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1 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Revision update April 2022
Aerospace Structures
Overview
2 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Northrop Grumman Today
Leading global security company
$36.8 billion sales in 2020
– 86% U.S. / 14% International
$81 billion total backlog
(as of Dec. 31, 2020)
~97,000 employees
Leading capabilities in:
– Space
– Missiles
– Advanced Weapons
Focus on Growth and Performance
– Aeronautics
– Mission Systems
Approved for Public Release March 2021
3 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Four Operating Sectors at a Glance
Mission Systems
Airborne Sensors and Networks
Artificial Intelligence/Machine
Learning
Cyber and Intelligence
Mission Solutions
Navigation, Targeting and
Survivability
Maritime/Land Systems and Sensors
Engineering & Sciences
Emerging Concepts Development
Multi-domain C2
Agile/DevSecOps Systems
Autonomous Systems
Aerospace Structures
Advanced Technologies and
Concepts
Aircraft Design, Integration and
Manufacturing
Long-range Strike
Multi-Domain Integration and
Operations
Intelligence, Surveillance
and Reconnaissance
Battle Management
Aeronautics Systems Defense Systems
Integrated Air & Missile Defense
Defensive Cyber and Information
Operations
Platform Modernization and Fleet
Operations Support
Advanced Weapons
Precision Munitions
Software Systems Modernization
and Sustainment
Training and Simulation
Propulsion Systems
Space Systems
Launch Vehicles
Propulsion Systems
Commercial Satellites
Military and Civil Space Systems
Science and National Security
Satellites
Human Space and Advanced
Systems
Space Components
Missile Defense
Space Exploration
Space ISR Systems
Approved for Public Release March 2021
4 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Northrop Grumman Today
Approved for Public Release March 2021
5 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Northrop Grumman Organization
Kathy Warden
Chair, Chief Executive Officer
and President
Operations
Mark Caylor
President,
Mission Systems
Tom Wilson
President,
Space Systems
Functions
Dave Perry
Chief Global
Business Officer
Sheila Cheston
General Counsel
Mary Petryszyn
President,
Defense Systems
Dave Keffer
Chief Financial
Officer
Lucy Ryan
Chief Communications
Officer
Ann Addison
Chief Human
Resources Officer
Lesley Kalan
Chief Strategy and
Development Officer
Tom Jones
President,
Aeronautics Systems
Approved for Public Release February 2022
Matt Bromberg
Vice President,
Global Operations
6 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Aerospace Structures
7 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Aerospace Structures Overview
World class manufacturer of composite structures for
commercial and military aircraft and launch vehicles
Leader in composite automation innovation
– Invented automated fiber placement process
– Developed world’s fastest fiber placement machine
– Invented automated stiffener forming machine
Approximately 1,722 Employees
Headquarters in Clearfield, UT
– Facilities in California, Massachusetts, Mississippi,
Ohio and Utah
8 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Aerospace Structures Products
Commercial Aircraft
• Fan Case and By-Pass Ducts
• Airframe Structures
• Composite Door Springs
• Fuselage Stringers & Frames
• Primary Stiffening Structures
Military Aircraft
• Wing Skins, Fixed Skins, Nacelles
• Edge Components
• Core Components
• Counter Balance Assembly
• Apertures/Radomes/Antennas
• Survivable Structures
• Low Observable Technology
Launch Structures
• 4m and 5m Payload Fairings
• Thermal Shields
• Interstages
• Nosecones
Photo credit: Boeing
9 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Aerospace Structures Locations
Logan, Utah
~17 Employees
Rancho Bernardo, CA
~25 Employees
Clearfield, Utah ~1,241 Employees
• 1.5 Million ft2
• Freeport Composite Center
• Aircraft Commercial
Iuka, Mississippi ~227 Employees
• 320,000 ft2
• 20 ft. Diameter Autoclave
• Large Composite Launch Vehicle Structures
• Advance Fiber Placement and Hand Layup
Dayton, Ohio ~152 Employees
• 175,000 ft2
• Radomes / Antennas
• Advanced Materials
• Cryogenic Component
Design and Fabrication
Hopkinton,
Massachusetts
~13 Employees
• RF Components and Testing
• Low Observable Technology
• Survivability Structures
• Advanced Fiber Placement
• Automated Manufacturing
Magna, Utah
~45 Employees
10 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Segments Execution and Growth
Functions & Shared Services
Margo Maw
Executive Assistant
Hollie Hill
Director
Industrial
Engineering/Lean
Esteen Bottlinger
Director
Engineering
Jason Burns
Director
Internal
Aero-structures
Segment
DeVor Taylor
Director
External Military,
Missiles & Launch
Segment
Bryan Loveless
Director
Safety and
Mission Excellence
Kathleen Paralusz
Corporate
Counsel Legal
Liz Newman
Director
Business
Development
Julie Valois
Director
Human Resources
Alan Smith
Director Business
Management
Bryan Warren
Manager
Communications
Tamara Humphrey
Vice President
Aerospace Structures
Andy Christensen
Integration
Brian Mercier
Director
Operations
(ACS, HTS,
Iuka)
Simon Mason
Director
External Commercial
Aero-structures
Segment
Mike Henry
Director
Operations /SCM/
Security** (ACCE,
FCC, Dayton)
Effective: May 2022
(A) Acting
Aerospace Structures Organization
* IT is Solid Line Reporting to Mike Testa, MAS
** Security is Solid Line Reporting to Randy Taylor, MAS
11 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
ASBU Product Segment Portfolio
• Fuselage Stringers and Frames
• Fan Case and By-Pass Ducts
• Airframe and Primary Stiffening
Structures
• Composite Door Springs
• Wing Skins, Fixed Skins, Nacelles
• Bull Nose and Blade Seals
• Straps and fairings
• Screens
• Apertures
• Electromagnetic materials
• 4m and 5m Payload Fairings
• Thermal Shields
• Rocket Motor Cases
• Center Stages
• Nosecones
• Composite Overwrapped Pressure
Vessels
EXTERNAL MILITARY, MISSILES & LAUNCH SEGMENT
COMMERCIAL SEGMENT
• Large Assemblies
• Core Components
• Counter Balance Assembly
• Apertures, Radomes, Antennas
• Survivable Structures
• Low Observable Technology
INTERNAL MILITARY
SEGMENT
12 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Iuka Site
Floor Space: 320,000 ft2 (29,729 m2)
(27% clean room)
Commercial Aircraft
Floor Space: 615,000 ft2 (57,135 m2)
(17% clean room)
Dayton Site
Floor Space: 175,000 ft2 (16,258 m2)
(4% clean room)
ASD has 1,722 (unofficial) Employees and Over 2 Million ft2 (185,806 m2) of Manufacturing Capacity
CLEARFIELD, UTAH
Bldg. D-14
Bldg. C-14
Bldg. B-14
Freeport Composite Center
Floor Space: 403,000 ft2 (37,440 m2)
(12% clean room)
Advanced Composite Structures
Floor Space: 120,000 ft2 (11,148 m2)
(20% clean room by 2019)
DAYTON, OHIO
IUKA, MISSISSIPPI OTHER SITES
Rancho Bernardo, CA
Logan. UT
Hopkinton, MA
Advanced Composite Structures
Magna, UT
Floor Space: 90,000 ft2 (8,361 m2) (28% clean room)
Aerospace Structures Facilities
Bldg. G-12
ACCE
13 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
KEY FEATURES
Anchor Programs: Airbus A350/A400M
and Roll-Royce
• Floor Space: 615,000 ft2 (57,135 m2)
• Clean rooms 100,000 ft2 (9,290 m2)
• Open Capacity of 90,000 ft2 (8,361 m2)
• Automated Stiffener Forming Capacity
• Automated Linear Stringer Machines
• Automated Radial Frame Machines
• Engine Case Wrap Capacity
• CNC Milling Machine Capacity
• Large Diameter Autoclave Capacity
• NDI Systems - Automated Ultrasonic
Inspection (AUIS)
• Water Jet and Machining Capacity
• Hot Drape Forming
ASFM-Linear
Clean Room
ASFM-Radial
Clean Room
Engine Case Wrap
Clean Room
Machine and Trim
Non-destructive
Inspection
Shipping and
Receiving
Autoclave Cure
Area
Hot Drape Forming
90,000 ft2
(8,361 m2) Open
Capacity
Aeronautics Composite Center Elevated (ACCE)
AERONAUTICS
COMPOSITE
CENTER
ELEVATED
Located in
Clearfield, Utah
14 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Section
11-12
Section
13-14
Section
16-18
Section
15
Frame
Stringer
Northrop Grumman Builds Stringers For These Sections
Northrop Grumman Builds Frames
For These Sections
Northrop Grumman’s Automated Stiffener
Forming (ASF) utilized to manufacture 40
km (25 miles) per month at a 12 rate
Northrop Grumman Developed and Patented Technology
Frame Stringer
• 60% of all Frames
• 100% of all Stringers
• 684 parts per ship set
• More than 3,000 -900
tools; 1,930 -1000 tools
Sec 11-12
Stelia
Sec 13-14
Premium Aerotec
Sec 15
Spirit Aerosystems
& Airbus
Sec 16-18
Premium Aerotec
& Airbus
Sec 15
Spirit Aerosystems
& Airbus
Sec 16-18
Premium Aerotec
& Airbus
Airbus A350 XWB: Stringers and Frames
15 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
787 Fuselage Frames
• 150+ unique composite structures per 787-9 and 787-10 center and aft
fuselage
• Customers: Boeing and Alenia
• Customer satisfaction high – Exemplary technology transfer program
• Completed development & qualification ahead of schedule – Eleven
months from contract award to production-ready
• Meeting accelerated customer delivery schedule
• First in-service aircraft delivered to Air Canada on 31 August 2015
Other Boeing Programs Supported by Northrop Grumman
• 767 Torsion Springs: Counterbalance for bay doors on Boeing 767
Passenger, Cargo and Tanker
• C-17 Counterbalance Assembly
• 702: Composite tubes for Boeing Satellite program
Northrop Grumman Manufactures Frames
for Sections 44, 46 and 47
Boeing Programs
16 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Trent XWB 84K and 97K Composite Aft Fan Case
Utilizes Northrop Grumman Patented Forming Process
AFT Fan Cases for the Trent XWB Engine
• Trent Engine used on Airbus A350
• Fitted on both 84K an 97K thrust Engines
• Production Run estimate of 4,000 Cases
• Used as an Air Duct and
Mounting Hardware
• 22” wide x 112” in diameter
Northrop Grumman Notables:
• Rolls-Royce Supplier
Excellence for 2011
• Rolls-Royce Aerospace
Supplier of the Year 2013
• Rolls-Royce COO Award for 2015
Manufactured with Northrop Grumman's Patented,
Automated Wrap & Forming Process Technology
Rolls-Royce: Engine Component and Sub-assembly
17 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
A400M
Airbus A400M Program
Product Description:
• 122 T-Stringers per ship set
• 61 I-beams that are machined into 122 Ts
• Manufacturing Process: Hot Drape Forming (HDF)
• Won work transfer in 2012
• Originally built in Stade – Germany
• Northrop Grumman customized solution for making HDF charges
Airbus A400M Wing
Cover “T” Stringers
Typical industry HDF equipment
A400M Upper and Lower
Wing Structures
18 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
KEY FEATURES
Anchor Programs: Boeing 787 and
Lockheed Martin F-35
• Floor Space: 403,000 ft2 (37,440 m2)
• Clean room 48,100 ft2 (4,469 m2)
• 6 Fiber Placement Machines
• 3 Ovens
• 5 CNC Milling Machines
• 5 Autoclaves
• Automated Ultrasonic Inspection Systems (AUIS)
• ASFM R&D Machine
• Leica Measurement Systems
• Laser/Radar Measurement Systems
• Virtek Projection Systems
~32,000 ft2 Expansion
2 New FPMs
1 New Autoclave
Monorail Paint &
Coatings Area
15’ Dia. and 10’ Dia.
Autoclaves
15’ Dia. Autoclave
Non-destructive
Inspection System
4 Fiber Placement
Machines
Freeport Composite Center
FREEPORT
COMPOSITES
CENTER
Located in
Clearfield, Utah
19 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Northrop Grumman Aerospace Structures
F-35 JSF Content Per Variant
F-35B STOVL
F-35A CTOL F-35C CV
CV – 16 Parts
 Upper Wing Box Skin LH
 Upper Wing Box Skin RH
 Lower Wing Box Skin LH
 Lower Wing Box Skin RH
 Nacelle Skin LH FWD
 Nacelle Skin LH AFT
 Nacelle Skin RH FWD
 Nacelle Skin RH AFT
 Upper Access Cover LH
 Upper Access Cover RH
 Upper Access Covers CTR
 Upper Fixed Skin AFT
 Upper Fixed Skin FWD
 Strap
 Wing to Body Fairing LH
 Wing to Body Fairing RH
CTOL – 16 Parts
 Upper Wing Box Skin LH
 Upper Wing Box Skin RH
 Lower Wing Box Skin LH
 Lower Wing Box Skin RH
 Nacelle Skin LH FWD
 Nacelle Skin LH AFT
 Nacelle Skin RH FWD
 Nacelle Skin RH AFT
 Upper Access Cover LH
 Upper Access Cover RH
 Upper Access Covers CTR
 Upper Fixed Skin AFT
 Upper Fixed Skin FWD
 Strap
 Wing to Body Fairing LH
 Wing to Body Fairing RH
STOVL - 12 Parts
 Upper Wing Box Skin LH
 Upper Wing Box Skin RH
 Lower Wing Box Skin LH
 Lower Wing Box Skin RH
 Nacelle Skin LH FWD
 Nacelle Skin LH AFT
 Nacelle Skin RH FWD
 Nacelle Skin RH AFT
 Upper Access Cover LH
 Upper Access Cover RH
 Upper Access Cover CTR
 Upper Fixed Skin AFT
20 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Strap in Production
Finished Wing Skin
High-speed Automated Fiber Placement Wing Skin
Northrop Grumman Aerospace Structures F-35 JSF Production Articles
Engine Nacelles Final Assembly
Fiber Placed Wing Skin
Finished
Seals
Fiber Placed Nacelle
Lockheed Martin F-35 JSF: Production Articles
ENGINE
NACELLES
FORWARD
PANELS
LOWER WING SKINS
WING TO BODY FAIRING
UPPER
WING BOX
SKINS
ACCESS
COVERS
FIXED
SKINS
STRAP
SEALS
AFT INLET DUCT
VERTICAL TAIL
SEALS
WEAPONS BAY DOORS
WEAPONS BAY DOORS
21 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
OTHER COMPOSITE STRUCTURES
Pivot Shaft
Bypass Screen
Horizontal Stabilizer
F-22 Raptor
Counterbalance Assembly
Weapons Bay Door
Inlet Duct
Radome Radome
F-22 STRUCTURES
V-22
Structures
Global Hawk
Wing
Advanced Composite Hardware
22 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
APERTURES: ANTENNAS AND RADOMES
Horn Comparator
Notch Array Antenna
Link 16 Antenna
LOCOMM Antenna
TacSat 2 CDL AESA
Rigid Structures
Flexible Structures
PERFORMANCE VERIFICATION
Vacuum Optical Bench
Rancho Bernardo Test Facility
Compact Range #2
Dayton Site
• Floor Space: 175,000 ft2 (16,258 m2)
• (4% clean room)
• Radomes
• Antennas
• Advanced Materials (Loaded Core Structure)
• Cryogenic Component Design and Fabrication
• RF Components and Testing
• Low Observable Technology
• Survivability Structures – B1 and B2
Dayton Site: Advanced Aperture Solutions
23 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
IUKA SITE
Located in
Iuka, Mississippi
KEY FEATURES
Anchor Programs: ULA Atlas/Delta structures, Antares, OmegA
Floor space: 320,000 ft2 (29,729 m2)
• Clean room: 85,600 ft2 (7,953 m2)
• Open Capacity 150,000 ft2 (13,935 m2)
• Fiber Placement and Hand Lay Up
• Autoclaves
• 17.5 ft. Diameter x 50 ft. Length
• 20 ft. Diameter x 83 ft. Length
• Machining Centers
• 23m Belotti Machining Center
• 5-axis CNC Water Jet
• 3-axis Machining Center
• 5-axis CNC Router
• Automated Ultrasonic Inspection (AUIS)
• Horizontal and Vertical
• 13 Degrees of Freedom
• Modular: Wet, Dry and Radiographic NDI
• Dockable Gantry ATL and AFP
New Dockable Gantry ATL /
Fiber Placement System
Production Ready
Production Ready
23m Belotti
Machining Center
Fairings/Centerbody
Production Line
Fiber Placement
Machine
17.5 ft. Dia. & 20 ft. Dia.
Autoclaves
Large Structures
24 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
SIGNIFICANT NORTHROP GRUMMAN HERITAGE OF LAUNCH STRUCTURES
• OmegA structures
• Antares: 6 structures per launch vehicle
• ULA: Over 460 Delta IV structures manufactured
• ULA: Over 200 Atlas V structures manufactured
• Multiple Ariane V ISS structures manufactured
• Over 40 Pegasus missions
• Lockheed Martin Orion Ogive Fairings
Delta IV Centerbody in NDI
Launch Structures
Delta IV Antares
Atlas V
Boattail
Centaur
Interstage
Adapter
Debris Shield
(Not Seen)
Heat Shield
(Not Seen)
Payload
Fairing
Heavy
Interstage
Nose Cones
Center
bodies
Payload Attach
Fitting /
Diaphragm
(Not Seen)
Thermal
Shields
(Not Seen)
25 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Delta IV Interstage
4m Payload Attach Fitting
4m Payload Fairing - HLU
5m Payload Fairing - HLU
5m Interstage / Nose Cone
Delta IV Structures
26 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Aerospace Structures People
• Number of Employees (unofficial): approximately 1,722
• Locations:
• Clearfield, Utah
• Dayton, Ohio
• Hopkinton, Massachusetts
• 20% Female; 80% Male
• Average Employee Age: 42
• Average Years of Service: 8
• Workforce
Employee Statistics
<1
20%
1-3
28%
3-5
5%
10+
33%
5-10
13%
11%
19%
12%
58%
Funct Support
Engrg & Science
Ops/Program
Management
Prod/Tech
18-30
25%
61+
7%
41-50
17%
51-60
26%
31-40
25%
• Iuka, Mississippi
• Logan, Utah
• Rancho Bernardo, California
27 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Northrop Grumman:
A Leader in Composite Automation Innovation
Northrop Grumman Contribution to Composite Automation
ASD Innovation and Automation Drives Our Competitive Advantage
Improved
Manufacturing Flow
• Reduced labor hours
• Higher through-put
• More effective use of
staff
Improved Repeatability
• Machine optimized
performance
• Quality Improvement:
accuracy/repeatability
• Reduced product
scrap
Improved Cost
Performance
Why Automation?
1950’s–1970’s: Automated Filament Winding
1982: Invented Automated Fiber Placement
1950’s:
Allegany
Ballistics
Laboratory
Manufacturers
First Filament-
Wound Rocket
Motor
1971:
Introduces
S-glass/Epoxy
&
Kevlar/Epoxy
Materials
1978:
Introduced
Carbon/Epoxy
Materials in
Filament
Winding
1982:
Invented the
Fiber
Placement
Process
2002:
Developed
World’s
Fastest Fiber
Placement
Machine
2005:
Manufactured
Largest One-
piece Fiber
Placed Part on
Any Military
Aircraft
2007 – Future
Invented the
Automated
Stiffener
Forming
Machine
(8 Patents)
Automated Stiffener
Forming (ASF)
allows high rate
production of
uniquely designed
complex parts,
historically built by
hand layup
2003 – Future
Out of
Autoclave
Processing
Northrop Grumman
is advancing
Out-of-Autoclave
capability using its
Ultrasonic Tape
Lamination (UTL™)
and other in-situ
consolidation
technologies
2009 – Future
High Speed NDI
Northrop Grumman
developed high
speed automated
Non-Destructive
Inspection (NDI)
technology to
increase throughput,
detection fidelity and
data evaluation
2014
High Speed
Waterjet
Water jet robotics
holding fixture
means no
monuments and no
Machining Restraint
Fixture (MRF).
Water jet robot
bases saves 15-30
minutes per part in
MRF alignment,
scanning and
removal
2015+
Advanced
Dockable
Automated
Manufacturing
System
(ADAMS)
Combines both ATL
and AFP in a single
work cell. Capable of
handling very large
parts. Technology
potential to change
how we make large
structures
28 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
AFP is the Industry Standard in Large Structure
Composite Manufacturing
• Commercial aircraft structures
• Aircraft engine components
• Launch structures
• Liquid propulsion and reusable launch vehicles
• Propulsion cases
• Armored vehicles
• Oil and energy industry structures
• Satellite structures
Northrop Grumman Leads the Industry with Fiber
Placement Machines
• 5 Northrop Grumman design and built machines
• 7 Fives machines (formerly MAG)
• 2 NG/Fives co-developed machines
• 1 Electro Impact
AFP For Complex Layups On Large Surfaces: Steer, Drop/Add Narrow Prepreg Tow
Electro Impact AFP
Machine at Northrop
Grumman
Northrop Grumman / Fives
AFP Machines
Northrop Grumman
AFP Machine
Northrop Grumman
AFP Machine
Automated Fiber Placement (AFP)
An Industry Standard
29 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
yaw
joggles
roll
pitch
Northrop Grumman Innovation = Design Flexibility, Speed and Quality Improvement = Lower Cost
ASF: Stringer Production Machine Automated Engine Case Forming ASF: Frame Production Machine
Automated Stiffener Forming (ASF) allows high rate production of uniquely designed complex parts, historically
built by hand layup
• Uses woven fabric and/or unidirectional prepreg material forms
• Complex stringer geometries easily manufactured: pitch, yaw and roll
• Ramps, joggles and variable cross sections: Omega, C, Z, etc.
Automated Stiffener Forming (ASF) Process
30 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Advanced Dockable Automated
Manufacturing System (ADAMS)
• First of kind in industry
• Northrop Grumman plans to add end-effectors (EEs) to ADAMS for
flexibility and productivity of the work cell:
• Ability to change heads makes it affordable to add different EE
configurations: 1/8” Tow, 1/2” Tow, 3” tape, etc. increases optimization
for efficiency of part geometries
Part Layup Capacity: ~ 21’ W x 98’ L x 10’ V
End Effectors (EEs) under consideration include:
ADAMS set-up for up
to 8 docking stations
ATL Head In
Docking Stand
AFP Head
Empty AFP Head
Docking Stand
Dual head: ATL & AFP Head change <2 min
• Multiple tow width AFP Heads
• AFP heads of same Tow width
• Dual Phase ATL Head
• Automated Stiffener Forming Heads
• Ink Jet Marking Heads
• Adhesives and Coatings Application Heads
• Dry Preform Heads
31 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Northrop Grumman developed high speed automated Non-Destructive Inspection (NDI) technology
to increase throughput, detection fidelity and data evaluation
Advanced Ultra-Sonic Systems
Northrop Grumman developed NDI technology:
• Multiple independently operated detection heads, coupled
with advanced signal processing software to greatly reduce scanning time
• Integrated ultrasonic phased array inspection technology in automated scanner with 3D
full contour following capabilities
• Up to 15 inch per second inspection speeds
• Dual probe machines have eliminated the need to change out probes during scan
CINSP-AUIS-1 11-Axis 24m UT Scanner
CINSP-AUIS-2 11-Axis 18m UT Scanner Radial Phased Array
Inspection of complex surface 3D Laser Displacement Sensor
Automated High Speed NDI
32 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Design and Analysis Expertise
• Design and analysis of composite structures for a broad range of launch vehicle
and aircraft applications
• Optimization of composite structures
• Design for manufacturing - close integration between product design and
process development
• Materials development
State-of-the-Art Tools
• FE Analysis: ABAQUS, MSC. NASTRAN, NX NASTRAN, ANSYS
• Pre/Post Processing: ABAQUS CAE/Viewer, MSC. Patran, Altair HyperMesh
and HyperView
• Structural Optimization: HyperSizer, Altair OptiStruct and HyperStudy
• Computational Fluid Dynamics: Fluent
• Solid Modeling and Drafting: Catia V5, NX
• Special Purpose Applications: Composite pressure vessel design and
analysis, damage simulation, CLT and micromechanics, fracture mechanics
and fatigue
Experienced in Design and Analysis of Advanced Composite Structures
Experienced in Design to Specification
33 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
AS9100 accredited since 1997 – Revision D certified by Eagle Registrations,
Inc. in June 2018
NADCAP accredited by PRI (Performance Review Institute)
• Composite Fabrication accredited since 2004
• Non Metallic Material Testing, accredited since 2012
• Non Destructive Testing system, accredited since 2006
Aerospace Structures Has All Standard Industry Certifications
Aerospace Industry Approvals
34 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
A r t o f P o s s i b l e w i t h N o r t h r o p G r u m m a n
Experience Innovation Engaged People
Commitment to Quality Driving Down Costs Increasing Capacity
Partner of Choice
35 O12 – ASBU Overview 2021 – Approved for Public Release #11132018
Liz Newman Northrop Grumman Aerospace Structures
Liz.Newnan@ngc.com
BUSINESS DEVELOPMENT
BUSINESS SEGMENTS
Simon Mason Commercial
Simon.Mason@ngc.com
LEADERSHIP
Bryan Warren Northrop Grumman Aerospace Structures
Bryan.Warren@ngc.com
COMMUNICATIONS
Tamara Humphrey Vice President
Northrop Grumman Aerospace Structures
Tamara.Humphrey@ngc.com
Aerospace Structures
PO Box 160433, MS YA15
Clearfield, UT 84016-0433
www.northropgrumman.com
Contacts
Jason Burns Internal Military
Jason.Burns@ngc.com
DeVor Taylor External Military, Missiles & Launch
DeVor.Taylor@ngc.com
36 O12 – ASBU Overview 2021 – Approved for Public Release #11132018

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Northrop Grumman - Aerospace Structures Overvi.pdf

  • 1. 1 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Revision update April 2022 Aerospace Structures Overview
  • 2. 2 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Northrop Grumman Today Leading global security company $36.8 billion sales in 2020 – 86% U.S. / 14% International $81 billion total backlog (as of Dec. 31, 2020) ~97,000 employees Leading capabilities in: – Space – Missiles – Advanced Weapons Focus on Growth and Performance – Aeronautics – Mission Systems Approved for Public Release March 2021
  • 3. 3 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Four Operating Sectors at a Glance Mission Systems Airborne Sensors and Networks Artificial Intelligence/Machine Learning Cyber and Intelligence Mission Solutions Navigation, Targeting and Survivability Maritime/Land Systems and Sensors Engineering & Sciences Emerging Concepts Development Multi-domain C2 Agile/DevSecOps Systems Autonomous Systems Aerospace Structures Advanced Technologies and Concepts Aircraft Design, Integration and Manufacturing Long-range Strike Multi-Domain Integration and Operations Intelligence, Surveillance and Reconnaissance Battle Management Aeronautics Systems Defense Systems Integrated Air & Missile Defense Defensive Cyber and Information Operations Platform Modernization and Fleet Operations Support Advanced Weapons Precision Munitions Software Systems Modernization and Sustainment Training and Simulation Propulsion Systems Space Systems Launch Vehicles Propulsion Systems Commercial Satellites Military and Civil Space Systems Science and National Security Satellites Human Space and Advanced Systems Space Components Missile Defense Space Exploration Space ISR Systems Approved for Public Release March 2021
  • 4. 4 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Northrop Grumman Today Approved for Public Release March 2021
  • 5. 5 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Northrop Grumman Organization Kathy Warden Chair, Chief Executive Officer and President Operations Mark Caylor President, Mission Systems Tom Wilson President, Space Systems Functions Dave Perry Chief Global Business Officer Sheila Cheston General Counsel Mary Petryszyn President, Defense Systems Dave Keffer Chief Financial Officer Lucy Ryan Chief Communications Officer Ann Addison Chief Human Resources Officer Lesley Kalan Chief Strategy and Development Officer Tom Jones President, Aeronautics Systems Approved for Public Release February 2022 Matt Bromberg Vice President, Global Operations
  • 6. 6 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Aerospace Structures
  • 7. 7 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Aerospace Structures Overview World class manufacturer of composite structures for commercial and military aircraft and launch vehicles Leader in composite automation innovation – Invented automated fiber placement process – Developed world’s fastest fiber placement machine – Invented automated stiffener forming machine Approximately 1,722 Employees Headquarters in Clearfield, UT – Facilities in California, Massachusetts, Mississippi, Ohio and Utah
  • 8. 8 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Aerospace Structures Products Commercial Aircraft • Fan Case and By-Pass Ducts • Airframe Structures • Composite Door Springs • Fuselage Stringers & Frames • Primary Stiffening Structures Military Aircraft • Wing Skins, Fixed Skins, Nacelles • Edge Components • Core Components • Counter Balance Assembly • Apertures/Radomes/Antennas • Survivable Structures • Low Observable Technology Launch Structures • 4m and 5m Payload Fairings • Thermal Shields • Interstages • Nosecones Photo credit: Boeing
  • 9. 9 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Aerospace Structures Locations Logan, Utah ~17 Employees Rancho Bernardo, CA ~25 Employees Clearfield, Utah ~1,241 Employees • 1.5 Million ft2 • Freeport Composite Center • Aircraft Commercial Iuka, Mississippi ~227 Employees • 320,000 ft2 • 20 ft. Diameter Autoclave • Large Composite Launch Vehicle Structures • Advance Fiber Placement and Hand Layup Dayton, Ohio ~152 Employees • 175,000 ft2 • Radomes / Antennas • Advanced Materials • Cryogenic Component Design and Fabrication Hopkinton, Massachusetts ~13 Employees • RF Components and Testing • Low Observable Technology • Survivability Structures • Advanced Fiber Placement • Automated Manufacturing Magna, Utah ~45 Employees
  • 10. 10 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Segments Execution and Growth Functions & Shared Services Margo Maw Executive Assistant Hollie Hill Director Industrial Engineering/Lean Esteen Bottlinger Director Engineering Jason Burns Director Internal Aero-structures Segment DeVor Taylor Director External Military, Missiles & Launch Segment Bryan Loveless Director Safety and Mission Excellence Kathleen Paralusz Corporate Counsel Legal Liz Newman Director Business Development Julie Valois Director Human Resources Alan Smith Director Business Management Bryan Warren Manager Communications Tamara Humphrey Vice President Aerospace Structures Andy Christensen Integration Brian Mercier Director Operations (ACS, HTS, Iuka) Simon Mason Director External Commercial Aero-structures Segment Mike Henry Director Operations /SCM/ Security** (ACCE, FCC, Dayton) Effective: May 2022 (A) Acting Aerospace Structures Organization * IT is Solid Line Reporting to Mike Testa, MAS ** Security is Solid Line Reporting to Randy Taylor, MAS
  • 11. 11 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 ASBU Product Segment Portfolio • Fuselage Stringers and Frames • Fan Case and By-Pass Ducts • Airframe and Primary Stiffening Structures • Composite Door Springs • Wing Skins, Fixed Skins, Nacelles • Bull Nose and Blade Seals • Straps and fairings • Screens • Apertures • Electromagnetic materials • 4m and 5m Payload Fairings • Thermal Shields • Rocket Motor Cases • Center Stages • Nosecones • Composite Overwrapped Pressure Vessels EXTERNAL MILITARY, MISSILES & LAUNCH SEGMENT COMMERCIAL SEGMENT • Large Assemblies • Core Components • Counter Balance Assembly • Apertures, Radomes, Antennas • Survivable Structures • Low Observable Technology INTERNAL MILITARY SEGMENT
  • 12. 12 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Iuka Site Floor Space: 320,000 ft2 (29,729 m2) (27% clean room) Commercial Aircraft Floor Space: 615,000 ft2 (57,135 m2) (17% clean room) Dayton Site Floor Space: 175,000 ft2 (16,258 m2) (4% clean room) ASD has 1,722 (unofficial) Employees and Over 2 Million ft2 (185,806 m2) of Manufacturing Capacity CLEARFIELD, UTAH Bldg. D-14 Bldg. C-14 Bldg. B-14 Freeport Composite Center Floor Space: 403,000 ft2 (37,440 m2) (12% clean room) Advanced Composite Structures Floor Space: 120,000 ft2 (11,148 m2) (20% clean room by 2019) DAYTON, OHIO IUKA, MISSISSIPPI OTHER SITES Rancho Bernardo, CA Logan. UT Hopkinton, MA Advanced Composite Structures Magna, UT Floor Space: 90,000 ft2 (8,361 m2) (28% clean room) Aerospace Structures Facilities Bldg. G-12 ACCE
  • 13. 13 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 KEY FEATURES Anchor Programs: Airbus A350/A400M and Roll-Royce • Floor Space: 615,000 ft2 (57,135 m2) • Clean rooms 100,000 ft2 (9,290 m2) • Open Capacity of 90,000 ft2 (8,361 m2) • Automated Stiffener Forming Capacity • Automated Linear Stringer Machines • Automated Radial Frame Machines • Engine Case Wrap Capacity • CNC Milling Machine Capacity • Large Diameter Autoclave Capacity • NDI Systems - Automated Ultrasonic Inspection (AUIS) • Water Jet and Machining Capacity • Hot Drape Forming ASFM-Linear Clean Room ASFM-Radial Clean Room Engine Case Wrap Clean Room Machine and Trim Non-destructive Inspection Shipping and Receiving Autoclave Cure Area Hot Drape Forming 90,000 ft2 (8,361 m2) Open Capacity Aeronautics Composite Center Elevated (ACCE) AERONAUTICS COMPOSITE CENTER ELEVATED Located in Clearfield, Utah
  • 14. 14 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Section 11-12 Section 13-14 Section 16-18 Section 15 Frame Stringer Northrop Grumman Builds Stringers For These Sections Northrop Grumman Builds Frames For These Sections Northrop Grumman’s Automated Stiffener Forming (ASF) utilized to manufacture 40 km (25 miles) per month at a 12 rate Northrop Grumman Developed and Patented Technology Frame Stringer • 60% of all Frames • 100% of all Stringers • 684 parts per ship set • More than 3,000 -900 tools; 1,930 -1000 tools Sec 11-12 Stelia Sec 13-14 Premium Aerotec Sec 15 Spirit Aerosystems & Airbus Sec 16-18 Premium Aerotec & Airbus Sec 15 Spirit Aerosystems & Airbus Sec 16-18 Premium Aerotec & Airbus Airbus A350 XWB: Stringers and Frames
  • 15. 15 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 787 Fuselage Frames • 150+ unique composite structures per 787-9 and 787-10 center and aft fuselage • Customers: Boeing and Alenia • Customer satisfaction high – Exemplary technology transfer program • Completed development & qualification ahead of schedule – Eleven months from contract award to production-ready • Meeting accelerated customer delivery schedule • First in-service aircraft delivered to Air Canada on 31 August 2015 Other Boeing Programs Supported by Northrop Grumman • 767 Torsion Springs: Counterbalance for bay doors on Boeing 767 Passenger, Cargo and Tanker • C-17 Counterbalance Assembly • 702: Composite tubes for Boeing Satellite program Northrop Grumman Manufactures Frames for Sections 44, 46 and 47 Boeing Programs
  • 16. 16 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Trent XWB 84K and 97K Composite Aft Fan Case Utilizes Northrop Grumman Patented Forming Process AFT Fan Cases for the Trent XWB Engine • Trent Engine used on Airbus A350 • Fitted on both 84K an 97K thrust Engines • Production Run estimate of 4,000 Cases • Used as an Air Duct and Mounting Hardware • 22” wide x 112” in diameter Northrop Grumman Notables: • Rolls-Royce Supplier Excellence for 2011 • Rolls-Royce Aerospace Supplier of the Year 2013 • Rolls-Royce COO Award for 2015 Manufactured with Northrop Grumman's Patented, Automated Wrap & Forming Process Technology Rolls-Royce: Engine Component and Sub-assembly
  • 17. 17 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 A400M Airbus A400M Program Product Description: • 122 T-Stringers per ship set • 61 I-beams that are machined into 122 Ts • Manufacturing Process: Hot Drape Forming (HDF) • Won work transfer in 2012 • Originally built in Stade – Germany • Northrop Grumman customized solution for making HDF charges Airbus A400M Wing Cover “T” Stringers Typical industry HDF equipment A400M Upper and Lower Wing Structures
  • 18. 18 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 KEY FEATURES Anchor Programs: Boeing 787 and Lockheed Martin F-35 • Floor Space: 403,000 ft2 (37,440 m2) • Clean room 48,100 ft2 (4,469 m2) • 6 Fiber Placement Machines • 3 Ovens • 5 CNC Milling Machines • 5 Autoclaves • Automated Ultrasonic Inspection Systems (AUIS) • ASFM R&D Machine • Leica Measurement Systems • Laser/Radar Measurement Systems • Virtek Projection Systems ~32,000 ft2 Expansion 2 New FPMs 1 New Autoclave Monorail Paint & Coatings Area 15’ Dia. and 10’ Dia. Autoclaves 15’ Dia. Autoclave Non-destructive Inspection System 4 Fiber Placement Machines Freeport Composite Center FREEPORT COMPOSITES CENTER Located in Clearfield, Utah
  • 19. 19 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Northrop Grumman Aerospace Structures F-35 JSF Content Per Variant F-35B STOVL F-35A CTOL F-35C CV CV – 16 Parts  Upper Wing Box Skin LH  Upper Wing Box Skin RH  Lower Wing Box Skin LH  Lower Wing Box Skin RH  Nacelle Skin LH FWD  Nacelle Skin LH AFT  Nacelle Skin RH FWD  Nacelle Skin RH AFT  Upper Access Cover LH  Upper Access Cover RH  Upper Access Covers CTR  Upper Fixed Skin AFT  Upper Fixed Skin FWD  Strap  Wing to Body Fairing LH  Wing to Body Fairing RH CTOL – 16 Parts  Upper Wing Box Skin LH  Upper Wing Box Skin RH  Lower Wing Box Skin LH  Lower Wing Box Skin RH  Nacelle Skin LH FWD  Nacelle Skin LH AFT  Nacelle Skin RH FWD  Nacelle Skin RH AFT  Upper Access Cover LH  Upper Access Cover RH  Upper Access Covers CTR  Upper Fixed Skin AFT  Upper Fixed Skin FWD  Strap  Wing to Body Fairing LH  Wing to Body Fairing RH STOVL - 12 Parts  Upper Wing Box Skin LH  Upper Wing Box Skin RH  Lower Wing Box Skin LH  Lower Wing Box Skin RH  Nacelle Skin LH FWD  Nacelle Skin LH AFT  Nacelle Skin RH FWD  Nacelle Skin RH AFT  Upper Access Cover LH  Upper Access Cover RH  Upper Access Cover CTR  Upper Fixed Skin AFT
  • 20. 20 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Strap in Production Finished Wing Skin High-speed Automated Fiber Placement Wing Skin Northrop Grumman Aerospace Structures F-35 JSF Production Articles Engine Nacelles Final Assembly Fiber Placed Wing Skin Finished Seals Fiber Placed Nacelle Lockheed Martin F-35 JSF: Production Articles ENGINE NACELLES FORWARD PANELS LOWER WING SKINS WING TO BODY FAIRING UPPER WING BOX SKINS ACCESS COVERS FIXED SKINS STRAP SEALS AFT INLET DUCT VERTICAL TAIL SEALS WEAPONS BAY DOORS WEAPONS BAY DOORS
  • 21. 21 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 OTHER COMPOSITE STRUCTURES Pivot Shaft Bypass Screen Horizontal Stabilizer F-22 Raptor Counterbalance Assembly Weapons Bay Door Inlet Duct Radome Radome F-22 STRUCTURES V-22 Structures Global Hawk Wing Advanced Composite Hardware
  • 22. 22 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 APERTURES: ANTENNAS AND RADOMES Horn Comparator Notch Array Antenna Link 16 Antenna LOCOMM Antenna TacSat 2 CDL AESA Rigid Structures Flexible Structures PERFORMANCE VERIFICATION Vacuum Optical Bench Rancho Bernardo Test Facility Compact Range #2 Dayton Site • Floor Space: 175,000 ft2 (16,258 m2) • (4% clean room) • Radomes • Antennas • Advanced Materials (Loaded Core Structure) • Cryogenic Component Design and Fabrication • RF Components and Testing • Low Observable Technology • Survivability Structures – B1 and B2 Dayton Site: Advanced Aperture Solutions
  • 23. 23 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 IUKA SITE Located in Iuka, Mississippi KEY FEATURES Anchor Programs: ULA Atlas/Delta structures, Antares, OmegA Floor space: 320,000 ft2 (29,729 m2) • Clean room: 85,600 ft2 (7,953 m2) • Open Capacity 150,000 ft2 (13,935 m2) • Fiber Placement and Hand Lay Up • Autoclaves • 17.5 ft. Diameter x 50 ft. Length • 20 ft. Diameter x 83 ft. Length • Machining Centers • 23m Belotti Machining Center • 5-axis CNC Water Jet • 3-axis Machining Center • 5-axis CNC Router • Automated Ultrasonic Inspection (AUIS) • Horizontal and Vertical • 13 Degrees of Freedom • Modular: Wet, Dry and Radiographic NDI • Dockable Gantry ATL and AFP New Dockable Gantry ATL / Fiber Placement System Production Ready Production Ready 23m Belotti Machining Center Fairings/Centerbody Production Line Fiber Placement Machine 17.5 ft. Dia. & 20 ft. Dia. Autoclaves Large Structures
  • 24. 24 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 SIGNIFICANT NORTHROP GRUMMAN HERITAGE OF LAUNCH STRUCTURES • OmegA structures • Antares: 6 structures per launch vehicle • ULA: Over 460 Delta IV structures manufactured • ULA: Over 200 Atlas V structures manufactured • Multiple Ariane V ISS structures manufactured • Over 40 Pegasus missions • Lockheed Martin Orion Ogive Fairings Delta IV Centerbody in NDI Launch Structures Delta IV Antares Atlas V Boattail Centaur Interstage Adapter Debris Shield (Not Seen) Heat Shield (Not Seen) Payload Fairing Heavy Interstage Nose Cones Center bodies Payload Attach Fitting / Diaphragm (Not Seen) Thermal Shields (Not Seen)
  • 25. 25 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Delta IV Interstage 4m Payload Attach Fitting 4m Payload Fairing - HLU 5m Payload Fairing - HLU 5m Interstage / Nose Cone Delta IV Structures
  • 26. 26 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Aerospace Structures People • Number of Employees (unofficial): approximately 1,722 • Locations: • Clearfield, Utah • Dayton, Ohio • Hopkinton, Massachusetts • 20% Female; 80% Male • Average Employee Age: 42 • Average Years of Service: 8 • Workforce Employee Statistics <1 20% 1-3 28% 3-5 5% 10+ 33% 5-10 13% 11% 19% 12% 58% Funct Support Engrg & Science Ops/Program Management Prod/Tech 18-30 25% 61+ 7% 41-50 17% 51-60 26% 31-40 25% • Iuka, Mississippi • Logan, Utah • Rancho Bernardo, California
  • 27. 27 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Northrop Grumman: A Leader in Composite Automation Innovation Northrop Grumman Contribution to Composite Automation ASD Innovation and Automation Drives Our Competitive Advantage Improved Manufacturing Flow • Reduced labor hours • Higher through-put • More effective use of staff Improved Repeatability • Machine optimized performance • Quality Improvement: accuracy/repeatability • Reduced product scrap Improved Cost Performance Why Automation? 1950’s–1970’s: Automated Filament Winding 1982: Invented Automated Fiber Placement 1950’s: Allegany Ballistics Laboratory Manufacturers First Filament- Wound Rocket Motor 1971: Introduces S-glass/Epoxy & Kevlar/Epoxy Materials 1978: Introduced Carbon/Epoxy Materials in Filament Winding 1982: Invented the Fiber Placement Process 2002: Developed World’s Fastest Fiber Placement Machine 2005: Manufactured Largest One- piece Fiber Placed Part on Any Military Aircraft 2007 – Future Invented the Automated Stiffener Forming Machine (8 Patents) Automated Stiffener Forming (ASF) allows high rate production of uniquely designed complex parts, historically built by hand layup 2003 – Future Out of Autoclave Processing Northrop Grumman is advancing Out-of-Autoclave capability using its Ultrasonic Tape Lamination (UTL™) and other in-situ consolidation technologies 2009 – Future High Speed NDI Northrop Grumman developed high speed automated Non-Destructive Inspection (NDI) technology to increase throughput, detection fidelity and data evaluation 2014 High Speed Waterjet Water jet robotics holding fixture means no monuments and no Machining Restraint Fixture (MRF). Water jet robot bases saves 15-30 minutes per part in MRF alignment, scanning and removal 2015+ Advanced Dockable Automated Manufacturing System (ADAMS) Combines both ATL and AFP in a single work cell. Capable of handling very large parts. Technology potential to change how we make large structures
  • 28. 28 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 AFP is the Industry Standard in Large Structure Composite Manufacturing • Commercial aircraft structures • Aircraft engine components • Launch structures • Liquid propulsion and reusable launch vehicles • Propulsion cases • Armored vehicles • Oil and energy industry structures • Satellite structures Northrop Grumman Leads the Industry with Fiber Placement Machines • 5 Northrop Grumman design and built machines • 7 Fives machines (formerly MAG) • 2 NG/Fives co-developed machines • 1 Electro Impact AFP For Complex Layups On Large Surfaces: Steer, Drop/Add Narrow Prepreg Tow Electro Impact AFP Machine at Northrop Grumman Northrop Grumman / Fives AFP Machines Northrop Grumman AFP Machine Northrop Grumman AFP Machine Automated Fiber Placement (AFP) An Industry Standard
  • 29. 29 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 yaw joggles roll pitch Northrop Grumman Innovation = Design Flexibility, Speed and Quality Improvement = Lower Cost ASF: Stringer Production Machine Automated Engine Case Forming ASF: Frame Production Machine Automated Stiffener Forming (ASF) allows high rate production of uniquely designed complex parts, historically built by hand layup • Uses woven fabric and/or unidirectional prepreg material forms • Complex stringer geometries easily manufactured: pitch, yaw and roll • Ramps, joggles and variable cross sections: Omega, C, Z, etc. Automated Stiffener Forming (ASF) Process
  • 30. 30 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Advanced Dockable Automated Manufacturing System (ADAMS) • First of kind in industry • Northrop Grumman plans to add end-effectors (EEs) to ADAMS for flexibility and productivity of the work cell: • Ability to change heads makes it affordable to add different EE configurations: 1/8” Tow, 1/2” Tow, 3” tape, etc. increases optimization for efficiency of part geometries Part Layup Capacity: ~ 21’ W x 98’ L x 10’ V End Effectors (EEs) under consideration include: ADAMS set-up for up to 8 docking stations ATL Head In Docking Stand AFP Head Empty AFP Head Docking Stand Dual head: ATL & AFP Head change <2 min • Multiple tow width AFP Heads • AFP heads of same Tow width • Dual Phase ATL Head • Automated Stiffener Forming Heads • Ink Jet Marking Heads • Adhesives and Coatings Application Heads • Dry Preform Heads
  • 31. 31 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Northrop Grumman developed high speed automated Non-Destructive Inspection (NDI) technology to increase throughput, detection fidelity and data evaluation Advanced Ultra-Sonic Systems Northrop Grumman developed NDI technology: • Multiple independently operated detection heads, coupled with advanced signal processing software to greatly reduce scanning time • Integrated ultrasonic phased array inspection technology in automated scanner with 3D full contour following capabilities • Up to 15 inch per second inspection speeds • Dual probe machines have eliminated the need to change out probes during scan CINSP-AUIS-1 11-Axis 24m UT Scanner CINSP-AUIS-2 11-Axis 18m UT Scanner Radial Phased Array Inspection of complex surface 3D Laser Displacement Sensor Automated High Speed NDI
  • 32. 32 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Design and Analysis Expertise • Design and analysis of composite structures for a broad range of launch vehicle and aircraft applications • Optimization of composite structures • Design for manufacturing - close integration between product design and process development • Materials development State-of-the-Art Tools • FE Analysis: ABAQUS, MSC. NASTRAN, NX NASTRAN, ANSYS • Pre/Post Processing: ABAQUS CAE/Viewer, MSC. Patran, Altair HyperMesh and HyperView • Structural Optimization: HyperSizer, Altair OptiStruct and HyperStudy • Computational Fluid Dynamics: Fluent • Solid Modeling and Drafting: Catia V5, NX • Special Purpose Applications: Composite pressure vessel design and analysis, damage simulation, CLT and micromechanics, fracture mechanics and fatigue Experienced in Design and Analysis of Advanced Composite Structures Experienced in Design to Specification
  • 33. 33 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 AS9100 accredited since 1997 – Revision D certified by Eagle Registrations, Inc. in June 2018 NADCAP accredited by PRI (Performance Review Institute) • Composite Fabrication accredited since 2004 • Non Metallic Material Testing, accredited since 2012 • Non Destructive Testing system, accredited since 2006 Aerospace Structures Has All Standard Industry Certifications Aerospace Industry Approvals
  • 34. 34 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 A r t o f P o s s i b l e w i t h N o r t h r o p G r u m m a n Experience Innovation Engaged People Commitment to Quality Driving Down Costs Increasing Capacity Partner of Choice
  • 35. 35 O12 – ASBU Overview 2021 – Approved for Public Release #11132018 Liz Newman Northrop Grumman Aerospace Structures Liz.Newnan@ngc.com BUSINESS DEVELOPMENT BUSINESS SEGMENTS Simon Mason Commercial Simon.Mason@ngc.com LEADERSHIP Bryan Warren Northrop Grumman Aerospace Structures Bryan.Warren@ngc.com COMMUNICATIONS Tamara Humphrey Vice President Northrop Grumman Aerospace Structures Tamara.Humphrey@ngc.com Aerospace Structures PO Box 160433, MS YA15 Clearfield, UT 84016-0433 www.northropgrumman.com Contacts Jason Burns Internal Military Jason.Burns@ngc.com DeVor Taylor External Military, Missiles & Launch DeVor.Taylor@ngc.com
  • 36. 36 O12 – ASBU Overview 2021 – Approved for Public Release #11132018