On track with metals

Trust plays an important role in the aerospace supply chain. New suppliers may arrive on the market promising lower cost materials and components, but having an extensive track record of providing the right products, with the right properties and capabilities is just as important to the OEMs.

It’s not surprising then that when Boeing was developing the 787 it turned to Alcoa, a company with which it had a history dating back to the 1950s and the 707.

Eric Roegner is COO of Alcoa Investment Castings, Titanium and Engineered Products and President of Alcoa Defense.

He begins: “Since the 707 we have continued to supply parts to Boeing’s key aircraft platforms including wing spars for the Boeing 747 in the 1960s and various alloys to the Boeing 777 in the 1990s. Our 2524 alloy was first launched on the 777 and became the standard for high performance and damage tolerant aircraft fuselage sheet applications.

“Our 2099 alloy plate was the first aluminium-lithium structural plate product to be launched on the Boeing 787. In 2015, we announced multi-year supply contracts for fasteners and titanium seat tracks valued at US$2.5 billion for the 787 and other Boeing platforms.”

Alcoa is now the sole supplier of titanium seat track assemblies for the 787 Dreamliner. The company’s acquisition of RTI International Metals (RTI) means the company now has more control of the entire manufacturing process for the part.

Roegner continues: “RTI (now known as Alcoa Titanium & Engineered Products) provides seat tracks for all the 787 variants including the contract for the 787-10 which was signed in 2015. Titanium seat tracks are stronger, weigh less and offer superior corrosion resistance compared with traditional materials. Alcoa is supplying the seat tracks, from raw material to finished part, by utilising its titanium ingot melting and billet making, extrusion, machining, processing and assembly capabilities gained through the acquisition of RTI.”

From start to finish

So what are the benefits for Alcoa of being able to supply titanium components from the raw ingot to the finished product?

“With the acquisition of RTI, Alcoa expanded its reach in titanium which is the fastest growing metal used in aerospace,” says Roegner. “Together, we create a near complete titanium value chain with more advanced technologies and more innovations.”

As well as securing the seating to the aircraft floor, the seat tracks – together with the floor beams – also contribute to the overall strength and stiffness of the fuselage. Alcoa also supplies sheet and plate materials used in Boeing aircraft, including the 787.

“Alcoa’s sheet and plate products have a long-standing connection on all metallic fuselages and wings, as well as our partnering efforts on structural parts through the Boeing raw material strategy. Our plate products are used in applications such as wing ribs, wing skins or other structural parts of the aircraft on every Boeing platform.”

Last year Alcoa also signed its biggest ever contract to supply fastenings to Boeing.

“Under the contract, we supply advanced titanium, stainless steel, alloy steel, aluminium and nickel-based super-alloy fastening systems for every Boeing platform, including the 777X, the 737 MAX and the 787 Dreamliner. Our fastening systems provide improved joint fatigue performance, reduced assembly cost and time, improved lifecycle costs, increased reusability and reduced weight.”

With the 787 well-known for its extensive use of composites in the airframe some have suggested that the role for metallic materials, such as those supplied by Alcoa, is reducing but Roegner believes they still they have a long future ahead of them in aerospace.

“It’s a multi-material world. Metals such as titanium and aluminium are still needed in composite-intensive aircraft. For example, the Boeing 787 has 20% aluminium and 15% titanium made up of its construction. Alcoa is marrying materials science with manufacturing process innovation to deliver performance improvements and lower costs. Our advanced alloys, such as our aluminium-lithium alloys, are lighter and stronger and help reduce aircraft weight to help customers meet fuel efficiency targets.”

Two’s company

Alcoa’s long-standing relationship with Boeing looks set to continue. In 2016 it announced a contract for multi-material aerospace parts for the wing, fuselage and landing gear. And the company is also evolving to reflect the material split between its aluminium-based products and the latest advanced alloys and other materials used in aerospace.

“In the second half of 2016 Alcoa will separate into two industry leading companies,” Roegner comments. “The upstream company (which will retain the name Alcoa) will be a competitive global leader in bauxite, alumina and aluminium, with a portfolio of value-add cast houses and substantial energy assets. Our value-added company – to be known as Arconic – will be a premier innovator of high performance multi-material products and solutions in attractive growth markets, including aerospace. Arconic will be a differentiated supplier to the high-growth aerospace industry with leading positions on every major aircraft and jet engine platform, underpinned by market leadership in jet engine and industrial gas turbine aerofoils, and aerospace fasteners.”

Aerospace is just one part of Alcoa’s metal offering to industry, so how does Roegner foresee the group’s future in the sector?

“The long-term aerospace trend is strong, with the order book for commercial jet airframes and jet engines representing more than nine years of production at 2015 delivery rates. Alcoa has been building its multi-material aerospace business and has become a leader in jet engine components and aircraft structures. As well as acquiring RTI International Metals, we’ve also incorporated TITAL and Firth Rixson.

“Alcoa has also grown organically to build its aerospace portfolio. It opened the world’s largest aluminium-lithium facility in Lafayette, Indiana; expanded jet engine parts production in La Porte, Indiana and Hampton, Virginia; launched the installation of advanced aerospace plate manufacturing capabilities in Davenport, Iowa; doubled its coating capabilities for jet engine components and invested in technology that strengthens metallic structures of traditional and additive manufacturing parts in Whitehall, Michigan. It has also launched an expansion of its R&D centre in Pittsburgh, Pennsylvania to accelerate development of advanced 3D printing materials and processes.”

www.alcoa.com