New multi-million Rand Airbus contract to boost SA industry

The "ribs, spars and sword" form the inside structure of the aircraft's very distinctive vertical tail plane. The spars which are seven metres in length and the two metre long ribs will be manufactured out of composite materials at Denel Aerostructures' production facilities in Kempton Park.

Riaz Saloojee, the group chief executive officer of Denel says the approximate R157 million contract over a period of eight years demonstrates the confidence of major international companies in the design and manufacturing capabilities of the local aerospace industry. "We have proven ourselves to be a reliable and innovative top tier supplier to one of the most sophisticated aircraft manufacturing programmes in the world. Airbus's decision to place a third major order with Denel shows satisfaction with the quality of our design and manufacturing processes and our ability to deliver on time and within budgets," says Mr Saloojee.

Manufacturing process

Production on the tail plane parts will start in the coming months and the first finished parts will be shipped to Airbus' manufacturing plant in Stade, Germany in August 2013. The 7x2 metre structure consists of two vertical beams ("the spars"), 16 horizontal composite machinings ("the ribs") and a connecting plate at the bottom ("the sword"). All parts are made out of carbon fibre composites and then covered by a metallic skin, added to the internal structure prior to assembly.

Ismail Dockrat, the CEO of DAe says the new contract "places the company at the core of the global aerospace manufacturing industry." The vertical tail plane is a flight-critical part of an aircraft of the size of the A400M and contributes to its unique ability to land and take off carrying payloads in excess of 35,000 kg.
In addition to the ribs, spars and swords, DAe also manufactures two other work packages:

• The Wing to Fuselage Fairing: an essential part of the aircraft that provides protection against lightning strikes, hail damage and bird strikes to the sensitive equipment under the centre wing portion.
  
• The Top Shells: made up of more than 1100 parts consisting of a large machined skin, engineered out of an aluminium alloy. Each aircraft is fitted with two top shells, positioned in front of, and behind the wings where it is joined to the fuselage. The approximate 1000 system brackets support the vital electric and electronic wiring, hot air and heat exchange piping and include the aircraft's life rafts.

Dockrat says DAe was responsible for the initial design of the tail plane detail parts but the manufacturing was placed on hold following South Africa's decision to cancel its acquisition of the A400M. Airbus Military decided in 2012 to give the green light for manufacturing and the take-over of the design responsibility. This was followed by the signing of a renegotiated agreement between Airbus Military and Denel in July 2012.

The manufacturing process for the ribs, spars and swords will mirror the company's ramped-up production of the WFF and Top Shells. These parts are manufactured at a rate of sixteen ship sets in 2014 and 24 - two per month - in the subsequent years.

Efficient and cost-effective

DAe has just completed a relocation of all its operations under one roof in a move that will improve efficiencies and cut costs significantly. It also positions the company for future manufacturing work on subsequent parts for Airbus and other original equipment manufacturers.

Dockrat says the new order also confirms that South Africa is at the forefront of global trends to use composite materials for high-tech manufacturing. The aerospace sector is leading the move away from metallic structures towards advanced materials which offer superior properties such as durability, hardness, elasticity and high strength-to-weight ratios.

Denel Aerostructures has made significant investments in a composite facility in which it is able to manufacture products ranging from simple aircraft parts to complex main rotor blades for helicopters. The raw carbon fibre materials are bonded, moulded, heated and polished until the required properties are achieved.

"Government, in its Aerospace Sector Development Plan, recognises the immense potential of the composite sector, noting that it will be dominant in aerospace going forward and should be integral to future business planning," says Dockrat.

For more information, go to www.denelsaab.co.za.