Technology for Innovative Engine Composites

Transcription

1 akeoff 23 F A C C C U S T O M E R M A G A Z I N E Technology for Innovative Engine Composites New Project Passenger Cabins for Legacy 450 and Legacy 500 Airbus A330/A340 Serial Production of Flap Track Fairings Started On the Road to Success FACC Interiors with Strong Growth in Turnover

2 16 2 TAKEOFF takeoff F A C C C U S T O M E R M A G A Z I N E EDITORIAL CONTENTS Dear readers, 03 No Relief in Sight At the beginning of this year, the changes in the ownership structure of FACC were issues for investors, partners and the media. Now an important milestone has been reached, and a new, promising partner has been found. The ACC Kooperationen und Beteiligungen GmbH has bought % of the company shares, thus creating a very good foundation for healthy growth for FACC. The investor and the board agree on the goals: to strengthen the excellent position of the company as a development and system supplier for the aviation industry; well directed expansion; and a further increase in corporate value. This is the news at the end of a bidding process that lasted months and that marks an important milestone in the development of FACC. Dr. Hannes Androsch, co-partner of the ACC Kooperationen und Beteiligungen GmbH and Chairman of the Supervisory Board of FACC AG, has written an article about his confidence in the perspectives of FACC and the company strategy. The Interiors division of FACC is weathering the current adverse financial crisis well - it is developing extremely well. Various new projects, new customers and a consistent expansion of the market position allow the turnover of the division to continue to grow, and will also do so in the future. In an interview with take off, Gerhard Mörtenhuber, Vice President Interiors, speaks about the reasons for this success. Another milestone was reached by the employees of Facility 3 in Ort, Austria. They began serial production of the flap track fairings for the Airbus A330 and A340 after a development phase of only 12 months and carried out the first delivery on schedule. We congratulate them on this milestone and in this issue report about the details of the project. Further highlights of the last months were the expansion of the collaboration with Boeing on the new Boeing program and the delivery of the 1000th outer bypass duct for the BR710 Rolls- Royce engine. Read more about this and other topics on the following pages. The editorial team hopes you enjoy our new issue. Andrea Schachinger Editor PS.: We welcome your comments. [email protected] 04 Ownership in FACC A Company Geared to the Future 06 New Project: Passenger Cabins for Legacy 450 and Legacy FACC Interiors Division On the Road to Success 09 Bombardier Learjet: FACC Delivers the 200 th Learjet Passenger Cabin 10 Airbus A330/A340: FACC Started Serial Production of Flap Track Fairings 12 New Boeing 747-8: FACC Delivers Wing Components 14 Milestone: 1000 th Outer Bypass Duct for a BR Everyone Waltz! The Viennese Opera Ball Published by: FACC AG, Fischerstraße 9, A-4910 Ried/Austria. Editorial Staff: Walter Stephan, Bernhard Matzner, Andrea Schachinger. Photos: Peter M. Mayr AIC Vienna, Alois Furtner Ried, Embraer São José dos Campos, Boeing Seattle, ACAC Shanghai, Bombardier Aerospace Montréal, Andreas Friess/picturedesk.com, Vienna Paint Wien, Oskar Pointecker Mehrnbach, shutterstock.com, FACC Ried. Design and Composition: Oskar Pointecker, 4941 Mehrnbach. Cover: FACC employee Johannes Probsteder during the installation of a BR725 Duct on a CNC measuring machine. The examination of all demanded measures of the duct is performed fully automatic.

3 F A C C C U S T O M E R M A G A Z I N E takeoff 3 NO RELIEF IN SIGHT >> The current plight of the economy, especially in the world of finance, leads us to expect turbulent times. These will accompany and influence FACC AG in its new era in our last issue we reported about the new company structure. The United States, Europe and Japan are now in a recession and the crisis is holding important financial institutions in its grip, causing a noticeable shortage of available capital. Effects on the aviation industry have so far not made themselves felt. If one considers the information of our customers, their sector still seems to be unaffected by the crisis. The order books of the airplane manufacturers have once again grown this year. At the end of October the incoming orders at Airbus and Boeing were over 1,400 planes and surpassed by far the planned 900 airplane deliveries in However, all other signs indicate stormy times in the aviation industry as well. As a supplier we want to be prepared in good time and in the right way. At present the facts are as follows: Air traffic: Compared to last year, in September the number of passengers worldwide fell by just under 3%, within America by 8.2% and in Asia by 6.8%. Fuel: The fuel prices are under $50 USD per barrel and reduce the necessity for fuel-efficient airplanes. Individual airlines have already announced that they will postpone the delivery of new planes and continue to use older, less efficient planes. Profit situation of the airlines: Falling fuel prices are basically good news for suffering airlines. At the same time, the question must be asked in how far the global drop in air traffic could undo this bonus. Available assets: Market experts assume that due to the credit crunch, already in 2009 around one third of new airplanes, i.e. $20 billion USD worth of planes to be delivered, will have to be financed by airplane manufacturers, since many financial institutions shun the financing of airplanes. The strengthening US dollar: The exchange rate of the dollar is basically good news for FACC AG. However, due to currency hedging already transacted, this will not yet be effective and will weigh itself on business results of the coming years. In the mid-term range a strong US dollar will bring noticeable relief. Given all these factors, one can assume that 2009 will be a great year for airplane deliveries. For the following years, however, we are anticipating a reduction of the production rates for the established airplane families. We consider it a compensation that the A380, Boeing 787 and the ARJ21 programs, the last of which successfully carried out its first flight on November 28 th, which have been greatly effected by delays, are really getting into full gear. As a result, our production volume will continue to increase. The implementation of targeted measures, together with our strong backlog and the new reliable ownership structure, make us confident that our joint efforts will enable us to master the numerous challenges that the difficult market environment brings. Walter A. Stephan Chairman of the Board and CEO FACC AG <<

4 16 4 TAKEOFF takeoff F A C C C U S T O M E R M A G A Z I N E OWNERSHIP IN FACC A Company Geared to the Future The business year of 2008/09 set a decisive change of direction for FACC and will present a turnaround in revenue. The year before we were forced to cope with a loss on our balance sheets that took the company to the limits of financing. >> This negative development had several causes. Time and again we were confronted with technical delays in production and delivery of new airplane models such as the Airbus A380 or the Boeing Dreamliner 787. As a supplier for these models, FACC had to get involved in their development from the very beginning and this meant a great financial strain. The returns on this investment have therefore been delayed. However, due to the long product life of airplanes and the reliability of the models, a high return flow can be counted on over a long period of time. In addition, we had recently been confronted with a dollar that had become weaker and weaker. It hit rock bottom on July 15, 2008, with a rate of $1.599 to the euro. This situation put us in a troubling position, since our revenues are on a dollar basis, while around 50% of our costs are in euros. At FACC there has also been a change in the ownership structure. The shares of the Fischer Group were taken over in June 2008 by the ACC Kooperationen und Beteili - gungen GmbH. They now have a % share of FACC, just like Austrian Salinen AG. The remaining shares are owned by Stephan GmbH. The present owners want to expand FACC AG into a company strong enough for the future. The new owners expressed their commitment by increasing the company s capital stock. This step strengthened our key customers confidence in the company, which in turn freed us from the pressure of having to look for a strategic investment partner. Under the present conditions the company strategy is based on solid ground. All measures taken should make it possible for us to break even at the end of the current business year and to once again achieve positive results in the future. The returns on investment in the A380 and Boeing 787 models have been delayed. However, due to the long product life of airplanes and the reliability of the models, a high return flow can be counted on over a long period of time. Dr. Hannes Androsch Chairman of the Supervisory Board of FACC AG Lastly, there were and still are many internal problems to solve. The over-riding goal is maximum cost efficiency and the best possible quality assurance. Thus the amount of reworking, for example, must be reduced to a minimum as quickly as possible. The strategy of FACC is aimed at further expanding our position as a reliable and competent partner of the world s leading airplane manufacturers. This is to be achieved primarily through innovations as well as high quality standards at competitive prices and the expansion of

5 F A C C C U S T O M E R M A G A Z I N E takeoff 5 our product and service spectrum. singly prepared to contract signifi- secure jobs. Even when times are FACC should be positioned even cant parts of their supply chain to getting tougher due to the financial stronger than ever as a supplier of first tier suppliers. crisis and its real economic effects, total solutions. we have no reason to dread the The reconstruction of the organiza- future. At present our company is already tional structure into profit centers one of the fastest growing technolo- will also strengthen our competitive- I would like to thank our customers gy and quality leaders on the global ness and profitability, as well as for their confidence in us, our market for passenger planes. FACC assure the quality of our compo- employees for their dedication and has reacted to the above-average nents and our reputation for reliabili- our works council for their con- longtherm growth of the aviation ty. This in turn will contribute to an structive cooperation. sector with a consistent growth stra- uninterrupted capacity utilization of tegy. In this context we benefit from our facilities. the fact that lightweight construction Dr. Hannes Androsch keeps gaining in importance in the FACC AG will continue to be an Chairman of the Supervisory Board aviation industry. Manufacturers of attractive employer as we offer our of FACC AG << airplanes and engines are increa- employees interesting and above all Austrian Salinen AG % ACC Kooperationen u. Beteiligungen GmbH % Stephan GmbH 3.75% In June 2008 the ACC Kooperationen und Beteiligungen GmbH took over the shares of the Fischer Group. The FACC AG present owners want to strengthen FACC AG for the future and have shown their commitment Ownership structure chart of FACC AG by increasing the com - pany s capital stock.

6 6 takeoff F A C C C U S T O M E R M A G A Z I N E NEW PROJECT: Passenger Cabins for Legacy 450 and Legacy 500 Two years ago Embraer chose FACC as a supplier for the first time. The successful collaboration of the two companies is now being expanded. FACC is developing and producing the passenger cabins for the Brazilian aircraft manufacturer s new Legacy 450 and 500 business jets. >> During the 2008 Farnborough Airshow, Embraer awarded FACC with the contract for the development and production of the passenger cabins for their two new Legacy 450 and 500 business jets. The contract includes the manufacturing of the linings of the main cabin, the cockpit and the cargo compartment, all furnishings ranging from the galley to the lavatories, bulkheads, as well as the pocket table. In August FACC began the detail development of the passenger cabins for the Embraer business jets. At present, in the so-called joint definition phase, FACC is working together with the customer and other program suppliers on the configuration of the planes on site at the Embraer headquarters in Sao Jose dos Campos. This is being carried out in an entirely digital process using a virtual mock-up, CATIA V5 software and the most modern analysis, simulation and visualization technologies. In close collaboration with Embraer and the individual program partners, FACC technicians are developing and defining the interface to the aircraft, the installation process and the draft design of the various cabin elements. According to the contract, FACC will deliver the first complete cabin for the Legacy 500 model to Embraer at the end of The interior for the Legacy 450 will follow a year later. Our business relations with our customer Embraer are still very new, but are developing extremely positively, said Gerhard Mörtenhuber, Vice President Interiors of FACC AG. The foundation of this relationship is the optimal and most efficient co-operation of the Embraer and FACC engineering teams in the development of new products and programs. We want to use our comprehensive technological expertise to contribute to the success of the two new Embraer business jets. The current contract is already the fourth contract that Embraer has awarded FACC within the last two years. In addition to the two Legacy models, FACC also equips the Phenom 100, Phenom 300 and Lineage 1000 business jets with lightweight interior components.

7 F A C C C U S T O M E R M A G A Z I N E takeoff 7 The new Legacy contract and the other projects with Embraer will significantly help the Interiors Division - which could more than double its turnover in the last fiscal year to continue to grow with respect to turnover and employees, Mörtenhuber had to say about the pleasing developments for this division of the company. Legacy 450 and Legacy 500 The two Legacy 450 and Legacy 500 business jets have been completely newly developed by Embraer and complete the executive jet sector portfolio of the airplane manufacturers, whereby the mid-size Legacy 450 will have a range of up to 4,260 km and the super mid-size Legacy 500 a range of up to 5,560 km. The interior, designed by the BMW Group Designworks (USA) in co-operation with Embraer for the two planes, poses a quantum leap in the development of business jet interiors and will offer the passengers unsurpassed comfort and style. It is unique with its roomy cabin stand-up cabin (1.82 m tall) and a stepless floor, flat throughout, that makes the cabin comfortable to walk through. << FACC Interiors Division ON THE ROAD TO SUCCESS Considerable growth in turnover, numerous new projects, expansion of the market position and new customers: the Interior Division of FACC is growing extremely successfully. take off spoke with Gerhard Mörtenhuber, Vice President of FACC Interiors, about the reasons behind this success. take off: Please give our readers a short overview of the Interior Division. Mörtenhuber: The interior division develops, qualifies and produces complete passenger cabins for the largest airplane manufacturers like Airbus, Boeing, Bombardier and Embraer. Depending on the customer s wishes, we are in the position to be involved in a project already at the beginning of the development phase by carrying out the industrial design or merely take over the production of components. In the last years a clear market trend has become apparent that is moving steadily in the direction of vertical cabin development and cabin integration. We follow this trend and increasingly act as a complete solution provider covering the entire value added chain - from cabin design and development, qualification and certification to manufacturing, installation and customer support take off: Since its divestment eight years ago as a separate operation, how has the Interiors Division developed? What were the highlights? Mörtenhuber: Eight years ago we were in a crossroad situation, namely grow or give way. After intensive discussions with the owners, customers and our management we opted for the forward strategy, which at the time was not self-evident. In hindsight, we see that the interior team really stood behind this step and were totally committed. I am completely convinced that this was the actual success factor and why it was acknowledged by the market and rewarded with contracts. take off: How does FACC cope with the rapid ramp-up of aircraft production, especially of the A320 family for which FACC produces large cabin components? Which measures have been taken to increase production of interior components >>

8 8 takeoff F A C C C U S T O M E R M A G A Z I N E take off: What are the main reasons complex and comprehensive jobs in for the successful growth of the divi- other areas. This development has sion? been apparent for years and for a long time FACC has been working Mörtenhuber: There are always on establishing itself structurally. In several factors that lead to success- our product portfolio we see oursel- ful growth. The actual challenge ves in the upper segment. was not the strategic focus and the planning itself, but their implemen- take off: China is plainly the emer- tation. A branch that demands more ging market in aviation. FACC is and more flexibility, that is increa- involved in the ARJ21 project. What sing the pace and at the same time is your assessment of the further has distinct conflicts of goals more market development in this emer- than ever calls for an organization ging market? that is shaped by team competency and the ability to form a consensus. Mörtenhuber: The significance of In spite of diverse issues, we have the emerging markets, above all fulfilled many of our tasks, but are China, is beyond dispute. It is in the still working on some improve- offing that on the long run a new ments. balance between the established players in the West and the emer- take off: What are your strengths as ging ones in the East will materiali- "We increasingly act as in the course of the hike in Airbus compared to the competition and ze. FACC sees itself as an integrati- a complete solution production? on the market in general? ve part of the entire market and provider covering the showed this quite early with its entire value added Mörtenhuber: The development Mörtenhuber: I would like to ans- commitment to the ARJ21 project. chain from cabin phase of the A320 cabin went hand wer this question with feedback design and develop- in hand with the development and from our customers. Our customers take off: What are the future ment, qualification and start of production of three other see our strengths above all in our research and development plans in certification to manu- airplane cabins; with the introducti- technological innovations, our flexi- the interior area? facturing, installation on of new projects for Embraer; and bility as well as in the high level of and customer support." particularly with the escalated pro- quality of our components. Mörtenhuber: The continuous furt- duction ramp-up of the cabin for the her development in all areas, not Gerhard Mörtenhuber, Bombardier Challenger 300 busi- take off: Airplane manufacturers only on the component, is a must in Vice President ness jet. The combined implemen- are reducing their supplier base at every industry. We always try to FACC Interiors tation of all these programs was the the same time that they are transfer- keep an eye on the entire process real challenge. Problems that arose ring more and more tasks to the chain. In the area of classic R&D we were recognized on time, communi- suppliers. Where does FACC Inte- are concentrating on materials and cated openly and successfully sol- riors stand in international competi- processes as well as design innova- ved. In the course of the develop- tion? What are the prospects for tions which lead to either more effi- ment and the ramp-up of the new FACC? ciency, reduced weight or lower A320 Enhanced Cabin, a series of costs. improvements in logistics and pro- Mörtenhuber: The consolidation of duction processes were put into the supplier base in cabin furnis- take off: As far as the future and place. Furthermore, each producti- hings differs widely as to how far goals of FACC Interiors go, what do on process was carefully tested to advanced it is. While the consolida- you wish for the long-term future of see which would be the most effi- tion in the area of cabins for com- FACC? cient. Step by step these improve- mercial jets is already very advan- ments are being put into place in ced, there is still a strong segmenta- Mörtenhuber: I can answer this every program. All of these new pro- tion in the business jet area. Howe- question objectively, since it is jects can only be managed if the ver, the trend on both sides is the important for everyone. In my view cooperation between the customer, same our customers concentrate the ultimate goal is a long-term and the FACC team and suppliers on their core competencies, the sustainable perspective in running works. It is also important that our development of the entire plane and our business, and a solid position owners are supportive during diffi- integration. This is why they are among the top three interior manu- cult phases. passing over to the supplier more facturers.

9 F A C C C U S T O M E R M A G A Z I N E takeoff 9 BOMBARDIER LEARJET FACC Delivers the 200 th Learjet Passenger Cabin By delivering the 200 th passenger cabin for a Learjet 45 XR (45-376) to Bombardier Aerospace in August 2008, FACC has reached an important milestone. In Wichita, the 200 th cabin was installed in a business jet which was then delivered to Tiara Air LLC. in Columbus, Ohio, USA. Tiara Air was quoted at the time of delivery for their aircraft as stating that they particularly loved the interior of the aircraft. >> The long lasting and ever expanding partnership with Bombardier is an important foundation in the success story of FACC s interior sector. This began six years ago when the Canadian aircraft manufacturer gave FACC an order to start the serial production of interiors for the Learjet 40 and 45XR business jets. This event would mark the first time that FACC would enter into the business jet market segment for aircraft interiors. In order to support the needs of the Learjet production line, FACC Solutions, Inc., the wholly owned U.S. subsidiary of FACC, opened the Wichita Kansas facility in October of This facility has been responsible for the final assembly of the Learjet interior components, delivery of the final product to Learjet s receiving personnel, production line support, and FACC s liaison for design and production issues at Bombardier s Learjet facility. Since the start of the program, the high demand for Learjet aircraft in the business jet market has allowed FACC to constantly increase the production rate to around 60 airplanes annually. FACC is responsible for the production of the entire cabin of both the 40 and 45XR Learjet s, from the ceiling and sidewall linings, to forward partitions, to the exclusive custom cabinets. Based on this model of success Bombardier further decided to expand its cooperation with FACC and since 2006 FACC has been the system integrator of the passenger cabin of the Challenger 300 business jet. << David Watson (l.) hands over the 200 th passenger cabin for a Learjet 45 XR to Kevin Wilson, Bombardier (r.) The FACC Solutions, Inc. (FSI) Wichita Team: (From Left to Right) Blake Jones, Technician; Brian Harvey, Administrations Manager; Dave Watson, Operations Manager; John Pasquale, General Manager; Remon Shaw, Technician; Chad Hilton, Technician

10 10 takeoff F A C C C U S T O M E R M A G A Z I N E AIRBUS A330/A340: FACC Started Serial Production of Flap Track Fairings Beginning October FACC handed over the first flap track fairings for an A to Airbus. The wing components made of composite materials were delivered to the facility in Bremen where the wings of the long-range planes A330 and A340 are assembled. Meanwhile, the serial production of the wing components is in full swing. The successful FACC team and representatives of Airbus celebrated the milestone of the first delivery of the flap track fairings for the Airbus A330/A340 family (Picture above from left to right): Hannes Schlosser FACC; Günter Döhle, Peter Simonis, Christian Schäfer, Kathi Hohn, Alexander Nonnen each Airbus; Matthias Hacker, Robert Machtlinger both FACC and Bruno James Airbus) >> FACC celebrated the program milestone with a small ceremony at facility 3 in Ort im Innkreis, Austria, where the flap track fairings are being produced. FACC employees celebrated the start of serial production together with representatives of Airbus Germany. In September 2007, FACC signed a contract with Airbus for the production of the flap track fairings for the Airbus models A330 and A /-300, as well as the design and procurement of the production tools. The serial production of the wing components was started after a mere 12 month development phase. After reaching the monthly rate of nine ship sets in March 2009, around 100 additional employees will be working on the project at FACC. Per wing, FACC produces four flap track fairings of different dimensions. The largest fairing is 6.88 m long, 0.52 m wide and 0.85 m high. The aerodynamic fairings contain numerous technical systems necessary for flight operations, for whose integration FACC, as a system integrator, is responsible. These include channels for emergency fuel draining lines. In addition to supplying the A330 and A340 models, FACC also produces flap track fairings for the Airbus A380. The contract expands the cooperation with Airbus and enables FACC to implement their existing expertise acquired from the development and integration of the technologically complex system for the wide-body plane A380 in the A330/A340 program in an optimal way, and further expand their core competencies in the area of aerostructures. <<

11 F A C C C U S T O M E R M A G A Z I N E takeoff 11 Robert Machtlinger Vice President Structures FACC AG The signing of this contract to supply all future needed A330/A340 flap track fairings further establishes the successful partnership between Airbus and FACC. FACC can expand its position as a system supplier for Airbus for complex surface structures and once again successfully apply the acquired system expertise. Matthias Hacker Project Manager Hannes Schlosser Program Manager Development Airbus Structures, both FACC AG In only one year after starting the detail development phase, we were able to deliver the complete first sample set to Airbus. This could be described as an outstanding achievement and an amazing success of which we can all be very proud. We are especially pleased that the entire FACC / Airbus project team met all challenges with the necessary team spirit. The program manage ment would like to thank every single person who worked on the project for the extraordinary support and the good team work. Bernhard Buchmayer Group Leader Production FACC AG The decision to produce the flap track fairings for the A330/A340 planes in the structure facility in Ort was made on short notice. That is why it is all the more remarkable to note the excellent performance of each individual on the project team and in production that was necessary to be able to deliver the first sample to the customer on schedule. I am convinced that this team will be able to manage the upcoming ramp-up. I would like to thank everyone who made this success possible. Flap Track Fairings: A Core Competency of FACC The development and production of flap track fairings are core competencies of FACC AG. As a development and production partner of Airbus, FACC has introduced different innovations, advanced materials and improved aerodynamics, which contribute towards reducing operating costs of the planes. The goal of FACC is to optimize the structure of this aerodynamic sophisticated wing component while simultaneously reducing weight and thus reducing air drag, noise, weight and fuel consumption. Through an optimal choice of materials in the component lay-up, the static and dynamic requirements are specifically fulfilled. Innovative sealing concepts and advanced paint systems allow for excellent surface properties and efficient aerodynamics. Along with an additional reduction in weight, newly designed mounting and adjusting mechanisms also guarantee simple assembly and easy access for maintenance work, as well as sufficient freedom of movement during flight.

12 12 takeoff F A C C C U S T O M E R M A G A Z I N E NEW BOEING 747-8: FACC Delivers Wing Components With the 747-8, Boeing has put a wide-body jet on the market that has the special advantage of being eco-friendly and very comfortable. The latest model of the 747 family utilizes the most modern technology of the 787 Dreamliner. One of the many innovations comes from FACC. >> For the new 747 generation, Boeing is once again relying on the tested and approved services of FACC. In May 2007, the American airplane manufacturer chose FACC as supplier for the articulated cove panel. FACC will produce the components for the Freighter and the Intercontinental, just as it did for the , and is also responsible for the development, production and procurement of the production tools and metal fittings. Cost-efficient Production The new long-range plane is derived from the Boeing , but has a fuselage that is six-meters longer, a new, elegant cabin, wings that are more aerodynamic, and will have the modern, efficient engines of the 787. Due to the enhanced design of the wings, Boeing has completely redesigned the articulated cove panel, whereby FACC engineers, working closely together with Boeing designers, were able to provide significant design input and could already ensure an ideal base for cost-efficient and high-quality production in the development phase. Our years of experience in the production of these components for the previous model were definitely an advantage, stated Franz Ahammer, project manager at FACC. However, higher static stress and the expectation of the customer to keep the weight at the same level required FACC to come up with a new design for the The new part design is essentially based on our expertise that we acquired on the 787 program, in particular on the spoiler of the long-range airplane, said Ahammer. One difference between this generation of the 747 and the previous model is that the articulated cove panel is not made of one single fibre glass panel, but two panels - one out of glass and the other out of carbon material. The two-panel concept instead of the previous design, as well as the additional use of carbon fiber, makes for better static performance of the component, thus meeting higher stress standards. Testing Phase Has Successfully Begun In mid-december 2008, FACC completed all preparations for production - the development and procurement of the lay-up tools, the complex assembly and milling equipment and the comprehensive hardware package - and produced two test parts. In the course of the subsequent test phase, the parts were used for testing, which proved that they were failure free. This guarantees that the components will withstand the forces and loads during flight. At the same time FACC is already producing the first article components and is performing all activities towards part qualification by the customer and the aviation authorities. The delivery of the parts to the Boeing plant in Everett, FACC has been a supplier for Boeing s 747 programs since Due to the positive feedback during years of collaboration, Boeing has once again chosen FACC as a partner, this time for the new 747 generation. Our design input has resulted into a cost-efficient production as well as a high-quality product. Franz Ahammer Project Manager, FACC AG

13 F A C C C U S T O M E R M A G A Z I N E takeoff 13 Wash., pre-assembled by FACC and ready to install, will begin in early According to the new contract for the 747-8, FACC is also responsible for the installation of the entire hardware package and will deliver a ready-to-install panel, is how Franz Ahammer explains the difference between this and the conventional component of the and also emphasizes the advantages of the extended cooperation. This way Boeing saves time in the final assembly of the airplane. FACC, on the other hand, profits from a much higher added value. In spite of the substantial amount of metal parts, the component of over 3.3 meters long and 2 meters wide weighs only 89 kilograms and thanks to the optimized composite laminate, FACC was able to meet the requirements of higher stress at the same weight. The articulated cove panel is an aerodynamic wing panel that covers the area between the wing surface and landing flaps on the upper surface of the wing adjacent to the fuselage. During flight and particularly when deploying the landing flaps, the component is exposed to a multitude of forces, which makes the high load capacity of the component necessary. << New Eco-friendly Boeing The Boeing Intercontinental ket for planes with 400 to 500 and the Freighter are the seats. new high-performance members of the 747 family. The model number was chosen in order to the first Freighter in August Boeing began production on emphasize the technological similarities of the 787 and the new delivered to Cargolux the third The first freighter will be 747. The utilizes the innovative technologies of the 787 to and flight test. The first quarter 2010 following assembly considerably improve the efficiency and the functionality of the 747- very is planned for the second Intercontinental passenger jet deli- 400, at the same time improving quarter of Since the program began in November 2005, fuel consumption and reducing emissions and noise. The newest eleven customers have so far family of 747 planes complies with ordered 106 Boeing Intercontinentals and Freighters. the wishes of the airlines for a passenger plane that serves the mar- Technical Characteristics Boeing Seating 467 passengers in a three-class configuration Engines (Thrust) GEnx-2B67 (66,500 pounds) Maximum Takeoff Weight 975,000 pounds (442,255 kg) Range Intercontinental 8,000 nmi (14,815 km) Freighter 4,420 nmi (8,185 km) Cruise speed Mach 0,855 (Intercontinental) Mach 0,845 (Freighter) Wing span 224 ft 7 in (68.5 m) Length 250 ft 8 in (76.4 m) Height 64 ft 2 in (19.5 m)

14 16 14 TAKEOFF takeoff F A C C C U S T O M E R M A G A Z I N E MILESTONE: 1,000 th Outer Bypass Duct for a BR710 The long and successful partnership between FACC and the engine manufacturer Rolls-Royce is celebrating a significant milestone: In September FACC officially handed over the 1,000 th outer bypass duct for a BR710 engine to Rolls-Royce. The outer bypass duct was delivered to the Rolls-Royce plant in Dahlewitz, Germany. >> Since October 2001, FACC has been producing these weightsaving, sound-absorbing components for the BR700 engine family. Just a few months ago Rolls-Royce further expanded its cooperation with FACC by awarding the company with a contract for the supply of the outer bypass ducts for the BR725 the newest of the BR700 engine family, still in the development stage. This new contract boosts FACC s market leadership in the development and production of engine nacelle components using advanced composite technology. In turbofan engines, the outer bypass duct channels the outer air flow (bypass flow or secondary air flow) past the core engine. The fan works like a sheathed propeller and produces around 80% of the propulsion, depending on the model. Innovative Technology for Efficient, Eco-friendly Engines For years, and in cooperation with engine manufacturers, FACC has been intensively researching the area of engine and engine nacelle components. The focus of the R&D is on improving the efficiency and environmental soundness of new engines that feature reduced fuel consumption and produce less noise and pollutants. By using more composites in engines, the total weight and fuel consumption of the aircraft can be reduced. Due to their design, their material properties and the processes used, composite components can significantly minimize the noise levels of planes. In the production of engine nacelle components, FACC uses innovative manufacturing processes that are unique in Europe, among others a special technology for the processing of acoustic, noise-absorbing surfaces for engine nacelles. << Arrived in the four-digit range: The FACC team celebrated together with representatives of Rolls-Royces the delivery of the 1000 th outer bypass duct for a BR710 engine.

15 F A C C C U S T O M E R M A G A Z I N E takeoff 15 EVERYONE WALTZ! The Viennese Opera Ball Coffee houses, the Sachertorte and the Opera Ball three things that inevitably are connected with Vienna. On the last Thursday of the carnival season the social event par excellence of the Austrian ball season is celebrated: the Opera Ball. >> Once a year, the stage and stalls of the State Opera House are turned into a huge dance palace for one night. The Viennese Opera Ball, which was first held in 1935 as a charity event, is today among the largest and most successful dance events that is attended by local and international celebrities and VIPs. Whether they are rich, beautiful, important or just there, the elite from politics, business and culture meet there and mingle with a dabbling of stars and starlets. The ball is opened with the classic Fächerpolonaise, whereby around 160 dance couples from the youth committee enter the ballroom to the melody composed by Carl Michael Ziehrer. After obligatory song and dance performances, it is traditional that the dance floor is turned over to the ball attendees with the com- mand coined by Johann Strauss: Everyone waltz!, and the guests twirl in three quarter time in the nostalgic ambience of the Opera House. The Opera House during the Ball During the ball the Viennese State Opera House is open from cellar to attic fully accessible to all. In the Schwind foyer above the main formal staircase the Casinos Austria install a casino every year, expressly for the ball guests. Myriads of restaurants, champagne bars, oyster bars and even a wine tavern cater to the guests. A Ball Dances around the World The Viennese Opera Ball exists not only here in Austria. Viennese balls are held in many cities such as New York and Dubai, as well as in Istanbul, Zagreb and Kuala Lumpur, partly sponsored by the Vienna Opera Ball in order to guarantee the original Viennese flair. << The Vienna State Opera, with its nostalgic atmosphere is the venue of the annual Opera Ball.

16 A MEMORABLE DAY: On Friday, November 28, 2008 the ARJ21 took to the skies, a key step in China s ambitious aviation program. With value-added innovations, FACC is proud to support the ARJ21 commercial aircraft program in delivering a high-quality passenger cabin. Congratulations to COMAC and ACAC for the successful first flight of the ARJ21! FACC AG A-4910 Ried/Austria, Fischerstraße 9, P.O.Box 192 Tel. +43 / 59 / 616-0, Fax +43/ 59 / [email protected],