Flag Counter

Sunday, October 28, 2012

Airbus to double U.S. spending by 2020


(Reuters) - Airbus, which last year paid $12 billion to U.S. suppliers of the parts and services it needs to build its planes, will double that spending by 2020 as it gears up to build a new plant in Mobile, Alabama.

Airbus Americas Chairman Allan McArtor will tell an educational summit in Los Angeles on Friday that the spending boost will result from company's planned $600 million plant to assemble its A320 short- and medium-distance planes.

Southern California is likely to be a big winner from the procurement, with a doubling of the $1 billion the aircraft maker, part of EADS (EAD.PA), spends in the region.

"LA has a good talent base and there's a lot of innovation going on here," McArtor said in an interview after attending groundbreaking ceremonies for the $80 million factory that Valencia, California-based Aerospace Dynamics International is building to supply large structural components of Airbus' next generation A350 extra-wide body aircraft.

To get the added work, however, the Airbus executive said southern California will need to become more competitive with other states and countries by improving its educational institutions to turn out skilled workers, engineers and others the aerospace industry will demand.

"We have to make it attractive here so that the brightest kids don't go to private equity firms,"

McArtor said. "If they can't improve the business climate here, then southern California may lose out to South Carolina, Texas or somewhere else."

By 2015 Airbus expects to have 13 daily flights by carriers flying its A380 aircraft to Los Angeles International Airport.

That equates to $9.4 billion in added economic activity in tourism and other services, Airbus said, making calculations based on a 2007 study by the Los Angeles Economic Development Corp.
The flights would add an estimated 3,900 jobs in the region.

Airbus, which spends more than 40 percent of its procurement budget on U.S.-based suppliers, projects annual growth in air travel will more than double over the next 20 years.

By 2031, McArtor estimated 32,550 airplanes will be in service, up from 15,550 today.

By then, China will pass the United States as the largest market for air travel, the executive said, and will account for 35 percent of all newly delivered aircraft. North America and Europe will each account for 21 percent.

Singapore Airlines in $7.5 billion Airbus deal


(Reuters) - Singapore Airlines (SIAL.SI) will order five Airbus A380 aircraft and 20 more A350 planes in a deal valued at $7.5 billion, looking beyond a business slowdown that has led the carrier to stop hiring cadet pilots for now.

"This major order will provide us with additional growth opportunities and is consistent with our longstanding policy of maintaining a young and modern fleet," SIA's chief executive, Goh Choon Phong, said in a statement on Wednesday.

The order also reflected the Singapore flag carrier's confidence in the strength of the market for premium full-service travel, he added.

International Air Transport Association (IATA) said last week that the number of passengers flying on first and business class rose 8.5 percent in August from a year ago.

SIA is facing increased competition from Middle Eastern carriers such as Emirates EMIRA.UL on longer routes at a time when passengers in the West have become more cost-conscious.

The Singapore carrier has frozen cadet-pilot recruitment and cut flying hours for junior pilots, the Straits Times newspaper reported earlier this week.

SIA operates 19 A380-800 superjumbos and already has firm orders in place for 20 A350s. Deliveries of the new Airbus (EAD.PA) planes, which have a list price of $7.5 billion, are due to begin in 2017.

Hints of the SIA-Airbus deal emerged on Tuesday when French Prime Minister Jean-Marc Ayrault, who has just returned from a business trip to Singapore and the Philippines, told Airbus workers their company had signed an order for 15 aircraft and taken options for the A350 and possibly the A380.

SIA said that as part of its deal with Airbus, the European aircraft maker will buy back five A340-500s, which will be removed from service in the fourth quarter of 2013.

The withdrawal of the A340-500s will result in the end of non-stop flights between Singapore and Los Angeles and between Singapore and Newark. The Newark service, which connects Singapore to New York in 19 hours, is an all business-class flight and one of the world's longest scheduled service.

In a separate statement on Wednesday, SIA's long-haul low-cost unit Scoot said it agreed to acquire 20 Boeing 787 aircraft for delivery starting in 2014. The 787s were originally ordered by SIA, Scoot said.

The B787 aircraft will replace Scoot's Boeing 777-200 fleet and help its ongoing expansion, the low-cost carrier said.

Boeing Sees Hurdles Next Year After 2012 Forecast Boosts

Boeing Co. (BA), which has boosted its 2012 profit forecast three times as commercial and military aircraft sales rose, said it expects challenges next year that include a tougher defense market and higher pension expense.

The projected $3.5 billion in pension expense next year will be about $1 billion more than this year’s, the planemaker said today. The defense unit, source of more than 40 percent of total sales last year, is bracing for cuts in Pentagon spending, according to Boeing, which won’t forecast 2013 performance until January.


Those obstacles may temper sales growth from commercial- plane deliveries as Chief Executive Officer Jim McNerney takes advantage of a $307 billion backlog, bolstered by airlines seeking to trim fuel expenses with more efficient aircraft. Boeing is increasing the division’s output by 60 percent in the four years through 2014.

The non-cash pension expense is about $500 million higher than Barclays Plc had projected and “will weigh on consensus estimates more than we originally expected,” Carter Copeland, a New York-based analyst, said in a note to clients after the company’s third-quarter earnings report. “We expect this to be the central push-back point on an otherwise strong quarter.”

The expense may prompt a reset of 2013 earnings projections, said JPMorgan Chase & Co.’s Joe Nadol, who called it “a whopper.” Higher pension costs have also weighed on earnings this year, lowering third-quarter profit by $194 million.

Voluntary Payments

Boeing Chief Financial Officer Greg Smith said the company plans to make voluntary cash pension contributions next year “to proactively manage our liability and expense.” This year’s voluntary payment was $1.5 billion. Smith said his top priority is to return cash to shareholders, and he will give an update on share repurchase plans by the end of the year.

Free cash flow in the quarter was $1.17 billion, up from $69 million a year earlier, Chicago-based Boeing said in a statement. The company increased its outlook for operating cash flow this year by $500 million, to more than $5.5 billion.

Earnings in 2012 will be $4.80 to $4.95 a share, Boeing said, a projection that exceeds the $4.70 average estimate of 29 analysts in a Bloomberg survey. Third-quarter sales rose 13 percent to $20 billion as shipments of aircraft and equipment to customers climbed 28 percent.

Boeing Commercial Airplanes, which accounted for more than half of 2011 sales, is responding to what McNerney termed a “dramatic” replacement cycle, with airlines trying to reduce fuel costs by investing in new planes.

Commercial Backlog

The commercial-jet backlog rose 2.5 percent last quarter and now stands at 4,100 airplanes valued at more than eight times the unit’s revenue last year.

In the defense business, McNerney warned on an earnings call that 2013 would be a challenge because of this year’s “unusual strength” in sales to foreign militaries and because of the threat of sequestration, the $500 billion in automatic U.S. defense cuts slated to go into effect unless lawmakers agree on an alternative deficit-reduction plan.

Boeing fell 0.2 percent to $72.71 at the close of trading in New York. The shares previously dropped less than 1 percent this year, trailing a 12 percent gain in the Standard & Poor’s 500 Index.

The company delivered 149 commercial jets and 50 military aircraft, helicopters and satellites in the three months through September.

Third-quarter net income at Chicago-based Boeing fell 6 percent to $1.03 billion, or $1.35 a share, from $1.1 billion, or $1.46, a year earlier. That beat the average of 25 analysts’ forecasts for $1.12 a share.

Higher Margins

“With no major execution issues this quarter, operating margins came in comfortably ahead of our expectations,” Rob Stallard, an analyst with RBC Capital Markets in London, wrote in a note, keeping his neutral rating on the shares. Operating margin in the commercial-planes business fell 1.9 points to 9.5 percent in that period, while remaining steady at 9.9 percent for the year through September.

Boeing said it still expects total airliner deliveries to rise to 585 to 600 this year after 436 in the first nine months. The company plans to deliver more 777s, 787s and 737s next year. Carriers pay about 60 percent of the price of a plane in installments leading up to delivery, and the rest when they pick up the jet.

Airbus SAS, which had delivered more planes than Boeing every year since 2003, handed over just 405 through September and has forecast 570 for the full year.

Jetliner Deliveries

Boeing reiterated that it will deliver 70 to 85 of the new wide-body 787s and 747-8s this year, split about evenly between them. The company expects more orders by year-end for both the passenger and freighter versions of the 747-8, which entered service a year ago, McNerney said.

The higher deliveries last quarter pushed the commercial unit’s sales up 28 percent to $12.2 billion. Earnings rose 6 percent to $1.15 billion, reflecting dilution from the lower- margin 747-8 and 787 Dreamliner, which was delivered to its initial customer in 2011 after more than three years of delays.

Boeing’s defense business tripled the number of Chinook transport helicopters it delivered to 18, and handed over 10 Apache attack helicopters in the period compared with none a year earlier. Deliveries for other programs declined, and shipments of F-15 fighter jets dropped to zero.

Defense revenue fell 4 percent to $7.84 billion as deliveries of less-costly aircraft increased, and operating profit grew less than 1 percent to $827 million. The defense unit’s margin rose by half a point to 10.5 percent.

The margin growth is consistent with companies across the industry as contractors including Boeing focus on cost reduction ahead of the Pentagon’s expected budget cuts, wrote Douglas Harned, an analyst with Sanford C. Bernstein & Co. in New York who rates the stock outperform.

Boeing is repositioning its military business and focusing on getting 30 percent of revenue from abroad in the near future, McNerney said. That would be up from 24 percent last year.

Did French Prime Minister Accidentally Reveal Big Airbus Order?

Airbus parent EADS, whose merger talks with BAE Systems leaked to the press in the summer, may find more of its business subject to accidental early disclosure - this time by the French prime minister.
Airbus
Getty Images

Jean-Marc Ayrault, who has just returned from Singapore and Philippines to help drum up business for French companies, told Airbus workers his trip had highlighted the importance of remaining competitive on world export markets.

But departing from a prepared speech for the opening of a new Airbus factory in southwest France, Ayrault then referred to billions of dollars of plane orders that did not appear to correspond to business already announced from those countries.

"I would like to add that during this trip, Airbus signed an order for 15 aircraft and took options for the A350 and possibly the A380," Ayrault told an audience of 1,000 staff and media.

The expressions of Airbus executives at the event gave nothing away, but aerospace industry watchers have said Singapore Airlines is among a number of top carriers seen as candidates to consider fresh orders for long-haul jets.

Such deals are sure to grab industry attention because a battle between Airbus and Boeing over the lucrative "mini-jumbo" market for large twin-engined jets has reached a crucial phase.

Airbus is looking to bag a high-profile endorsement for its A350-1000 long-range jet, while Boeing is pondering upgrades for its 777 airliner which is enjoying record sales.

During Ayrault's trip, Philippine Airlines confirmed an order for 10 Airbus A330 jets on top of a purchase in the summer. An official in the French prime minister's office said his comments alluded to this latest purchase "and nothing else."

An official government transcript of his comments confirmed the wider reference to potential A350 and A380 orders.

Airbus declined comment. Neither the Singapore nor Philippine carriers were immediately available for comment.

Ayrault was speaking as Airbus inaugurated a factory for the A350 in the latest chapter of its rivalry with U.S. planemaker Boeing.

Airbus hopes to boost sales of the A350-1000, the largest variant due to seat 350 people. A four-year drought ended when Hong Kong's Cathay Pacific placed an order for the airplane and upgraded 16 orders for smaller A350-900s in July.

Armed with Cathay's endorsement, Airbus is widely expected to target other standard-bearers including Singapore Airlines and major Western carriers that might be ripe for an upgrade to the larger model or a brand-new order. Singapore Airlines already has 20 A350-900s on order.

"They're big 777 users, and anything that indicated a pattern of 777-300ER migration towards the A350-1000 would be a big wake up call for Boeing," said analyst Richard Aboulafia.

The 777-3000ER is the most recent version of Boeing's most profitable aircraft and sells for $298 million apiece.

The A350-1000 is worth $321 million at list prices.

Airbus says the lightweight carbon-composite aircraft will beat the 777 on efficiency, but will not be available before late-decade. Airbus plans to increase output of the largest A350 to try to break Boeing's firm hold on the mini-jumbo market.

Influential aircraft lessor Steven Udvar-Hazy, founder of Air Lease Corp, urged Airbus to focus on this model.

"We are trying to persuade Airbus to de-emphasize the A350-800 in favor of the A350-1000," he told Reuters.

For its part, Boeing wants to persuade major customers like Singapore to keep ordering the current 777-300ER or else wait for a possible upgrade around the turn of the decade. Airlines such as Emirates have pressed it to firm up the design plans.

Airline sources say the U.S. planemaker is holding a summit of carriers next week to discuss their large-jet requirements.

Boeing declined to comment on the meeting.

"We schedule a series of meetings with customers to discuss twin-aisle airplanes, including our existing product line and future development options," a spokesman said by email.

"We are always talking with our customers about their fleet requirements, and per Boeing policy, do not discuss details".

SIA Places Large Order For Airbus Widebodies

October 24, 2012
 
Singapore Airlines (SIA) has revealed an order for five more Airbus A380s and another 20 Airbus A350-900s, stressing that the move reflects its confidence in the future of premium air travel.

Prior to today’s announcement SIA had 20 A350-900s on order, so the new order increases the total to 40. Delivery of its first A350 is due in 2015. SIA already operates 19 A380s, but had none left on order backlog. It says deliveries of the new five will start in 2017.

The Star Alliance carrier has also disclosed that the 20 Boeing 787-9s it already had on firm order, for delivery from 2014, will be assigned to its medium-haul low-cost carrier Scoot.

“As part of the [new] deal, Airbus has agreed to acquire SIA’s five A340-500s, which will be removed from service in 2013’s fourth quarter,” the carrier says. This means it is cutting its non-stop services to Los Angeles and New York Newark. The airline says the decision to axe the A340-500s is in line with its “policy of maintaining a young fleet.” The Aviation Week Intelligence Network shows that the SIA A340-500s are nearly nine years old.

It is widely known in the industry that SIA’s A340-500 non-stop flights to the U.S. are unprofitable, because of the four-engined aircraft’s higher fuel burn. Some SIA executives were also questioning why the carrier was going to the trouble of maintaining such a small fleet of A340s.

The decision to stop flying non-stop to the U.S. is disappointing, but “we remain committed to the U.S. market,” SIA CEO Goh Choon Phong says. “Over the past two years we have increased capacity to both Los Angeles and New York by deploying A380s on flights via Frankfurt and Tokyo.”

SIA’s fleet of 777-200ERs is actually older than its A340s. The Aviation Week Intelligence Network shows the 34 aircraft are about 11 years old on average. The A350-900s will replace some of the 777-200ERs. The airline has already phased out some of its -200ERs by placing the aircraft with Scoot or leasing them to Royal Brunei Airlines.

New Inspections Ordered For A380 Trent 900s

October 23, 2012
 
Operators of Rolls-Royce Trent 900-powered Airbus A380s have been instructed to inspect, and if necessary replace, parts of seals around the low pressure turbine (LPT) following damage to an engine caused by vibration.

An airworthiness directive issued by the European Aviation Safety Agency (EASA) says that the condition, if not corrected, could lead to cracking developing in the engine’s LPT second stage, “possibly resulting in an uncontained engine failure and subsequent damage to the aircraft.”

The issue, which is not related to the oil-system problems that led to the uncontained failure of a Trent 900 on a Qantas Airways A380 in Singapore in 2010, was uncovered when debris was found in the tailpipe of an engine that had experienced increased vibration during a revenue flight.

The inspection revealed the turbine disc had lost material from part of the interstage seal, sending parts into the downstream LPT stages. Preliminary findings indicate that fins on the interstage seal had “rubbed into the stage 2 honeycomb seal, which overheated and cracked, finally resulting in releasing a portion of the ISS (interstage seal) area of the disc.”

The AD, which is effective as of Nov. 5, says inspections must be conducted within 10 flights if an engine health monitoring system picks up vibration levels that exceed the preset alert limits.

In August, EASA issued an AD calling for inspections and replacement if needed of the Trent 900 LPT shaft and bearing housing end cover. The action followed an in-flight turn back which resulted from the seizing up of the low pressure system in one of the A380’s engines. The fault was traced to oil starvation of the bearings caused by a fracture in an oil transfer tube. It had fractured because a support piece was missing.

Airbus Opens A350 Final Assembly Line

Airbus is trying to reassure suppliers and customers that its A350XWB remains on track for first flight in the summer of 2013. The aircraft manufacturer officially opened the A350 final assembly line on Tuesday alongside a two-day supplier conference. “Our message is: the program is on plan and the upcoming major milestones will be on plan, too,” Airbus Chief Operating Officer Guenther Butschek said.

Two issues surrounding the program had been noticed with concerns amongst suppliers: Airbus’ decision to introduce weight improvements and changes in several batches, which leads to extra work and some performance shortfalls for early models, and the recent wing drilling troubles that have led to some delays for later aircraft, although not the MSN1. A350 program chief Didier Evrard told suppliers that introducing the aircraft in batches was a normal process.

Airbus has attached the wings to the first A350 fuselage, MSN5000, which will be used as the fatigue test aircraft. The aircraft is currently placed in one of the two stations (40) that are dedicated to wing-body-joining work. Adjacent to it, the fuselage of MSN1 is at station 50. One of the wings for MSN1 has arrived and is in the final assembly hangar next to the fuselage. The other wing is expected to arrive by the end of October.

According to Evrard, Airbus has built a total of five wings using a manual process after it has turned out that software glitches in the automatic process were causing delays. Those wings were intended for MSN5000 and MSN1. A fifth wing is currently at IABG to perform initial load testing ahead of the actual fatigue tests that will happen using MSN5000 in Toulouse.

Evrard says the software issues caused initial automatic drilling to take around 2-3 months per wing, when it was supposed to have lasted only one month. But for MSN3, the next aircraft in the assembly process, the automatic drilling process is “back on target” and Airbus has already progressively reduced the manual work.

Evrard also points out that at least the initial two flight test aircraft will be kept at Airbus and no decision has been made whether to keep MSN2 and MSN4, the subsequent aircraft. Airbus plans to assemble two aircraft this year and start producing a third before the end of the year. In the second half of 2013, the manufacturer is aiming for a production rate of one aircraft per month. “Ramping up production will be crucial,” Evrard says.

Airbus is understood to roll out the first A350 (MSN1) in April, the company has not specified in detail when the aircraft will make its first flight, other than saying it expects to reach that milestone next summer.

Work is progressing on a second assembly hall that will allow Airbus to increase production rates from 2014. Initial assembly is performed in one hall that includes four stations, three of which are duplicated. Once the additional building is completed, station 30 (for systems testing and cabin installation) will move over. A total of four station 30s will be available.

Airbus CEO Fabrice Bregier indicates that Airbus might raise production of the A350-1000, the largest of the three planned A350 versions. “We expected around 40-50 aircraft per year, but we will be much better than that.” If that decision was made, Airbus would have to also invest more into dedicated A350-1000 facilities. Bregier insists that Airbus will build all three planned versions, even though he concedes that customers have “less appetite for the -800”, the smallest variant.

“The market will slightly move to bigger aircraft. But we are observing that trend with other models, too.”

Germany’s decision to withhold payment of around €500 million in refundable loans will not cause any delays and put the program at risk, Bregier says. However, getting the government-backed financing would be a way for Airbus to rule out risk, even if it comes at higher than usual interest rates.

 Germany is the only one of the Airbus countries (including France, U.K. and Spain) that has not gone ahead with the support yet. The government wants further assurances about the German workshare in the A350 and has concerns that German sites might lose out in the long term.

Airbus Wins A380 Order as Original Customer Singapore Tops Up

Airbus SAS secured an order for five additional A380 superjumbos from Singapore Airlines Ltd., the first carrier to fly the double decker, in a much-needed vote of confidence after trailing a sales target this year.

The order for the aircraft, with a combined list price of about $2 billion, is part of a broader purchase by the Asian carrier. Singapore said today it is also adding 20 A350-900s to double its fleet of the long-range jet. The A350 is the European planemaker’s newest wide-body model and is undergoing final assembly for entry into service in late 2014.

Airbus has struggled to win orders this year for its A380 flagship model, hurt by an economic slump and as cracks appeared in wing components that will require eight weeks for repairs. The only order this year so far was from Russia’s OAO Transaero Airlines, leaving the manufacturer trailing a target of selling 30 units to customers in 2012.

“It’s clearly a good sign if Singapore comes back, because they are quite a demanding customer,” said Zafar Khan, an analyst at Societe Generale in London who has a “buy” rating on the shares of Airbus parent European Aeronautic, Defence & Space Co.

Other customers that have come back with additional orders include Deutsche Lufthansa AG, which added two more A380s in September 2011 to an existing order for 12. Qantas Airways Ltd., Australia’s largest airline, in 2006 added eight more A380s to an original order for 12 and Emirates ordered 32 more in 2010 to bring its total order book to 90.

Singapore started flying the A380 in 2007. The carrier offers the aircraft in a three-seat configuration, with first- class passengers enjoying amenities including a closed-off cabin that comes with a full-size bed and flatscreen televisions.

The A380, which typically seats about 520 passengers on two decks, is Airbus’s response to Boeing Co. (BA)’s 747 jumbo. That plane’s latest variant, the 747-8, has also failed to sustain the momentum of earlier versions.

The A380 costs about $389.9 million, though customers typically get discounts.
Airbus has delivered 20 A380s so far this year, and would need to hand over 10 more to reach its annual target. The company has delivered 87 A380s to customers so far.

A350 Wing Sub-Assembly Ramps Up At New GKN Site

October 22, 2012
 
Guy Norris Bristol, England

With the wing of the Airbus A350 already under close scrutiny before the first flying example has been put together, key suppliers are focusing more than ever on a steady production ramp-up and delivering to specification.

Despite the news earlier this year of delays to the delivery of wings for the first flight-test aircraft, as well as for the fatigue-test article, major A350 wing sub-assembly suppliers continue to accelerate their production processes. Although development issues with automatic drilling machines have been fixed, Airbus has acknowledged an expected related delay of around three months to first deliveries of the initial A350-900s in early 2014.

The European manufacturer is therefore looking to its complex supply chain for even sharper performance as it seeks to smooth out any remaining kinks in its production system. GKN Aerospace, which is responsible for the A350 aft composite spar and fixed trailing edge, has a pivotal role in the production flow, as it perfects new assembly concepts in a £170 million ($274 million) purpose-built fully automated facility near Bristol.

Five complete A350 wing sets, including static and fatigue units, have so far been delivered from GKN's Western Approach plant to Airbus UK's wing final assembly facility at Broughton, North Wales, where the complete wing is integrated. The company took over the lease for the site, originally designed to be a distribution center, in April 2009. “When GKN acquired the facility, it was an empty shell,” says Vice President Steve Colebrook, who adds that “we broke ground in May 2009 and laid foundations in July that year.”

The initiative traces its roots to 2008, when GKN launched an aggressive growth plan for its aerostructures work by acquiring Airbus UK's wing component manufacturing and assemblies operation in nearby Filton for £136 million. “It was aimed at keeping the wing center of excellence in the U.K.,” says Colebrook. “The A350 was originally due to be housed within that but because of its size and magnitude it was moved here.”

Currently employing almost 270, the workforce at the Western Approaches facility is expected to grow by another 60 or more as the rate increases on the A350 as well as for the composite wing on the A400M military airlifter, major sections of which are also manufactured here.

The facility is made up of two main buildings, one of which is a climate-controlled, clean room area for the layup and fabrication of the large-scale composite structures, and the other an “industrial area” where the assemblies are completed. Although the composite manufacturing area is state-of-the-art with advanced automated fiber-placement (AFP) machines for the A350 and conventional automatic tape-laying for the A400M, it is in the assembly building where most of the production innovations are to be seen.

“This industrialization was a first for GKN,” says Colebrook. “Normally you'd take the spar to a jig, then take it out and continue to the next jig until it is built. With this one, the spar is loaded and locked into a bespoke jig. Then the jig moves down from station to station to hold the highest level of tolerance before we take it out and pop it into a final turn-over jig to deliver it to Airbus.”

“The key tolerance is the hinge line of the trailing edge,” says value stream manager Mark Howard. “We're making it to within +/- 0.15 mm [0.006 in.] over a roughly 30-meter-long [98-ft.] assembly,” he adds.

 Each of the two wings in the shipset is made up of three components; an inner, mid and outer spar section. Mounted on specially designed manually guided vehicles, the jigs containing the individual spar sections are picked up and moved through the production process. By bringing jigs to the machines, rather than the other way around, GKN is also reducing the amount of capital equipment required for the line, says Howard. Instead of four sets of static jigs per wing, “here we have just three, and two robots,” he adds.

The three sections combine to produce a trailing edge assembly 27 meters long and weighing about 1,800 kg (3,968 lb.) of which around 1,230 kg is made up of the carbon composite spar section. The inboard spar section, measuring 7.5 meters, weighs the most as it includes the spar root and attachment point for the main landing gear.

Composite laminates made up of a Hexcel pre-impregnated carbon/epoxy are “up to 25-mm thick at the deepest end around the wing root and landing gear pivot fitting, and thinner, just under 5 mm, at wingtips,” says chief engineer Clint Diffin.

Assembly of each section begins when five-axis AFP machines, made by M. Torres of Spain, wind composite tows from up to 16 bobbins onto a Cytec-made rotating composite mandrel. The machine is programmed to lay varying thicknesses to tailor the structure for stress requirements and provide foundations for parts such as rib attachment points along the spar.

“When we're at full rate production we will be up to 13 wingsets per month and using up to 20 tons of [Hexcel] composite material per month,” adds Diffin. Three AFP machines are in place, with a fourth in development.

“The A350 inner spar is the thickest we build. It undergoes a hard structural cure and is then prepared for the addition of sacrificial material before being cured again in a secondary cure. This gives us the opportunity to make sure the girth height is correct,” says Diffin, who explains the AFP process was adopted over tape laying because of the higher assembly rates and more complex shaping of the A350 wing.

Left and right spars are laid up simultaneously on the mandrel in a process that takes up to eight 24-hr. working days. The units are then “de-bulked” to remove any trapped air, and inspected. Advances made in the performance of machines and controls during the initial batch of wing shipsets means that less time will be required in future for this process, adds Diffin.

The formed parts are loaded onto an Invar tool for curing in the autoclave. A second autoclave is about to be commissioned as the rate rises. Once cured, parts go into one of two five-axis composite machining tools which combine waterjet and conventional cutting devices before undergoing non-destructive testing for porosity or inclusions. A third tool will be installed by the end of 2014 to match production demand.

The spars are then painted with primer, and metal rib posts are added before completion with trailing edge gear and flap fittings.

Three more wingsets are scheduled for delivery to Airbus UK by the end of the year.

Airbus advances towards first flight of A350 twinjet

Airbus has resolved the issues with the automated drilling process used to produce wings for the in-development A350 at its Broughton, UK factory.

The problems, caused by systems that were not properly optimised, had seen the airframer revert to manual drilling on the first two shipsets.

But Didier Everard, A350 programme manager, says those glitches are now behind it and the automated process has recommenced.

The wings for aircraft MSN3 are "almost finished" at Broughton and wing production is back at its target rate, he said at an event in Toulouse to mark the inauguration of the A350 final assembly line.

A350 ceremony Airbus
 Airbus  
Everard remains confident that the first flight of the twinjet - to be performed by fight test aircraft MSN1 - will take place in mid-2013, but he concedes problems could occur that would delay the maiden sortie.

Five aircraft will participate in the flight test campaign. Three will fly without cabins installed, while MSN2 and MSN5 will be used to test the interior systems.

Rolls-Royce has begun production of the first Trent XWB engines for the flight test aircraft, having already built 10 development powerplants, says Everard.

One of these has been in use on the airframer's A380 flying testbed where it has accumulated 144h in the air and a further 208h in ground tests.

Concerns had been raised by customers of the largest variant, the -1000, that it was overweight and underpowered. Everard says R-R has identified the modifications required to reach the increased 97,000lb thrust mandated by Airbus. This will be achieved through "technology insertion" to allow higher temperatures in the hot section and a larger core.

Although customer concerns remain, some have been mollified. Steven Udvar-Hazy, chairman of lessor ALC, says: "That's still to be seen as far as the weight of the aircraft is concerned. But in the briefings over the last 24 hours it's clear they understand the concerns and are addressing those issues and if necessary Rolls-Royce will have make sure there's a little extra power.

"They understand what the issues are and where they have to be and are on top of things, particularly in terms of weight control."

Airbus is placing most emphasis on the -900 and -1000 variants of the A350, amid continuing weakness in the backlog for the -800, the smallest aircraft in the family.

Although Airbus envisages the -800 being the second model produced, due to enter service in mid-2016, Everard says there is still flexibility in its schedule to advance the -1000 from its entry-into-service date of mid-2017 if required. "The sequence may change depending on the market if there is increasing demand for the -900 and -1000."

However, he says there is no risk of its cancellation "for the time being".

The A350-900 is due to enter service in mid-2014 with launch customer Qatar Airways.

FedEx to build Shanghai Pudong hub

FedEx plans to invest more than $100 million to establish a hub at Shanghai Pudong International Airport (PVG).

FedEx is the third international air express operator to establish a hub at PVG. UPS did so in December 2008 and DHL has established its North Asia hub at PVG.

FedEx’s hub is expected to begin operations in 2017 on a 134,000 square meter site with the capacity to handle up to 36,000 parcels and documents per hour. The facility’s annual sort capability is expected to reach more than 90 million parcels and documents.

FedEx noted in a statement that it will gradually expand its flight frequencies and cargo turnover at PVG to meet growing market demands. Today, it operates 68 weekly flights at PVG.

“Shanghai is one of the fastest-growing economies in China with foreign trade playing a significant role. The new FedEx hub will allow our customers in Shanghai and East China to benefit from these increasing trade flows,” FedEx Asia Pacific president David Cunningham said.

FedEx announced a $1.7 billion profitability improvement plan earlier this month (ATW Daily News, Oct. 10).

Boeing sees $820 billion commercial aircraft market in North America through 2031

Boeing said North American airlines will take delivery of 7,290 aircraft valued at $820 billion through 2031.

In a market forecast presented this week, the manufacturer said the North American commercial fleet will grow from 6,650 aircraft currently to about 8,830 by 2031 (including aircraft retirements).

Boeing Commercial Airplanes VP-marketing Randy Tinseth said, “The long-term outlook for the North American airline industry is approximately 3% annual traffic growth through the forecast period. The market is shaped by aggressive growth of low-cost carriers and the need to replace aging airplanes in the fleets of the established network carriers.”

The manufacturer predicted mainline North American carriers will “maintain strict capacity discipline. Low-cost carriers will continue to outpace network carrier growth to accommodate increased demand and fill some markets abandoned by network carriers.”

Boeing said narrowbody aircraft will comprise 69% of the North American fleet by 2031.

Long-haul international traffic to/from North America will grow at around 5% annually, outpacing the overall pace of growth in the region, Boeing predicted. “The international growth is primarily driven by anticipated passenger traffic to Southwest Asia, China, the Middle East, Africa and South America,” the manufacturer stated. “Passenger traffic between North America and those regions is forecasted grow at or above 6% per year.”

This will require 1,320 new widebody aircraft for North American airlines over the next two decades, Boeing said. However, just 40 of these aircraft will be in the 747-size and larger range, it added.

Boeing noted that the continent’s airlines are operating more cautiously than in the past. “In response to market pressures, airlines are deploying capacity more strategically to help boost yields and cover higher fuel expenses,” it said. “Airlines are optimizing airplane utilization more closely to seasonal demand fluctuations, and passenger load factors remain near historic highs. The number of new-generation airplanes in the parked fleet remains low, indicating that airlines are shifting utilization to their most efficient assets.”

Finnair hails record buoyant 3Q, launches further cost cuts

Finnair (AY) has reported a third-quarter net income of €50.8 million ($65.9 million), up more than 200% from a €1.9 million profit reported in the year-ago period. The airline said these best-ever results were largely attributable to increased turnover, a high load factor, improved unit revenue, and cost cutting.

Turnover rose 7.1% to €650.3 million for the quarter, while expenses increased 3.3% to €603.5 million, producing an operating profit of €48.9 million, up 77.2% from a €27.6 million operating profit in the prior-year quarter.

Traffic rose 8.6% to 6.35 billion RPKs on a 3.4% increase in capacity to 7.81 billion ASKs, producing a load factor of 67.5%, up 3.2 points.

Yield rose 2.3% to 7.54 euro cents, as RASK increased 7.8% to 6.93 cents and CASM increased 6.1% to 6.60 cents. CASK ex-fuel was 4.43 cents, down 1.1%.

"This is the best quarterly result in Finnair's history. The improvement in the company's result is particularly positive considering that our most significant cost item, fuel, increased by some 25% year-on-year. Our more aggressive pricing and the continued optimization of our route network have resulted in improved load factors compared to 2011. The challenging market conditions have also reduced the intensity of competition on certain routes, which has benefited Finnair somewhat,” CEO Mika Vehviläinen said.

AY said a cost reduction program implemented last year, targeting €140 million savings, had “progressed well” and the airline therefore expects to make a full-year operational profit in 2012, the first since 2008.  It also announced a new cost cutting program targeting sustainable annual cost savings of €60 million by the end of 2014.

“We are still far off from our long-term profitability target of 6% operating profit margin,” Vehviläinen said, pointing out that the airline is committed to fleet renewal investment worth $1.2 billion over the next few years. This investment is “vital for the implementation of the airline's Asian growth strategy,” the airline said.

Vehviläinen also warned there were significant challenges ahead. “The fourth quarter is traditionally weaker than the third and continued uncertainty in the global economy makes the visibility for the rest of the year weak, particularly with regard to the demand for corporate travel.”

PurePower PW1100G-JM readies for tests

Pratt & Whitney has completed assembling its first PurePower PW1100G-JM test engine.
The test program for the Airbus A320neo engine option will comprise eight tests over the next 24 months; test engines will be built at Pratt’s West Palm Beach, Fla., and Middletown, Ct. facilities.

“The PurePower engine is an integral part of the Airbus A320neo family of aircraft,” Airbus SVP A320neo Family, Klaus Roewe said. “We continue to work closely with Pratt & Whitney to integrate the engine with the airframe, and we look forward to reviewing the initial test results from this first engine to test.”

Pratt has firm orders for 1,136 PW1100G-JM engines to power the neo and the engine’s entry into service is scheduled for October 2015.  The –JM engine is manufactured under a collaboration between Pratt, Japan Aero Engines Corporation and MTU Aero Engines (ATW Daily News, Oct. 6, 2011).

“Pratt & Whitney’s Geared Turbofan architecture is revolutionizing the single aisle marketplace with game changing benefits – reduced fuel burn, emissions, noise, and operating cost,” Pratt SVP-operations & engineering Paul Adams said.  “Our technology readiness execution for this engine family is robust. We’ve proven its benefits with extensive rig, ground, and flight testing.”

The –JM will be the third member of the PurePower PW1000G family to enter testing. The PurePower family has so far exceeded 3,700 hours and 11,000 cycles of full engine testing.

Boeing increases 777 build rate to 8.3 per month

Boeing produces a 777 on a production line in Everett. Courtesy, Boeing
Boeing said Tuesday it has started building the 777 at a rate of 8.3 aircraft per month, up 20% from the 7 per month rate it had been building the widebody aircraft (ATW Daily News, March 17, 2011).

The manufacturer said a rate of 8.3 aircraft per month is the “highest rate ever for a Boeing twin-aisle airplane … The first part, the lower lobe of the aft fuselage, of the first 777 [a freighter designated for Korean Air] to be built at the new rate was loaded into position in the factory earlier today.”

Boeing said the increase “reflects the strong demand for the 777.” It added that 1,049 777 passenger and freighter aircraft are currently in service.