Spirit AeroSystems

military helicopter against a blue, red and gold colored evening sky; logos of Spirit AeroSystems, Boeing, and Airbus in upper half

Spirit AeroSystems Announces Split Acquisitions by Boeing, Airbus

/ AEROSPACE HEAT TREAT NEWS, FEATURED NEWS

Spirit AeroSystems, a global manufacturer of aerostructures for commercial airplanes, defense platforms, and business/regional jets recently announced it has entered into a definitive merger agreement with The Boeing Company. Additionally, Spirit has agreed to a subsequent agreement in which aerospace manufacturer Airbus acquires certain Spirit assets that serve Airbus programs.

Dave Calhoun
President & CEO
The Boeing Group
Source: Linked In

The $8.3 billion Boeing transaction, expected to close mid-2025, will include all Boeing-related commercial, defense, aftermarket operations, and a commitment to ongoing partnership with the U.S. Department of Defense and Spirit defense operations. Spirit AeroSystems manufactures fuselage structures for the Boeing 737 MAX and 787 Dreamliner, among other aircraft programs.

Patrick M. Shanahan
President & CEO
Spirit AeroSystems
Source: U.S. Department of Defense

“This is an opportunity to bring back critical airplane manufacturing work on Boeing airplanes into our factories–where Boeing and Spirit world-class engineers and mechanics can work seamlessly together, focused on a common mission to build safe and quality airplanes for our customers,” said Dave Calhoun, president and CEO of Boeing, in a statement to employees on July 1, 2024.

The Airbus transaction will run concurrently with the closing of Spirit’s acquisition by Boeing and involves the potential acquisition of major activities related to Airbus, notably the production of A350 fuselage sections in Kinston, North Carolina, U.S., and St. Nazaire, France; of the A220’s wings and mid-fuselage in Belfast, Northern Ireland, and Casablanca, Morocco; as well as of the A220 pylons in Wichita, Kansas, U.S.

“Bringing Spirit and Boeing together will enable greater integration of both companies’ manufacturing and engineering capabilities, including safety and quality systems,” said Patrick M. Shanahan, president and CEO of Spirit. “We are proud of the part we have played in Airbus’ programs and believe bringing these programs under Airbus ownership will enable greater integration and alignment.”

In taking over those operations, Airbus will pay a nominal $1.00 and will be compensated with $559 million from Spirit AeroSystems.

Related press releases are available in their original form here, here, and here.

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Bombardier Offloads Aerostructures, Aftermarket Assets to Spirit AeroSystems

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Spirit AeroSystems Holdings Inc. recently announced it has entered into a definitive agreement to acquire select assets of Bombardier aerostructures and aftermarket services businesses in Belfast, Northern Ireland (known as Short Brothers); Casablanca, Morocco; and Dallas, Texas.

Spirit AeroSystems president and CEO Tom Gentile

The opportunity to expand its operations into Northern Ireland and Morocco and the addition of the entire work package for the A220 wing and its technology is critical for the future of next-generation aircraft, says Spirit. In aerostructures and fabrication, Bombardier supplies composite and metallic wing components, nacelles, fuselages, and tail assemblies, along with high-value mechanical assemblies made out of aluminum, titanium, and steel.

“The Bombardier operations bring world-class engineering expertise to Spirit and add to a strong track record of innovation, especially in advanced composites,” said Spirit AeroSystems president and CEO Tom Gentile. “Belfast has developed an impressive position in business jet fuselage production, in addition to the world-acclaimed fully integrated A220 composite wing. This acquisition is in line with our growth strategy of increasing Airbus content, developing low-cost country footprint, and growing our aftermarket business.”

 

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15 Quick Heat Treat News Chatter Items to Keep You Current

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel and Company Chatter

  • TimkenSteel has announced that Ward J. “Tim” Timken, Jr. has stepped down as CEO and president and as chairman of the TimkenSteel board of directors. Effective immediately, the Board of Directors has appointed Terry L. Dunlap as the company’s interim CEO and president. John P. Reilly, the current lead director of the TimkenSteel board of directors, will immediately assume the role of chairman of the board.
  • Rick Merluzzi has been promoted to the position of CEO at Metal Exchange Corporation. Mike Lefton, current chairman and CEO, will assume the title of executive chairman. Merluzzi oversees all their businesses, including Metal Exchange Trading, Pennex Aluminum Company, Continental Aluminum and Electro Cycle, Inc.
  • Platte River Equity has sold its portfolio company PRV Metals to Tinicum LP. PRV Metals, a leading supplier of specialty forged titanium and high-performance steel products to aerospace, defense, medical, energy, and industrial sectors, operates through two subsidiaries Sierra Alloys and TSI Titanium. 
  • US aviation group Collins Aerospace has extended the contracts for the supply of thrust reverser housings for the engine gondolas of the Airbus A350 XWB and Boeing 787 aircraft. The order includes the delivery of the engine cowlings into the next decade. This contract renewal is a major contribution to strengthening FACC’s position as an international partner in the Engines & Nacelles segment.
  • Bodycote Thermal Processing Inc has announced it will spend $15.3 million to renovate and equip a dilapidated, 58,000-square-foot building in Geddes, New York, to replace the company’s facility that burned down in Van Buren, New York, in 2018. Equipment will be purchased that will allow the company to perform heat treatment processes not currently available in the United States.
  • Element Materials Technology has announced that its new aerospace materials testing laboratory in Shanghai, China, is now open for business. Element confirmed it has completed a number of accreditations including ISO/IEC 17025:2017 and Nadcap, with OEM audits underway. The new laboratory specializes in a comprehensive range of services that include: chemical analysis; fatigue testing; failure investigation; mechanical testing; metallurgical analysis, and on-site testing at client sites. Customers will also benefit from pre-testing services, including a full machine shop and heat treatment furnaces for the treatment of materials prior to testing.
  • Construction is moving forward at a brisk pace at Stack Metallurgical Group‘s new Albany, Oregon site, where the company will offer both Hot Isostatic Pressing (HIP) and vacuum heat-treating services.

Equipment Chatter

  • Three intelligent waste heat recovery systems have been awarded by Tangshan Zhengfeng Iron & Steel Co., LTD, in Hebei Province, China, to Tenova, a Techint Group company specializing in innovative solutions for the metals and mining industries.
  • A contract to supply on-site nitrogen to Samwha Capacitor’s new multi-layer ceramic capacitor (MLCC) plant being built adjacent to its existing plant in Yongin, South Korea, has been awarded to Air Products. Under the new contract, Air Products will expand its nitrogen capacity to support the increasing demand from Samwha Capacitor’s existing and new plants.
  • Advanced soft magnetic expertise and ultra-efficient electrical components will be provided by Carpenter Technology to multiple OEMs to progress their electric aircraft aspirations.  Carpenter Technology will provide advanced soft magnetic expertise and ultra-efficient electrical components to be used in R&D and demonstrator motors and engines, leading to construction of lighter-weight, longer-lasting electric propulsion systems.
  • Two reheating furnaces to reheat blooms and billets have been delivered to Shijiazhuang Iron & Steel Company within China’s HBIS Group by Fives.

Kudos Chatter

  • Element Materials Technology has been awarded the 2018 Gold Boeing Performance Excellence Award (BPEA) for its Huntington Beach, California, laboratory, while the Element Los Angeles laboratory won Silver. The annual award recognizes superior performance in the highest tiers of Boeing’s supply chain. This is the second year Element Huntington Beach has achieved the Gold award and the first year that Element Los Angeles has achieved Silver status.
  • Plibrico Corporation has awarded employees Joe Feldhacker, a project manager from Plibrico’s Omaha, Nebraska location, and Lou Calderon, refractory CAD designer in the company’s engineering department in Northbrook, Illinois, API 936 Refractory Personnel Certification. Both demonstrated advanced knowledge of installation, inspection, testing and repair of monolithic refractory linings, passing the rigorous API 936 exam administered by the American Petroleum Institute (API), a national trade association representing all facets of the natural gas and oil industry.
  • Spirit AeroSystems was recognised at the Composites and Advanced Materials Expo (CAMX) with the Award for Composite Excellence (ACE) in Manufacturing: Material and Process Innovation. Spirit received the award for its development of the Advanced Structures Technology and Revolutionary Architecture (ASTRA) demonstrator aircraft panel, which was displayed at the CAMX conference in Anaheim, California.
  • The 100th nacelle system for Airbus’ A330neo wide-body jetliner has been delivered by Safran Nacelles.

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to the editor at editor@heattreattoday.com

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Aerostructures Manufacturer Transitions Breakthrough Titanium Fabrication Technology from Lab to Factory

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, TITANIUM PROCESSING NEWS

A manufacturer of aerostructures for both commercial and defense headquartered in Wichita, Kansas, recently announced it is transitioning recent research breakthroughs—a new process that allows for more advanced production of titanium parts—from the laboratory to its factory.

Spirit AeroSystems developed The Joule Form™ process, a new proprietary method for forming titanium raw material at elevated temperatures in the fabrication of aerospace components. This method provides the company with a competitive advantage in the use of titanium, a highly desirable material thanks to its combination of strength and its light weightedness.

John Pilla, Spirit AeroSystems Senior Vice President and Chief Technology and Quality Officer
John Pilla, Spirit AeroSystems Senior Vice President and Chief Technology and Quality Officer

“We are the first in the aerospace industry to use this high-tech solution,” said Spirit AeroSystems Senior Vice President and Chief Technology and Quality Officer John Pilla. “The implementation of the Joule FormTM process allows for more advanced production of titanium parts, such as those on Spirit’s propulsion, fuselage and wing products. This approach offers a host of benefits that ultimately reduce costs and drive greater efficiencies.”

The Joule FormTM process allows Spirit to form parts out of titanium plates rather than relying on machining large blocks of titanium, significantly reducing waste and decreasing the amount of machining. The process was internally developed as part of one of Spirit’s key research focus areas, the Lean Metallic Structures Distinctive Capability.

Kevin Matthies, Spirit's senior vice president of Global Fabrication
Kevin Matthies, Spirit’s senior vice president of Global Fabrication

“This emerging manufacturing improvement can replace more expensive techniques,” said Kevin Matthies, Spirit’s senior vice president of Global Fabrication. “We want to build high-quality products in a cost-effective way. This is a great example of improving a process to better serve our customers.”

Joule Form™ technology can be used on aircraft components that are machined from plates or forgings, specifically on materials that are hard to machine and expensive to procure (like titanium and steel alloys). Spirit operates sites in the U.S., U.K., France and Malaysia. The company’s core products include fuselages, pylons, nacelles and wing components for the world’s premier aircraft.

Photo Credit: Still image from Spirit AeroSystems video

 

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First Nadcap Accreditation Awarded for Aero Structure Assembly to Kansas Facility

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The first ever Nadcap accreditation for Aero Structure Assembly has been awarded to an aerospace company based in Wichita, Kansas.

Lee Aerospace Inc., which designs, manufactures, installs, and repairs aerospace parts and assemblies for the aerospace industry, recently received the accreditation following a 2018 pilot audit that validated the audit criteria developed by the Nadcap Aero Structure Assembly Task Group and rigorously assessed the company’s compliance to the applicable industry standards and customer requirements.

Christopher Lowe of Spirit AeroSystems, Nadcap Aero Structure Assembly Task Group Chair

“There are more companies than ever involved in aerostructure assembly as activity is delegated through the supply chain by the airframers,” explained Christopher Lowe of Spirit AeroSystems, Nadcap Aero Structure Assembly Task Group Chair. “As a result, the need for supply chain oversight in this area was recognized as being of growing importance. Nonconforming assembly practices can cause serious escapes such as unseen product defects, delivery delays and rectification costs.

“Congratulations to Lee Aerospace Inc. for their notable achievement in being the first in the world to gain this prestigious accreditation. I am pleased to have had the opportunity, through Nadcap, to work with my peers at Airbus, Airbus Defense and Space, Arconic, BAE Systems, Helicomb International, Lee Aerospace Inc., Leonardo, Lockheed Martin, Northrop Grumman and Spirit AeroSystems to address this issue and I encourage others in the industry to get involved in this activity.”

Technologies covered in the Aero Structure Assembly audit criteria currently extend to fastening, electrical bonding, bushing and bearing installation, and sealant application.

Tommy Howland, Director of Quality for Lee Aerospace

Issuing the first accreditation is a significant step in the maturation of the newest Nadcap Task Group, whose members have been working towards this point since 2015 when the Nadcap Management Council approved Aero Structure Assembly as one of the specialized technologies that Nadcap accredits. Aero Structure Assembly now joins both long-standing practices such as heat treating, welding, and non-destructive testing, as well as newer activities such as composites and electronics in the Nadcap program.

“As an active member of Nadcap, when the opportunity to be the first company for accreditation in a pilot program presented itself, we literally jumped at the chance,” said Tommy Howland, Director of Quality for Lee Aerospace. “At Lee Aerospace, we strive to be the best in all aspects of our manufacturing processes, including transparencies, composites, and aerostructure assembly.”

 

Photo credit: Business Journals

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Aerostructures Company Strengthens Boeing Partnership, Expands Manufacturing Facility

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, FEATURED NEWS

The world’s largest first-tier aerostructures manufacturer recently announced that the company plans to expand operations at its Tulsa, Oklahoma, site by investing more than $80 million in capital projects to support fuselage manufacturing and assembly work.

Spirit AeroSystems, Inc., based in Wichita, Kansas, will be hiring about 250 employees as part of this expansion. The new Tulsa project will support increases in 737 production rates by freeing up required space in Spirit’s Wichita factory site.  The work expansion in Tulsa is part of a larger effort to maximize operational efficiencies across Spirit’s sites. As the production rates increase, the Wichita site will continue to hire additional workers to meet the increasing demand.

Spirit AeroSystems President and CEO Tom Gentile

The first phase of the Tulsa work expansion will begin with infrastructure set-up and employee training beginning in 2019. Full rate production is expected to be complete by the end of 2021.  Additional investment in equipment, tooling and facilities upgrades will take place through 2022.

“This expansion would not have been possible without the strong collaboration among Spirit, the UAW, and Oklahoma state and local officials,” said Spirit AeroSystems President and CEO Tom Gentile. “The Spirit team in Tulsa has made great strides in improving the site’s efficiency and demonstrating the capability to bring in additional work. The Tulsa site has a critical role in helping Spirit meet rising airplane production rates and pursue growth opportunities.”

In addition, Spirit announced that it executed a Memorandum of Agreement (MOA) with The Boeing Company, extending its partnership with the aerospace giant and leading manufacturer of airplanes, rotorcraft, rockets, satellites, and missiles worldwide. Spirit builds several important pieces of Boeing aircraft, including the fuselage of the 737, portions of the 787 fuselage, and the cockpit section of the fuselage of nearly all of its airliners.

“This agreement further strengthens the long-standing partnership between Boeing and Spirit as it removes uncertainty well into the next decade. The agreement establishes pricing and capital investment for a range of potential production rate increases on the 737 program. With the new agreement, we expect price to exceed cost eventually on the 787 program. We are excited to continue to build on our relationship and look forward to future opportunities with our largest customer,” said Gentile. “With this agreement, we maintain our target of 7 to 9 percent conversion of revenue to free cash flow.”

 

Photo caption: Spirit AeroSystems president and CEO Tom Gentile announces Tulsa expansion (Twitter).

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15 Quick Heat Treat News Items to Keep You Current

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

15 Quick Heat Treat News Items to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel and Company Chatter

  • ThermTech of Waukesha, Wisconsin, celebrates the groundbreaking of a 10,500-square-foot manufacturing addition. Construction is expected to be completed in December 2018. 
  • An Ohio-based engineering firm, Dana Incorporated, announced a new series of Brevini™ heavy-duty winch drives for marine and offshore applications.  This new series of lightweight winch drives have been engineered with a sealing system designed to withstand harsh marine environments, and with improved power density, housing made from either cast iron or steel, and high-radial load bearings to deliver reliable lifting performance for heavy loads.
  • Brunel University London opened its Advanced Metal Processing Centre (AMPC) at the Brunel Center for Advanced Solidification Technology (BCAST), which will enable R&D activity to enable innovations, such as lightweight car parts, to make the leap from the lab to full-scale industrial trials. The 1,500 sq m AMPC facility includes industrial and pilot-scale equipment for processing and fabrication of extruded metals (novel bending processes, machining, and advanced joining); additional casting processes (gravity die casting and sand casting, etc.), and supporting materials characterization technologies (strength and fatigue testing and 3D x-ray tomography).
  • A global leader in manufacturing and overhauling aerospace structures, systems, and components, Triumph Group, Inc., based in Berwyn, Pennsylvania, recently announced that its Aerospace Structures business has been awarded a multi-year airframe component contract for Lockheed Martin’s C130J Super Hercules program. Under initial terms of the contract, Triumph Fabrications in San Diego, California will provide 108 different part numbers for the C130J program. The parts include fabricated sheet metal structures made from a combination of aluminum, steel and titanium materials that will be fitted to the nacelle, wing and fuselage sections of the aircraft.
  • Aerospace equipment manufacturer Liebherr Aerospace has been awarded another contract from Boeing Commercial Airplanes for their 777 and 777X programs. Liebherr-Aerospace will deliver two electronic components of the main gear steering system for the two wide-bodies: the main gear steering control unit and the nose gear steering position transducer.
  • Engineered bearings and power transmission manufacturer, The Timken Company, based in Canton, Ohio, recently completed the acquisition of Rollon Group, a leader in engineered linear motion products. Rollon specializes in the design and manufacture of engineered linear guides, telescopic rails and linear actuators used in a wide range of industries such as passenger rail, aerospace, packaging and logistics, medical and automation.
  • Gear Motions, which has divisional offices in central New York, recently appointed to executive positions: Dan Bartelli to Director of Operations of Nixon Gear, a division of Gear Motions, and Anna Pastore to Corporate Controller. Bartelli, who began his career as a machinist, also recently celebrated his 30th anniversary with Nixon Gear, a division of Gear Motions. He is responsible for all Nixon Gear Division Operations including Manufacturing, Quality, and Engineering. Pastore previously served as Director of Finance for Cascade & Maverik Lacrosse, and Vice President of Finance of the Produce and Technology Division at Agway.
  • Worthington Industries, a metals manufacturing firm based in Columbus, Ohio, announced today that Mark Russell, president and COO is retiring. Andy Rose has been named president and will continue as chief financial officer (CFO). Geoff Gilmore has been named vice president and chief operating officer (COO) and will also continue to lead the Pressure Cylinders business.

Equipment Chatter

  • An electric box furnace has been supplied to a plant located in Louisiana that is a global supplier of large industrial valves for various industries. L&L Special Furnace Co., Inc., shipped this furnace, which is the fifth supplied by the company to this facility. The furnace is used to both heat treat and temper various rings and seals deployed in the manufacturing of valves used in the power-generation field. It is also used for general heat treating of various steels prior to machining.
  • Two furnaces have recently been shipped to customers from Grieve Corporation. No. 1040 is a 2200°F (1204°C), inert atmosphere pit furnace, currently used for heat treating automotive parts in baskets at the customer’s facility. No. 989 is an electrically heated, 2,000°F (1,093°C) inert atmosphere furnace from Grieve, used to process fabricated parts at the customer’s facility.
  • A leader in the technology industry recently purchased an electrically heated enhanced duty walk-in oven from Wisconsin Oven Corporation to be used for composite curing small parts. The batch oven has the capability to heat 16,000 pounds of a composite material from 70° F to 350° F within 6-7 hours.

Kudos Chatter

  • Akron Steel Treating celebrated its 75th anniversary August 31, 2018, with guests, officials, employees, customers, and suppliers in attendance, as well as the deputy mayor for economic development, Samuel D. DeShazior, who presented AST president Joseph Powell with a letter of congratulations from Mayor Daniel Horrigan. Joe’s grandfather, Prosper P. Powell, founded the company in 1943, and his daughter, Christina Somogye, recently purchased a 10% interest in ASTC and is an integral part of the succession plan.

  • For the second year in a row, GKN Aerospace has received a supplier award from Spirit AeroSystems. Spirit recognized GKN Aerospace with a Collaboration Values Partner award for superior performance at the 2018 Spirit AeroSystems supplier recognition banquet in Wichita, Kansas. In addition, GKN Aerospace also recently announced via Stratasys that the company is improving production times and removing design constraints for multiple tooling applications since integrating additive manufacturing at its Filton manufacturing site in the UK.
  • Retech Systems, a SECO/WARWICK company based in Mendocino County, California, recently won North Bay Maker Award for “best manufacturing process innovation”.
  • Induction heating company Ambrell Corporation is the honoree for the Global Advancement Award and Ambrell President Tony Mazzullo is a finalist for CEO of the Year at the Technology and Manufacturing Awards, created by the Rochester Business Journal and Rochester Technology and Manufacturing Association. The Global Advancement Award is given to a company that demonstrates dynamic growth through expansion of export opportunities and participation in new global markets. The CEO of the Year demonstrates leadership in the industry, commitment to staff development, and dedication to the Greater Rochester/Finger Lakes Region. Tony Mazzullo is one of two finalists and the winner will be announced on October 23rd.

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to the editor at editor@heattreattoday.com.

 

15 Quick Heat Treat News Items to Keep You Current Read More »

Agreement Reached to Initiate Titanium 3D Printing for Boeing 787

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, FEATURED NEWS, TITANIUM PROCESSING NEWS

 

A Wichita, Kansas-based, manufacturer of fabricated parts for the aerospace industry recently announced its partnership with the world’s pioneering supplier of aerospace-grade, additive-manufactured, structural titanium components to initiate qualification of parts for the Boeing 787.

Spirit AeroSystems and Norsk Titanium US Inc. have reached an agreement to initiate qualification of Spirit’s first additive-manufactured, titanium, structural component for the Boeing aircraft.

Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management

This qualification will validate NTi’s production and industrialization processes, integrate Spirit’s work scope of machining final parts from additively manufactured near-net shapes, and verify material and final part conformity to requirements.

“Spirit has had a comprehensive and long relationship with Norsk Titanium, and this part will be our first additive structural titanium component incorporated into a commercial airplane program,” said Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management.

NTi is the world’s first FAA-approved, OEM qualified, supplier of additive-manufactured, structural titanium components.  NTi’s proprietary Rapid Plasma Deposition™ (RPD™) process has been in serial production of Boeing 787 titanium components since April 2017.

“I am very proud of the Norsk Titanium team and this accomplishment. It represents years of technology development,” said Mike Canario, CEO of Norsk Titanium. “I also would also like to thank Spirit for this vote of confidence in the Norsk RPD™ process and capability.”

Mike Canario, CEO of Norsk Titanium

NTi’s Plattsburgh, N.Y., facility was recently added to Spirit’s Approved Supplier List (ASL) and Boeing’s Qualified Producer’s List (QPL).  Spirit and NTi have had an ongoing technology collaboration for more than nine years. In 2017, both companies signed a Master Procurement Agreement (MPA) for qualification and production activities.  The first commercial aircraft part will begin serial production later this year.

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