Thursday, March 21, 2013


Keynote Presentation on the Deck
8:00am – 9:00am

Mike Packer, Vice President, Advanced Manufacturing Development, Lockheed Martin Aeronautics


Morning Concurrent Technical Sessions
9:15am – 11:00am

(NOTE: Conference fees include exhibit hall access and crossover privileges between the AeroDef and Composites Manufacturing events.)


Composite Fabrication & Repair

Session Chair: Lou Dorworth, Division Manager, Abaris Training Services, Inc.


9:15 AM-9:45 AM
New Cutting Tools for Repair of Composites
Peter Mueller-Hummel, PhD, Senior Manager, and Abdelatif Atarsia, Aerospace & Composite BU Manager, MAPAL Inc.

  • 5 axis scarfing of composite instead of 2 axis sheet metal cutting
  • Advantage using a Torus type end mil
  • Residual stresses in the different layers had to be considered by choosing the scarfing strategy
  • How to scarf economically

The paper characterizes the difference between metals and composite repairs in aerospace applications. The main differences, focus on 5 axis scarfing instead of 2 axis sheet metal cutting, using a ball nose tool in comparison to a Torus type end mil. Even high feed / low speed strategy comes out to a better surface finish and longer tool life. Residual stresses in the different layers had to be considered by choosing the scarfing strategy. Using the higher step over on special typed end mills, this increases the tool life and consequently, lowers the cost per part. The new strategy and process understanding leads to more economic repair solutions.

9:50 AM-10:20 AM
Reclamation, and Reuse of Aerospace Carbon Fiber
Pete George, Associate Technical Fellow, The Boeing Company

The growing use of carbon fiber as a high performance reinforcement in aerospace structures and other high performance applications is creating growth in byproduct streams in the form of manufacturing excess generated during processing. Until recently this “manufacturing scrap” material was exclusively land filled for disposal. This presentation will summarize the state of the emerging carbon fiber recycling industry, describe reuse application demonstrations and present data on reclaimed material performance. Reclaimed “Aerospace Grade” intermediate modulus and high strength fibers potentially offer performance advantages over standard modulus and strength virgin fiber materials as short fiber reinforcements in the form of random mat broad goods and molding compound reinforcements. The time to consider recycling and loop closure potential for carbon fiber composites is now during demand growth to help ensure that there are solutions for end of life recycling as well.

10:25 AM-10:55 AM
Structural Repairs for Composites
Lou Dorworth, Division Manager, Abaris Training Resources, Inc.


Composites Drilling

Session Chair: Jim Hatch, Ogden Weber Applied Technology College


9:15 AM-9:45 AM
Effect of Surface plies on the Quality of Hole Produced When Drilling Carbon Fiber Reinforced Composites
Eshetu Eneyew, PhD Candidate, University of Washington

  • The effect of surface plies on drilling induced damages in CFRP
  • The effect of drilling parameters on cutting forces
  • Hole quality assessment when drilling CFRP

The effect of surface ply on the quality of the hole produced when drilling multi-directional Carbon Fiber Reinforced Plastic (CFRP) composite laminates was investigated. A series of drilling experiments are performed using a carbide drill tool on two multi-directional CFRP composite laminates. The two composite laminates have similar stacking sequence except their surface plies, namely woven fabric and fiberglass scrim. The thrust force and torque was collected during the drilling process. The drilled hole was sectioned in to two halves using a circular diamond saw in order to utilize access to quality analysis and inspection. The quality of the hole produced was examined in terms of surface roughness measurements, fiber pullout, and exit delamination factor. Surface profilometer, toolmaker’s microscope, and optical microscope were used in the measurements and analysis of the quality of the drilled hole. Using these measurements and analysis, the effect of surface plies on resulting cutting forces, surface roughness, fiber pullout, and delamination factor when drilling multi-directional CFRP composite laminate have been studied. Delamination factor at the hole exit from woven fabric surface ply found to be lower than that of fiberglass scrim, exit delamination increases with the increase of the feed rate in both surface ply case. Fiber pullout was found to be sever whenever the ply orientation is ± 450 ranging from 52 to 300 µm in depth, whereas, the width is approximately equal to a ply thickness. The surface ply used did not show any significant influence on surface roughness and fiber pullout.


9:50 AM-10:20 AM
Milling & Trimming of Composites for Increased Productivity
Jeffrey Stephens, CMfgT, Product Engineer, OSG Tap & Die

  • Learn the difference between 6 flute versus 4 flute herringbone style cutters
  • Learn about the the flawed design of the 6 flute cutter
  • Achieve better surface finishes & high feed rates with 4 flutes

The presentation will begin explaining the herringbone style router used extensively in the composite machining community. The current design primarily used is 6 flutes. This design has limitations at high feed rates due to the orientation of the 6 flutes. This is because the 6 flute tool cannot be overlapped completely. Meaning the 6 flute tool actually has only 3 effective cutting edges. The presentation will provide information showing the advantage of the 4 flute design, which as 8 effective cutting edges in the overlap portion of the cutter.


10:25 AM-10:55 AM
One-Shot Dry-Drilling of Composites/Titanium/Aluminium Hybrid Stacked Materials in H8 Quality
Peter Mueller-Hummel, PhD, Senior Manager, and Abdelatif Atarsia, Aerospace & Composite BU Manager, MAPAL Inc.

  • Dry drilling of Composite/Alu and Composite/Titan stacks
  • One shot drilling of Composite/Alu and Composite/Titan stacks
  • Guaranty on diameter drilling of Composite/Alu and Composite/Titan stacks
  • Drilling holes in H8 quality one shot

This presentation describes the main difference in drilling metal or composite. When drilling metal, like aluminum or titanium, a lot of heat for the machining is required. When cutting of composites, the tool must be as cold as possible and drill without external or internal coolant. A new drill design is now developed that allows the dry drilling of metals at very low temperatures. We are now able to drill, all batches (composite / titanium / aluminum) without MMS. The fast drilling and the shorter contact times between the tool and the material stack also results in approximately twice the life of the tool. The new tool has already qualified for drilling without MMS with a CPK of 2.4 for an application in the wing assembly. This gives us new economic method for one-shot-and-clean drilling in the assembly. There are some important criteria which the dry drilling permits at low temperature. Most of the tools on the market generate a lot of heat. This tool working perfectly for cutting metal, but they destroy the integrity of the composite surface and create a lot of burrs.


Design & Software for Composite Applications

Session Chair: Randy Kappesser, Composites Technology Leader, GE Aviation


9:15 PM-9:45 AM
From Fibers to Zero Faults with Next-Generation PLM-Composites Solutions
Rani Richardson, Composites Product Specialist, Dassault Systems

Gain an understanding of the forces driving the need for advanced composites materials, and the resulting challenges manufacturers are facing. Learn how a comprehensive Product Lifecycle Management (PLM) solution can help deliver advanced composite materials with zero faults. Learn how designers can visualize where manufacturing problems will occur, correct them, and avoid issues on the shop floor.

As the use of composites increases, a key challenge facing manufacturers is how to predict and optimize the behavior of materials and minimize their weight while increasing their performance. Companies in many industries – ranging from aerospace and automotive to consumer goods and energy – are pushing the capabilities of composites to the limit and as a result the complexity of the materials being used continues to increase. In turn, processing technologies – from manual to automated – need to become more sophisticated. By simulating manufacturing processes and linking this data to analysis and design models, the engineer can develop better products with greater robustness at lower cost. Simulating the behaviors of composite parts and fiber-reinforced parts down to ply thickness and material properties allows manufacturers to ensure that “unmanufacturable” or unsuitable plies are not incorporated into their design. Being able to visualize the lay-up process of composite parts and simulate ply-by-ply lamination can help produce a final product with reduced flaws.

This presentation will explore how simulation technologies are needed to better understand and accurately predict material behavior, assess manufacturability, and optimize manufacturing processes.

9:50 AM-10:20 AM
From the Freezer to the Autoclave and Beyond - RFID Technology Enhances Multi-Dimensional Optimization of Composite Part Fabrication
Avner Ben-Bassat, President & CEO, Plataine Technologies Ltd.

  • Technology for optimizing and automating the composite cutting process reduces waste and thus costs
  • Bridging the gap between existing software streamlines the production process reducing labor requirement
  • Tracking of products real time reduces bottlenecks, improves production flow and reduces material waste
  • Precise real-time location and identification of products reduces labor and ultimately costs

Composite component or part manufacturers use a variety of software to support their manufacturing processes. This is usually an evolutionary result of software acquired over many years of developing and improving specific processes. Individually, each software package may perform well according to its purpose; however, seldom do they perform well together, requiring expensive integration or manual intervention in order to share data.

10:25 AM-10:55 AM
Processing and Environmental Effects of Adhesively Bonded Joints
David Krzyzanowski, Composites Engineer, Advatech Pacific

  • Process-driven effects of adhesively bonded joints, Environmental effects of adhesively bonded joints, Effects of damage on strength of adhesively bonded joints

The overarching objective for this presentation is to present results of pristine, degraded, defective, and damaged bonded joints in composites structures. The results focus on the process-driven (mix ratios, cure cycles, etc.), environmentally-impacted (temperature, humidity, etc.), and geometrical (bond-line thickness, fillet shape, etc.) effects of the adhesive and the composite laminates. These effects were numerically formulated for incorporation into a multi-scale, FEA-based analytical tool that is capable of predicting damage initiation and propagation of real-world structures. These models are calibrated from actual test data so that additional analyses can be performed to provide insight into the underlying mechanical behavior of adhesive joints. By adopting this approach, the behavior of adhesive joints is a function of the manufacturing processes, the geometry, and the environmental conditions of the adhesive joint. This unified approach to analysis is useful for the generation of build procedures, processing specifications, and adhesive repairs as any deleterious effects of the manufacturing steps can be captured and quantified.

Lunch on the Expo Floor
11:00am – 12:30pm


Panel Discussion on the Deck
12:30pm – 2:00pm


The Role of Modeling and Simulation in 21st Century Aerospace and Defense System Development

Moderator: Rollie E. Dutton, Chief, Manufacturing and Industrial Technologies Division, AFRL/RXM, Wright Patterson AFB



Engineered Resilient Systems (ERS): Design Tools for Deep Trade Space Exploration
Dr. Robert Neches, Director, Advanced Engineering Initiatives, Office of the Deputy Assistant Secretary of Defense for Systems Engineering


CREATE Physics-Based Modeling to Reduce Design-Test-Build Cycles
Dr. Douglass Post, Chief Scientist, DoD High Performance Computing Modernization Program

Smart Manufacturing for Plant and Process Optimization
Dr. Jim Davis, Vice Provost, Information Technology, Chief Academic Technology Officer, UCLA

Virtual Manufacturing Methods for Producibility Optimization during Design
Dr. Al Sanders, Director, Technology & Advanced Operations, Advanced Manufacturing Engineering, Honeywell Aerospace

As the information age continues to unfold, long standing product development boundaries between design, engineering, and manufacturing are becoming increasingly blurred. The use of Modeling and Simulation (M&S) and High Performance Computing (HPC) technologies are rapidly evolving and changing the way we approach product development. The evolution of these technologies over the last two decades has enabled the creation of “virtual” environments that have the potential to both slash cycle times and reduce the risk associated with aerospace system development. Despite this potential, the use of M&S and HPC for aerospace system development is still in its infancy with its full potential yet to be realized. New design methodologies are needed to fully leverage and take advantage of these technologies.

This panel discussion will feature thought leaders working in four distinct areas of the product development process that are leveraging modeling and simulation to transform the way complex Aerospace and Defense (A&D) systems of the 21st century will be designed and developed.

Concurrent Technical Sessions:
2:15pm – 4:00pm

(NOTE: Conference fees include exhibit hall access and crossover privileges between the AeroDef and Composites Manufacturing events.)



Session Chair: Jim Hatch, Ogden Weber Applied Technology College


2:15 PM-2:45 PM
Shearography NDT of Aerospace Composites
John Newman, President, Laser Technology Inc

  • Shearography NDT is now recognized by ASNT, ASTM and NAS 410
  • Shearography NDT is a fast, single side access inspection for sub surface and surface defects
  • Shearography is easy to use and interpret with training courses available to ASNT SNT-TC-1A
  • Shearography can provide new solutions to NDT of advanced materials and processes.

Shearography nondestructive testing has gained rapid acceptance during the last decade as a highly cost effective means for the production inspection of aerospace composites and sandwich structures and is now included in NAS410. Shearography NDT was first introduced on the B-2 program in 1986 for inspecting composite materials and structures. Development of digital CCD cameras, the PC and small, high power solid-state lasers have led to dramatic performance improvements in shearography instruments and systems. Automated shearography scan systems can replace UT C-Scan for many applications and achieve throughputs from 10 to 50 times greater. Shearography is currently in use on a wide variety of aircraft including F-22, F-35 JSF, Cessna Citation X, Raytheon Premier I and the NASA Space Shuttle. This presentation will provide a brief background on shearography NDT technology and discuss these and other applications.

2:50 PM-3:20 PM
Thermographic Characterization and Inspection of Composite Materials
Steve Shepard, PhD, President, Thermal Wave Imaging, Inc.

3:25 PM-3:55 PM
Damage Assessment of Advanced Composite Structures
Randy Jones, Engineer, Inspection Technologies, Inc.

Innovative Applications for Composites

Session Chair: Brock Strunk, Chief Structures Engineer, Epic Aircraft, LLC


2:15 PM-2:45 PM
Manufacturing Flexibility for Commercial Aircraft Composite Interior Components
George Bullen, FSME CPIM, CEO, Smart Blades Inc.

  • Growth in composite use for Airframe interiors
  • Manufacturing Challenges
  • Technology Transfer
  • Customization while meeting cost and schedule challenges
  • Benefit

The combination of low weight, high strength, durable cosmetics and low flammability have driven commercial OEM designers to incorporate increasing amounts of composite materials into the interiors of airframes. The market potential for composites for OEM and aftermarket interiors segments represent a market for ≈ 22.5 million pounds of composites in 2012.

This presentation will provide the projected future of composites as a component of airframe manufacture. It will also illustrate and explain opportunities for transfer of manufacturing technology from the automotive manufacturing process to enable its efficient and effective use for aircraft interiors. The combination of low weight, high strength, durable cosmetics and low flammability have driven commercial OEM designers to incorporate increasing amounts of composite materials into the interiors of airframes.

2:50 PM - 3:20 PM
Automated Fiber Placement - New Ideas New Designs
Burak Uzman, Principal, ALA Group

Existing Automated Fiber Placement (AFP) machine architectures and designs have theoretical limits on the productivity levels they can achieve. Future commercial aircraft programs require composite part layup rates orders of magnitude higher than what is currently available. This presentation will provide description of one such alternative system architecture and design.

Discussion will focus on a system level analysis of existing AFP machine architectures, subsequent system level analysis, identification of constraints, major assumptions and invalidation of those assumptions to arrive at new machine architectures. Furthermore the presentation will present how the new machine architectures are better suited to fabricate the holy grail of composites; parts optimized for weight through the use of extensive fiber steering.

3:25 PM - 3:55 PM
New Advanced Test Methods for Determining Shelf Life Extension and Validation of Cure State
David Kesic, Alpha Technologies, a DYNISCO Company