World Leader in the Design and Integration of Flight Control and Utility Actuation Systems

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1 Special Edition 5 8 May 2015 World Leader in the Design and Integration of Flight Control and Utility Actuation Systems Moog is a global designer, manufacturer and integrator of precision motion control products and systems. Over the past 60 years, we have developed a reputation for delivering innovative solutions for the most challenging motion control applications. As a result, we have become a key supplier to the world s leading aerospace and defense manufacturers, and are positioned on virtually every platform in the marketplace supplying reliable mission critical products that are highly supportable and add significant value for our customers. A key element of our success has been our corporate culture, which embraces a strong customer focus, process and product innovation, solid work ethic and remarkable attention to purpose of our people. Through Moog s aftermarket services business, we have been providing the same highly responsive, customer-focused support to commercial and military operators around the world. With aircraft staying in service far beyond their intended life, Moog continually strives to develop enhanced repair processes and reliability improvements to keep products on wing longer, thereby increasing fleet availability and lowering lifecycle costs. In addition to providing world-class MRO services, we offer technical support and training, product modifications and upgrades, reliability enhancements and technology insertion, obsolescence management, logistics services and public-private partnerships. Moog Expands H-60/S-70 Flight Control Overhaul and Upgrade Services Moog developed the capabilities to provide overhaul services for the entire family of integrated trim/boost servoactuator assemblies on the H-60/S-70, including the Pitch Trim, Roll Trim and Yaw Boost Servoactuator configurations. Moog inspects and disassembles the integrated assembly, overhauls and tests the individual LRU s, and reassembles and tests the integrated assembly before delivery to the customer. Moog has recently won its second consecutive 5-year contract with the US Coast Guard (USCG) to provide overhaul services for their HH-60J/T flight controls, previously demonstrating a 50% improvement on turnaround time while significantly lowering the USCG s total overhaul cost. Moog Receives Approval for Advanced Corrosion Repair of Aircraft Parts by US DOD Moog continues to work closely with the U.S. Army to develop and qualify Cold Spray, an additive manufacturing process, to restore metal parts damaged by corrosion or wear, to a serviceable condition. This repair technique is ideally suited for aircraft parts made from magnesium, titanium, and aluminum, which due to their composition, make conventional repairs impractical. Moog has extensive experience and expertise in Cold Spray technology both high-pressure and low-pressure. Our Cold Spray process today reflects continuous refinements, improvements, and lessons learned over several years, so that program technical risk is very low. Moog is already approved by Boeing, Sikorsky, and Bell Helicopter to provide Cold Spray repairs for rotorcraft components. Moog is also approved by the Army Research Lab (ARL) as well as AMRDEC- Aviation Engineering Directorate (AED) and is currently working with both organizations on multiple Cold Spray projects. Most recently, AMRDEC-AED at CCAD approved Cold Spray for repair of UH-60 magnesium housings, and is currently evaluating additional UH-60 and AH-64 components as Cold Spray candidates. Before After IDEF 2015 SPECIAL EDITION

2 INTEGRATED SYSTEMS FOR MILITARY AIRCRAFT System Integrator for F-35 Joint Strike Fighter Primary and Leading Edge Flight Controls Moog is leading an industry team in the development and integration of the Primary Flight Control and Leading Edge Flap Actuation Systems for the Joint Strike Fighter Program. The F-35 power-bywire system represents an advancement on the more electric aircraft topology integrating: Power & Control Electronics Dual Tandem EHA Actuator Simplex EHA Actuator n Self-contained electrohydrostatic actuators (EHA) to position primary flight surfaces n Electronic Control Units to remotely drive and control the EHAs n Electrically-driven PDUs to position the maneuvering leading edge flaps As the prime contract holder, Moog s role includes management of the industry team, integration of the complete actuation system, and supplier of critical technologies and major subsystems. Moog is also supplying the wingfold actuation system on the F-35 C-variant. Electric Hydraulic Electric Drive Unit Flap Actuation System Moog Supplies Lift Fan and Swivel Module Actuation Systems for F-35B STOVL The F-35B is a Short Take-Off and Vertical Landing (STOVL) variant of the Joint Strike Fighter. The hovering ability of this distinctive aircraft is provided through a combination of a thrust vectoring nozzle directing main engine exhaust downward to generate aft vertical lift, and a centrally mounted lift fan which provides counterbalancing forward vertical lift. Moog designed, qualified and now manufactures the sophisticated actuation systems for both of these applications. Specifically, Moog supplies the actuation system for the three-bearing swivel nozzle which rotates the main engine s exhaust downward through 90 degrees. In addition, Moog provides the actuation system controlling the lift fan s variable area nozzle and inlet guide vane which control airflow through the lift fan. These actuation systems use electronically controlled hydraulic and fueldraulic servoactuators specially designed for operation in extreme temperature and vibration environments. Supplier of Primary Flight Control Actuation for T129 ATAK T129 ATAK is a new generation, tandem two-seat, twin engine helicopter specifically designed for attack and reconnaissance purposes. T129 ATAK, developed from the combat proven AgustaWestland A129CBT, incorporates totally new system philosophy with new engines, avionics, weapon systems and flight controls. The T129 ATAK is the helicopter selected in 2007 by the Government of Turkey for the Turkish Land Forces; development and production assured by the ATAK Team, a Joint Partnership of Turkish Aerospace Industries, Inc. (TAI) and AgustaWestland. Moog was selected by AgustaWestland to design, qualify and manufacture the main rotor swashplate and tail rotor actuators for this aircraft. The first TAI-manufactured helicopter was delivered to Turkish Land Forces in April Supplier of A400M Primary Flight Control Actuation Moog is providing the design, manufacture and integration of eight fly-by-wire servoactuators for the Airbus A400M primary flight control surfaces. Moog is supplying electrohydraulic (EH) actuators for the aileron, elevator and certain spoiler surfaces and electric backup hydraulic actuators (EBHA) for positioning other Spoiler panels. The EBHA includes a self-contained electrohydrostatic actuator (EHA) with integral pump and electronic controls. During normal operation, the EBHA operates as a conventional EH actuator using the aircraft s main or backup hydraulic systems. When in backup mode, the onboard pump and controller provide hydraulic power for positioning the spoiler surfaces, allowing the elimination of the third hydraulic channel. 2 IDEF 2015 SPECIAL EDITION

3 INTEGRATED SYSTEMS FOR MILITARY AIRCRAFT All Electric Primary Flight Control Actuation System for Mantis Unmanned Air System Mantis is an advanced technology demonstrator for Medium Altitude Long Endurance (MALE) Unmanned Air Systems (UAS) jointly sponsored by the UK MOD and industry. It celebrated its first flight in October 2009 and has completed operational testing in Australia. Moog was selected by vehicle prime contractor BAE Systems to design, manufacture and integrate an All Electric primary flight control actuation system to control aileron, elevator and rudder flight surfaces. To meet the program s aggressive development schedule contract award to hardware delivery in less than 9 months Moog developed a modular system architecture which included common electromechanical (EM) actuator designs, high power EM drives, and a remote electronics unit for distributed control. Moog also leveraged this same modular solution for the aircraft s nose wheel steering. Systems Integrator for X-47B Primary Flight Control Systems Moog is the Primary Flight Control Actuation Systems Integrator for Northrop Grumman s X-47B unmanned combat air system. The system includes a fully redundant architecture featuring multifunction system controllers and modular electrohydraulic (EH) actuators. The system controller features a high speed 1394 bus interface, redundancy management, and full digital closed loop control for all flight surfaces and advanced vehicle functionality. The high-dynamic dual tandem EH actuators position the aileron, elevon and spoiler flight control surfaces. Moog Selected to Provide Actuation System for Boeing Next-Generation KC-46 Tanker Moog was selected by Boeing to provide the refueling boom actuation system on the KC-46 aircraft. In 2011, the United States Air Force selected Boeing to build the next generation KC-46 aerial refueling tanker to replace 179 of the service s 400 KC-135 tankers. Moog will provide the design, integration and qualification of the complete actuation system used to extend, retract and guide the refueling boom during in-flight refueling operations. Moog s system will include fly-by-wire actuators to provide precision control of the boom s rudder and elevator flight surfaces. Moog will also provide the telescoping and hoist actuators used to extend and retract the entire boom. Bell Selects Moog to Provide Integrated Flight Control System for the V-280 Valor Moog was selected by Bell Helicopter to design, manufacture and qualify an integrated flight control system, consisting of flight control computers, support software and flight control actuation, for the Bell V-280 Valor, Bell s third generation tiltrotor. With a combination of range, speed and combat capability, the Bell V-280 will offer U.S. Army commanders a combat maneuver platform with unmatched operational agility to self-deploy and perform a multitude of vertical lift missions, making this key program the most operationally effective aircraft for the U.S. Army s Future Vertical Lift requirements. 3 IDEF 2015 SPECIAL EDITION

4 INNOVATIVE SUPPORT FOR MILITARY AIRCRAFT World Class Repair and Overhaul Support for F-16 Leading Edge Flap Drive System Moog is the OEM supplier for the F-16 maneuvering Leading Edge Flap Drive System (LEFDS). Our products include the power drive units, hydromechanical actuators, rotary mechanical actuators, EM control actuators, angle gearboxes, torque shafts and asymmetry brakes. Moog has recently expanded its capability to support F-16 customers with repairs, overhauls and spares for the Leading Edge Flap (LEF) power drive unit (PDU). The PDU is a complex electrohydromechanical system that accurately controls the position of the leading edge flaps in response to changes in aerodynamic conditions. Moog has also developed internal capabilities to provide cost effective repair and overhaul services for the complete PDU and for all of the subassemblies that make up the PDU. Modifications of older design PDU s into the latest configuration can also be accomplished to minimize support costs for the end user. Moog Signs Umbrella Corporate Contract with DLA Moog has recently signed an Umbrella Contract with DLA - Defense Supply Center Richmond. The corporate contract covers critical component parts and sub-assemblies required to support depot repair activity for all Moog Aircraft Group products. This new contract benefits DLA, the USAF depots and Moog by streamlining the procurement process and providing more cost-effective and timely access to parts required to support legacy aircraft systems. Defense Supply Center Richmond is the aviation supply and demand chain manager for the Defense Logistics Agency and serves within the Defense Department as the primary source of supply for more than 1.2 million repair parts and operating supply items. DLA recently assumed responsibility for procurement management and related support functions for depot-level repairables at the Oklahoma City, Ogden and Warner Robins Air Logistics Centers. DLA s mission is to provide best value aviation weapon systems and logistics support to America s armed forces on land, at sea and in the air. Moog Adds New F-16 Flight Control Support Capabilities Moog has recently expanded its capability to support F-16 customers with repairs, overhauls and spares for the Leading Edge Flap (LEF) power drive unit (PDU). The PDU is a complex electro-hydro-mechanical system that accurately controls the position of the leading edge flaps in response to changes in aerodynamic conditions. Moog has also developed internal capabilities to provide cost effective repair and overhaul services for the complete PDU and for all of the subassemblies that make up the PDU. Modifications of older design PDUs into the latest configuration can also be accomplished to minimize support costs for the end user. Moog Supports Ongoing Public-Private Partnerships Moog is committed to supporting its customers through the use of public-private partnerships. Moog currently has several partnerships in place, covering multiple platforms and applications. These partnerships provide significant value by leveraging the specialized expertise, equipment and facilities of each organization. Moog has been under a public-private partnership with Ogden Air Logistics Center since March of 2008 for the overhaul and upgrade of the F-15 pitch and roll channel assembly. Most recently, Moog entered into a partnership with the OC-ALC in Oklahoma City for the repair and overhaul of the B-2 primary flight control actuators. Moog has also been under a public-private partnership with the Fleet Readiness Center Southeast for the F/A-18 leading edge flap system and under a commercial service agreement with the Fleet Readiness Center East for the V-22 Osprey. Moog is also actively engaged in dis cussion for future commercial service agreements with the Fleet Readiness Center Southwest for the F/A-18 E/F and F IDEF 2015 SPECIAL EDITION

5 INNOVATIVE SUPPORT FOR MILITARY AIRCRAFT Moog Expands Global Support Capability for Military Aircraft Products As part of a recent acquisition, Moog now offers full service capabilities for the relevant actuation products originally sold under the GE Wolverhampton, Smiths Wolverhampton and Dowty Wolverhampton names. Key products which have been added to Moog s support capabilities include: n CN235 Trailing Edge Flap Actuation & Controls n C295 Trailing Edge Flap Actuation & Controls n Typhoon Primary Flight Actuation n F-35 STOVL Lift Fan & Swivel Module Actuation n A129 Primary Flight Actuation n AMX Primary Flight Actuation Moog Expands Support for International C-130 Operators Moog recently acquired the Milwaukee Operations of Triumph Accessory Services. With a long history of supporting international operators with turnkey logistics services, the Moog Milwaukee office enhances and expands Moog s military aftermarket support program. This program includes comprehensive repair and overhaul support, spare parts support, performance upgrades, reliability enhancements and obsolescence management, and provides nose to tail solutions to C-130/L-100 operators and maintenance facilities around the world. For more information contact: n Eric Filter , efilter@moog.com n Mike Krueger , mkrueger@moog.com Active Vibration Control Systems for Military and Civil Rotorcraft Moog is supplying its active vibration controls for Sikorsky s UH-60M Blackhawk helicopter. Moog s Vibration Suppression Actuation System (VSAS) includes a DSP-based controller and a pair of counter-rotating force generators per channel. Vibration levels within the air vehicle are monitored and the force generators inject cancellation forces at discrete locations throughout the airframe, dynamically adapting to changes in the vibration environment. By eliminating the need for heavy passive vibration absorbers, the system offers weight savings while providing a number of secondary benefits including enhanced situational awareness, passenger comfort and increased aircraft component life. The system is currently flying aboard the Sikorsky S-92, Bell/ Boeing V-22, UH-60 Blackhawk and SH-60 Seahawk rotorcraft. Moog Offers Reliability Upgrade for H-60/S-70 Pitch Trim Actuator Moog is now offering a reliability upgrade to the UH-60 Blackhawk pitch trim actuator. This upgrade, available exclusively through Moog, will enable the pitch trim to stay on wing longer and provide better performance in harsh climates such as salt water, humidity and sand. A tungsten carbide coating has been added to the booster piston providing additional corrosion and scratch protection. The design of the dust boot has been modified to help keep the pitch trim flying longer and the newly designed mounting feet will prevent corrosion by better allowing the surface to shed moisture. All of these reliability upgrades can be implemented on your current pitch trim through Moog s exclusive overhaul process. 5 IDEF 2015 SPECIAL EDITION

6 INNOVATIVE SUPPORT FOR MILITARY AIRCRAFT Moog Advanced Repair Processes Approved for T700 Engine Parts The GE T700 engine family is used on 25 different rotary and fixed wing aircraft with applications across all US services as well as 50 other countries. As with many aerospace parts, corrosion and wear damage are major maintenance issues for the T700. Moog has been working with the engine manufacturer and operators to develop and qualify repair processes to salvage corroded and worn parts which otherwise would be scrapped providing significant savings in cost and lead time. As Received Moog has qualified repairs to the T700 front frame housing using supersonic particle deposition (cold spray). The contact surface between the inlet guide vane spindle and the front frame housing are prone to corrosion and wear. Moog s repair allows the surface to be restored and re-machined to original specifications, thereby allowing a significant number of parts to be salvaged and returned to service. Cold Spray Repair for Manufacturing Defect Moog recently repaired a manufacturing defect using Cold Spray repair on an actuating cylinder purge door body for an international aftermarket logistics management company. During the casting process, corrosion and manufacturing defects can occur, resulting in a part needing to be scrapped. With Cold Spray repair, Moog was able to salvage the castings, allowing the customer to save time and costs already invested during the manufacturing process. Defective Part Corroded Part Cold Spray Repair for Galvanic Corrosion Moog recently completed a corrosion repair on a cargo guide base for a major aircraft MRO service provider. Extensive corrosion pitting occurred due to a galvanic corrosion cell reaction between a non-aluminum washer placed in contact with the cargo guide base, which is composed of aluminum alloy Using a Cold Spray aluminum matrix, Moog was able to recover a high dollar, high demand housing that otherwise would have been scrapped. Defective Part Cold Spray Repair for Magnesium Jet Engine Parts Moog has been developing Cold Spray techniques to repair a large variety of damage on magnesium thrust reverser cascades. Damage due to debris strikes during operation and mishandling during routine maintenance can result in parts being taken out of service. The pictures to the left show the before and after of a cracked mounting flange repair. The pictures to the right show the before and after of a broken vane repair. Moog is able to salvage these cascades at a fraction of the replacement costs, saving the customer valuable time and money. Defective Part 6 IDEF 2015 SPECIAL EDITION

7 HIGH PERFORMANCE PRODUCTS Moog Crossbow Introduces Integrated Guidance, Navigation and Control System for Unmanned Aircraft Moog Crossbow recently introduced the GNC1000, a highly integrated guidance, navigation and control system that includes Autopilot, Flight Control Computer, Actuation Control, Attitude Heading and Reference System and Air Data. While robust in features, the GNC1000 is compact, light-weight and low power; making it ideal for a wide range of unmanned platforms. The system core is based on Moog s proprietary avionic solutions currently operating aboard large commercial transports and high end business jets. Because of its highly configurable nature, the GNC1000 is easily integrated into a variety of vehicle architectures. Product Features: n Autopilot and user-specified flight control laws n Attitude heading reference system (AHRS) n Built-in GPS and magnetic references n Air-data system meeting FAA TSO 106 requirements n Serial I/O including 10/100 Ethernet (4), RS-485 (8), RS-232 (2) and CAN (2) n Digital I/O including discrete (8I/4O), PWM (6), and Slip Rings and Fiber Optic Rotary Joints for Aerospace and Defense Slip rings are used in systems that require unrestrained, continuous rotation while transmitting power and/or data from a stationary device to a rotating structure. Today s battlefield requirements depend on Moog s slip rings for high bandwidth, high reliability and long life operation. With over 10,000 baseline designs, models are available in standard and custom configurations. Fiber Optic Rotary Joints (FORJ) pass optical signals across rotating interfaces while maintaining the advantages of fiber such as high bandwidth capability and EMI immunity. These products are designed for high performance operation in extreme environments, including shock and vibration, temperature, humidity and dust. solid state relay n Analog input +/- 10V, OAT n Ruggedized design complying to D0-160G and MIL-STD-810G and MIL-STD-461F n Compact, low power (<7W) and light weight (<3lbs) Moog Crossbow Offers Affordable MEMS GPS/IMU Solutions The Moog Crossbow NAV440 is an integrated GPS and Attitude & Heading Reference System (AHRS) that utilizes low drift MEMSbased inertial sensors with GPS aiding to provide unmatched price and performance. Developed in response to years of extensive application experience in a wide variety of commercial and COTSmilitary airborne, marine and land applications, the NAV440 also incorporates many new and enhanced design features. Typical applications include navigation, control and stabilization in manned and unmanned aircraft, marine and land environments. Product Features: n Complete GPS-Aided AHRS Solution n Accuracy < 0.2 deg n Output Data Rate > 100Hz n High-Range Sensor Options (400 deg/sec and 10g) n WAAS and EGNOS Enabled GPS n Low Power < 4W n Rugged Sealed Enclosure Moog Crossbow Introduces New Card-Level MEMS-Based Attitude Heading and Reference System (AHRS) The ANAV200 is Moog Crossbow s most compact, card-level MEMS GPS-aided AHRS for embedded use within integrated navigation and guidance systems. The ANAV200 has a small footprint volume of only 7 cubic inches and weighs less than 80 grams. Example applications include UAV flight control, SATCOM on the move, land vehicle and missile guidance, platform stabilization and micro-robotics. Product Features: n High reliability MEMS sensors n High range sensor option available n High accuracy < 0.2 n Small form factor < 7in3 n Low power < 1W n Lightweight < 80 grams n External SAASM GPS and integral 3-axis solid statemagnetometer interface 7 IDEF 2015 SPECIAL EDITION

8 WORLDWIDE For more information contact: Paul Blunden, Regional Business Development Director, Military Sustainment Phone: John Ungoed, Business Development Manager, Military OEM Europe Phone: jungoed@moog.com M Moog Inc. East Aurora, New York Fax: IDEF 2015 SPECIAL EDITION