Utilising specialist materials and processes, GKN Aerospace produces assemblies and components for the whole nacelle and engine system
Nacelles
Ring, Cases and Modules
Cases and Structures
Inlet and Exhaust Nozzle
Specialist composite assemblies
Blades
Turbine Components
Blisks/IBRs/Impellers
With over twenty years experience in the design and manufacture of nacelles, GKN Aerospace has established a strong position in military turboprop nacelles and at the lower thrust end of the turbofan market. It combines innovative design with advanced composite and metallic materials and the application of advanced manufacturing technology to provide lightweight nacelles with fewer components and lower life cycle costs. Nacelles have been designed and manufactured for a range of aircraft programmes, including the Lockheed Martin C-27J Spartan and the Honeywell AS907 engines for the Bombardier Continental.
GKN Aerospace also designs and manufactures nacelle and thrust reverser
components in a diverse range of materials for military and civil aircraft
applications. Components include the inner fixed structure for the CFM56-5C2
engine from bonded aluminium and honeycomb, a range of thrust reverser
components with improved acoustic properties from resistance welded
honeycomb sandwich structure, the inner cowl door for the C-17 nacelle
using Super Plastic Forming (SPF) techniques and blocker doors using
Resin Transfer Moulding (RTM).
GKN Aerospace pioneered the use of roll-formed and welded aluminum extrusions to reduce the cost of cases for large commercial aircraft engines. For the newest generation of fan and containment cases, the weight saving benefits of Unistructure™ technology have been applied, offering over 100 pounds per unit compared to a structurally equivalent single shell design. GKN Aerospace supply the complete Rolls Royce fan containment system for the Trent 800 engine. This module assembly consists of a Unistructure™ stiffened titanium rear fan case and a 2219 aluminum fan containment case, inner V-groove, OGV assemblies, plus composite honeycomb panels bonded in place and Kevlar wrapping on the containment case. In addition to manufacturing this unit, GKN Aerospace actively participated in the design and concurrent engineering of the module, helping in the target to make the engine a lighter overall power system.
The Unistructure™ process is also used in the manufacture of jet engine bypass fan and augmenter ducts for military aircraft that operate in a high vibration environment with high internal pressure loads, enabling graeter reliability through the reduction in parts count. Benefits offered are 25-40% less weight than skin/stringer equivalents, with cost benefits in the order of 10-20%.
GKN Aerospace Engine Products provides a uniquely effective combination of diverse manufacturing experience, engineering expertise and state-of-the-art equipment for prototypes and production components. GKN Aerospace Engine Products uses electro chemical machining (ECM) technology combined with multi-axis milling to produce gas turbine engine cases and structures. By combining ECM technology with the strength inherent to a forging, GKN Aerospace can cost-effectively produce engine cases with intricate shapes, contours and embossments. In addition, manufacturing an engine case by ECM offers metal removal rates that exceed those associated with conventional machining methods.
GKN Aerospace is the world’s largest producer of resistance welded honeycomb sandwich structures which are formed into three dimensional structures using proprietary processes. Soundwich™ and Stresskin™ produce noise reduction structures for civil aircraft and lightweight robust structures for high stress, high temperature areas of military engines. Examples include the lightweight titanium exhaust system for the Airbus A330.
Using the Resin Transfer Moulding (RTM) composite process, high performance, precision moulded parts with closely controlled contour and laminate thickness are produced. A further benefit of the RTM process is the ability to mould multi parts into one single process thus reducing parts count and weight.
Fan blades - GKN Aerospace Engine Products leads the industry in Fan Blade manufacturing and is a proven fan module supplier offering in-house forging capabilities which complement our manufacturing expertise, providing superior quality and value to our customers. We work closely with OEM’s on development blades and are recognized worldwide for high volume production capabilities.
Compressor Blades - GKN Aerospace Engine Products offers multi-axis high speed machining and ECM manufacturing of compressor blades and vanes. We have a combination of dedicated cells for production as well as flexible cells for development.
GKN Aerospace Engine Products specializes in turbine/compressor airfoils. We offer short lead times with flexible production schedules. GKN Aerospace Engine Products offers complete life cycle support of parts from the development stage to production runs and have established a niche serving out-of-production spares.
GKN Aerospace Engine Products leads the industry in manufacturing blisks/IBRs. Depending on the specified geometry, we produce blisks/IBRs through our ECM technology and high-speed 5-axis machining, providing the greatest combination of product quality and speed for your application. Our extensive experience and advanced computer-integrated equipment allow rapid turnaround of high quality components. Our ability to manufacture production quantities of blisks/IBRs is completed by our assembly/balancing capabilities, providing our customers with a one-stop shop, delivering engine-ready kits or modules right to your assembly line.
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