Work is well underway in the second phase of a GBP1.5 million funded Midlands Aerospace Alliance, MAA, programme, designed to encourage the development of new technologies by companies operating within the West Midlands aerospace and defence supply chains. With part funding from regional development agency Advantage West Midlands (AWM) and the European Regional Development Fund (ERDF), the Aerospace Technology Exploitation Programme (ATEP) is helping larger manufacturers work in partnership with both SMEs and our leading Universities to develop new technologies that address emerging market requirements for future aircraft programmes.

In total, the Midlands represent around a quarter of the UK’s aerospace industry (by jobs and value) and a further 25 per cent of these firms transfer their skills and expertise to solutions in the defence sector. This contribution has grown by five per cent in the last two years thanks to contracts won on defence programmes, including Eurofighter Typhoon, Lockheed Martin F-35 Lightning II and Airbus A400M.

The first phase of ATEP launched in 2006 with company grants from AWM totaling GBP390,000. Results from the five projects on aircraft programmes for the future have provided wide ranging benefits. One such manufacturer is Wolverhampton based Goodrich Actuation Systems, which worked with a local SME to develop an actuator gear box housing (on aircraft wings) in composite materials to replace traditional aluminium die casting. The component is significantly lighter than a conventional aluminium part. Following a series of rigorous and highly successful tests by Goodrich, the company’s technology has been welcomed into the Next Generation Composite Wing Programme, which is led by Airbus and part funded by the UK’s Technology Strategy Board.

Also based in Wolverhampton, HS Marston Aerospace – part of US company Hamilton Sundstrand Engine & Control Systems – has worked with a local SME to develop high temperature heat exchangers (for aircraft engines) made from new alloys. High temperature capability is a significant contributor to fuel burn efficiency, and the ability to operate at hotter temperatures can result in CO2 reductions of up to 10 per cent. Tests completed by the company show that the new alloy heat exchanger can operate at up to 300 degress celcius hotter than existing units. These results have led to HS Marston Aerospace becoming one of 10 partners on the Environmentally Friendly Engine Programme (EFE) launched by Rolls-Royce to develop greener engine technology for the future. Launched in 2006, EFE is addressing engine technologies to cut nitrous oxide emissions by 60 per cent, amongst other benefits.

Another project from ATEP Phase I has developed technology that is attracting much interest from outside aerospace and defence, including automotive and marine. Birmingham’s Meggitt Control Systems worked with the University of Birmingham and two local SMEs – Arden Precision and PAB Coventry – to perfect a heat transfer system that improves heat exchanger efficiency. This phase of ATEP also includes two other partnerships; Teer Coatings and Anapol Coatings joined to improve the life of tools for forging with the use of nano-coatings technology. The other was between the University of Wolverhampton, Ajax Toco and Unipart on a lower capital equipment cost process which has wide applications for aerospace and possibly other manufacturers.

The seven projects within ATEP Phase II, which started in 2009 with £750,000 of grant funding, are set to deliver some fascinating results. Headline developments include longer-life brakes, led by Meggitt Aircraft Braking Systems, research by Dunlop Aircraft Tyres into innovative designs and an SME team working on new spring designs. This lightweight spring project is noteworthy for bringing together three SMEs – G&O Springs, Alloy Wire and Reliable Spring – to work in partnership with the Institute of Spring Technology to develop parts for BAE Systems and Aero Engine Controls.  Several novel materials will be tested for the first time as complete springs with huge possible benefits for customers and SMEs alike.

Development of a novel, stronger aluminium alloy is being led by Aeromet of Worcester, working with Grainger & Worrall based in Shropshire, together with the University of Birmingham. The lead end user, Aero Engine Controls, is contributing valuable testing and validation support. Another trio of SMEs – Indestructible Paint, as project leader with Ashton & Moore and Clean Burner Systems – are aiming to remove hazardous elements from protective engine surface coatings.

All projects in ATEP Phase II are part of a three and a half year development programme, and are expected to conclude towards the end of 2012.

For further details log on to www.midlandsaerospace.org.uk

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