriere union. Airbus has agreed to pay special bonuses to workers on the project starting in September, backdated to the end of last year, it said in a notice giving the first detailed indication of the duration of the repair project. "We are supporting inspections on some aircraft in Toulouse," an Airbus spokesperson said. Emirates, which has said the problem does not represent an immediate safety issue, said there would be minimal impact to its operations from the inspection and repair programme which is based on specified time limits since each wing was installed. "We're working closely with Airbus and our MRO (maintenance and repair) partners to fulfil the wings inspection and repair requirements for our A380s," an airline spokesperson said. "A large part of the work will be conducted at Emirates' Engineering Centre and Airbus is providing us with supplementary MRO support in Toulouse." Ground time per jet will depend on findings and repairs, but is "estimated to average about 60 days," the spokesperson added. Emirates President Tim Clark told reporters last month that the first aircraft was being fixed and that the issue would have "very little impact on our operating profit". Opened in 2004, the Jean-Luc Lagardere site has been described as the world's second-largest building by usable space and remains one of the few industrial plants tall enough for A380s. There is also a shortage of third-party repair capacity. Both Airbus and Boeing (BA.N) are remodelling part of their largest and most iconic factory buildings as the industry's focus switches from discontinued four-engined jumbo jets towards in-demand smaller models to accommodate changes in air travel. Airbus data on Friday showed that total orders for the A321neo had topped 5,000 units to become its most-sold model. Curt Lewis