Final assembly of the first Airbus A321XLR-Aerospace manufacturing and design

2021-12-16 08:13:41 By : Ms. SARAH WONG

A321XLR MSN11000 will begin flight test and type certification program in 2022.

The structure of the Airbus A321XLR and MSN11000 final assembly line (FAL) in Hamburg, Germany is completed, followed by the assembly and equipment of the most recent main component assembly (MCA) and subsequent delivery and the introduction of FAL as planned in November 2021. These MCAs are mainly Including (but not limited to): nose and front fuselage delivered from Saint-Nazaire, France; center and rear fuselage assembled in Hamburg; wings from Broughton, UK; landing gear provided by Safran, vertical and horizontal tails Respectively from Ystad and Getafe.

Although other Airbus FAL locations will eventually produce A321XLR to meet this type of major customer order, Hamburg has been selected to test this new variant into mass production, starting with three development flight test aircraft that are now in different stages of completion.

Michael Menking, the project leader of the A320 series, explained: "We are currently preparing to deliver A321XLR from other single-channel FALs. Therefore, it is important to ensure that all teams learn from the Hamburg experience so that we can bring this knowledge to other facilities. In. This is also what we did for the A320 series of airspace cabins we launched in Hamburg."

Among the four A320 series assembly lines in Hamburg, the one that is processing the first A321XLR is called "FAL Line 2" and is located in the "Hangar-9" building. Two subsequent A321XLR development aircraft-MSN11058 and MSN11080-will follow up from the same assembly line.

Once all the MCAs of the initial-XLR aircraft have reached the FAL, they will then gather together at a series of stations to create a complete recognizable aircraft. The journey through these stations takes approximately four weeks.

At station 42/43, the open and independent rear and front fuselage parts provide the convenience of receiving a well-equipped monument (kitchen, toilet).

The connection of these fuselage parts and the final installation of the monument were subsequently carried out at station 41. There are more than 3,000 rivets connecting the front and rear fuselage sections. Importantly, these airframe parts contain an important new driver for the A321XLR: a special rear center tank (RCT) produced by Premium Aerotec. RCT has an additional 12,900 litres of fuel required for a 4,700 nautical mile range. The lower fuselage of the XLR also contains a larger waste water tank for ultra-long flights. In addition, the interior decoration (floor, cargo loading system and cockpit lining) and cabin electrical system were installed in station 41.

After the completion of the above phases, the FAL team carefully lifted the entire fuselage part by an overhead crane, and then put it into the fixture at the 40th station. This was the most visually impressive stage, where they physically positioned the waiting wing and landing gear components until their new fuselage with sub-millimeter accuracy.

Then, approximately 2,400 rivets were used to ensure a firm connection between the two wings and the fuselage. Here, the aircraft also received an engine pylon made in Toulouse. Another milestone of the site is the turn-on of functional power. Since then, the airplane no longer needs a crane because it can be pulled to the next stop on its own wheels.

Station 35 is equipped with horizontal and vertical tails (HTP in Getafe, Spain and VTP in Stade, Germany), tail cones, inner flaps, main landing gear doors, radome, weather radar, air ducts, air conditioning systems, water System, fuel system (modified for RCT on -XLR), belly fairing, APU, and all passenger and cargo doors. The hydraulic system is powered on, and the installation of the cabin lining, hat rack, passenger service channel and cargo hold panel is also carried out here. Finally, the fuel tank was sealed at station 35.

Testing and cabin installation have been carried out at station 25. This includes: airframe pressurization testing; HTP final rigging; interior furnishings (including emergency lights, lockers, etc.); cabin system testing (lighting, emergency lighting, audio, video systems, etc.); and system testing (avionics) , Communications and navigation testing, fuel tank leak testing).

The final FAL phase will be the final test and interior decoration at station 23. This includes seat installation for flight test engineers, main landing gear testing and overall cabin testing.

After passing through all these sites, the first A321XLR will be transformed from a set of independent components into a real aircraft, with the hangar 9 on its newly installed landing gear.

Gerd Weber, Head of Value Stream Management and FAL of the A320 series, pointed out: "In the final assembly stage of the A321XLR aircraft, there is not much difference compared with other A321 aircraft. The main difference of -XLR is reflected in the'pre-FAL', for example, Part of the assembly level for installing RCT."

He added: “This test aircraft is equipped with a partial cabin to make room for all the necessary flight test equipment. The special feature of this first A321XLR aircraft is that there is still a lot of documentation work to be done, especially Test flight installation, which is very different from our serial process. This requires all teams to pay special attention when closing documents and dealing with any differences."

From here, the MSN11000 will enter a working group to install its complex flight test instrument (FTI) kit, and then install its CFM LEAP engine and nacelle. Then the engine will be tested for the first time, as well as the landing gear retracting mechanism and door fairings, and then a comprehensive quality inspection of the aircraft will be carried out.

The next production step is to apply the aircraft's exterior paint scheme shortly before the aircraft is delivered to the flight test team. Desiring to own their new machine for the first time, they will start and pass a series of ground tests of all systems, flight controls, engines and APUs. They will perform the taxi and first flight of XLR, which will take place next year.

The interactive exhibition will be exhibited locally by Parker Aerospace until January 2, 2022.

Explore the future of aerospace technology in the traveling exhibition "Above and Beyond", which has landed at the Great Lakes Science Center in Cleveland, Ohio until January 2, 2022.

Sponsored by Boeing and exhibited locally by Parker Aerospace, Above and Beyond showcased a 5,000 square foot interactive demonstration showing how aerospace has evolved from the first powered flight to the latest innovations in aircraft and spacecraft design.

The exhibition is suitable for families, students (especially children between 7 and 14 years old), and adults, and its content is bound to be favored by aerospace enthusiasts and professionals in the aerospace industry.

In the exhibition, guests can design and drive supersonic jets in a virtual high-speed flight competition, step into the simulated space elevator to take them to the edge of the universe, and fly like a bird in a clever flight simulation-sensing technology.

Five main interactive galleries focus on upward, faster, farther, higher and smarter. Exhibits showcase advanced technologies, including additive manufacturing, solving space debris problems, the concept of future aircraft, carbon fiber materials and unmanned The use of machine systems.

The expansive multi-touch timeline and stories about the people behind the progress of flight reveal the historical roots of aviation. A montage of dreamers and doers shared their excitement about work and flying in the next century. There is even a place to add your own dreams to the vision of flying collaboration 100 years from now.

The child-friendly, informative, and learning-by-learning educational exhibition emphasizes the interaction that anyone who has played video games can have. Evergreen Exhibitions produced these fascinating experiences through extensive input from a wide range of experts from NASA and the Smithsonian National Air and Space Museum.

Claire Dorset, deputy director of strategic content at the Great Lakes Science Center, said that "Beyond Yourself" tells a story that resonates with the audience. "They come out of our door, are still thinking about their experiences, and can begin to identify where these concepts are relevant to them in their world."

Dorsett added that Above and Beyond is the perfect complement to science, technology, engineering, and mathematics (STEM) education because it draws children’s attention to STEM pathways that may lead to career development.

Dorsett explained: "First is awareness, then more in-depth contact and immersion, and then guide them into these pathways. Our goal is to stimulate students' curiosity and inspire their confidence in pursuing STEM."

She added that the interactive exhibition creates a context related to what the country and local manufacturers are doing. "This is not just what other people are doing, it emphasizes that this is what is happening in your own backyard, and you can be a part of it."

Beyond and Beyond will last until Sunday, January 2 and is included in the general admission ticket to the Great Lakes Science Center at GLSC, 601 Erieside Ave., Cleveland, OH 44114. The Great Lakes Science Center also includes the NASA Glenn Visitor Center, where there is an Apollo capsule.

Processing aerospace parts: Working with Sandvik Coromant experts to meet the growing industry needs with safety and reliability; DMG MORI USA's Center of Excellence in Medical Competence.

As the aerospace industry continues to recover, shortening cycle time will become more and more important to meet increasing demand. Positive industry trends indicate the need for new solutions to efficiently process HRSA materials, maximize material removal, and produce quality parts in a predictable manner. With this in mind, Sandvik Coromant experts will share best practices to meet these needs and introduce Sandvik Coromant’s latest innovations for processing difficult-to-machine materials and aerospace parts.

Attend this conference and learn:

• How to increase process safety when turning parts-and how the stability of CoroTurn® 107 makes it possible

• Why the new CoroMill MH20 is a powerful high-feed cavity milling solution that ensures safe and vibration-free machining

• The combination of VERICUT and M5 series produces a higher quality surface finish

• How the new S205 HRSA turning grade for higher speeds can increase productivity in semi-finishing and finishing applications

• Key solutions for efficient turning of difficult-to-machine materials in the aerospace industry

Click here to register for the Manufacturing Lunch + Learning on December 16, 2021 at 12 noon EST.

David DenBoer, Sandvik Coromant Aerospace Industry Expert

Scott Lewis Aerospace Industry Expert, Sandvik Coromant

DMG MORI American Medical Center of Excellence Capability

DMG MORI USA established a Medical Center of Excellence at its headquarters in Hoffman Estates, Illinois, to advance design and manufacturing solutions for the medical industry. Hear feature previews and discussions on how DMG MORI USA provides a complete solution.

Dan Strubel, DMG Mori, US Application Engineer

Carson Huber, Application Engineer, DMG Mori, USA

Manufacturing and supply chain expert, MBA, CSCP, CLTD, LMA Consulting Group Inc. President Lisa Anderson predicts that supply chain disruption will continue beyond 2024.

Manufacturing and supply chain expert, MBA, CSCP, CLTD, LMA Consulting Group President Lisa Anderson predicts that supply chain disruption will continue beyond 2024. LMA Consulting Group works with manufacturers and distributors to develop strategies and end-to-end supply chain transformation to maximize customer experience and achieve profitable, scalable, and significant business growth.

"Supply chain disruptions are real and will continue for a long time," Anderson commented. Every supply chain is a complex set of connections, from the supplier's supplier to the end user's product or service accessibility. "Let's look at the'causes' of the disruption. If you eliminate industry nuances, there are three main reasons for the disruption. The first reason is labor. The pandemic has exacerbated the continued loss of skilled baby boomers, many of them Retire early. The pandemic has also prompted workers to reassess their priorities. This has led people to decide that they don’t like their industry, job, or boss. This has been reflected in what many people call the great resignation,” Anderson said.

There are labor shortages in almost every industry and position.

"Manufacturing, transportation, distribution, these industries are no exceptions. Moreover, most of these industries affect consumers, who believe that the supply chain has been the most severely affected," she added.

 The second reason for supply chain disruption is misalignment.

"The pandemic causes a change in demand. When people encounter out-of-stocks, they find new products that are similar or better. This shift leads to a misalignment of the supply chain: putting the wrong product in the wrong place at the wrong time. Therefore, even if the original product is in place, the demand no longer exists because it has changed," she said.

The most expensive cause of supply chain disruption is equipment. "All departments lack equipment. This includes chassis used to unload trailers from ships. Trucks are in short supply, and equipment upgrades are required by law. Medical device equipment, agricultural and construction equipment, food processing equipment, and equipment needed for technological upgrades are all in short supply," Anderson pointed out.

"It all comes down to creating a never-ending supply chain circle, just like the supply chain is chasing its well-known tail. I don't think this can be easily solved by launching new laws or attracting workers with more money. Of course, It can help, but it is not a simple solution. It needs to be recognized that there may not be a new normal. Essentially, the supply chain will be in an evolving state. Successful manufacturers are responding to changes in demand and recognizing evolving The supply chain will be adaptable, flexible and forward thinking," she concluded.

Register now for the webinar on December 8, 2021.

GE Additive has signed a new agreement to provide Ti-6AI-4V powder for metal additive manufacturing applications.

AP&C-GE Additive-reached a new agreement with Airbus to provide titanium powder (Ti-6AI-4V) for metal additive manufacturing applications. The new multi-year agreement to provide Ti-6AI-4V powder deepens the partnership between AP&C and Airbus, which dates back several years.

“The momentum for the adoption of metal additive technology in the aerospace sector continues to increase. AP&C CEO Alain Dupont said that in highly regulated industries such as aerospace, one of the challenges to achieve this speed is to build a strong The supply chain can not only meet the industry standards of traditional and additive manufacturing parts, but also add value.

"Our goal is not just to provide customers with metal powder. To expand the scale of metal additive manufacturing, we can only achieve acceleration by sharing knowledge and best practices to reduce risk and improve stability. For example, we have supported Airbus in recent years One way is to help its internal additive manufacturing team establish its own methods and processes to verify the quality of Ti-6AI-4V powder,” DuPont added.

AP&C provides mass production of plasma atomized titanium, aluminum and nickel powder. The company continues to invest in its plasma atomization technology, which allows the production of new materials and ultimately reduces the cost of plasma atomized powder, while maintaining the high quality required by metal additive manufacturing users in the aerospace industry.

AP&C has increased its production capacity to more than 1,000 tons of titanium powder per year. This large-scale production is carried out in more than a dozen powder production lines in two manufacturing bases.