A TASTE OF ENGINEERING EXCELLENCE | Issue 10

AVICAST Inc. is ISO 9001:2008 Certified!

Issue

By

By

By Clive Priggen

Welcome to the tenth issue of

AVICAST Newsletter. We are proud to

announce that AVICAST Inc. is ISO

9001:2008 certified as of February 26th,

2016.

The ISO 9001:2008 Quality

Management System is applicable to

the following company business lines: Aviation Hardware Standardization,

Composites Solutions, Resource

Management, Classroom Training,

Data Management, and Hardware

Brokerage.

The certification has proven AVICAST

team’s dedication to continuously

improve and monitor the quality of

our engineering and training services.

AVICAST Inc. looks forward to provide

quality services and products. We

thrive to exceed the expectations of

our customers and fellow employees

through continuous improvement of

our Quality Management System.

March 16th, 2016 Mississauga, ON

1. AVIC CAPDI Visit Page 2

2. Introduction to Blind Rivets - Part 1

Source: http://thumbs.ebaystatic.com/images/g/kwcAAOSwT6pVnzHF/s-

l225.jpg

Bruce McDonald, Senior Engineer at

AVICAST Inc., provides his insights on

Blind Rivets

Page 3

3. Composite Materials-Where are we headed?

Source:https://en.wikipedia.org/wiki/Composite_material#/media/File:Compo

site_3d.png

Spyro Cacoutis, Senior Composite

Material Engineer, provides his insights

on the development of composite

materials.

Page 4

4. Picker to Stock System

Source: http://res.cloudinary.com/yaffa-

publishing/image/upload/fl_keep_iptc,c_fit,w_630/Monza%20Wave%20Pick

er_A4C9AE70-1625-11E5-B7E802E22D9E6A7F.jpg

Clive Priggen, Material Manager

Advisor at AVICAST INC., provides his

insights on picker to stock systems.

Page 6

A TASTE OF ENGINEERING EXCELLENCE | Issue 10

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On March 4th 2016, AVICAST was honored with the visit

from top executives from AVIC China Aviation Planning and

Design Institute. (CAPDI) CAPDI was formerly known as

APC and is a subsidiary company of Aviation Industry

Corporation of China (AVIC).

AVIC CAPDI offers a full service solution from top-level

consulting to engineering design, from general contracting

to financing for global clients in diverse industries

worldwide. The company is an excellent Engineering

Procurement Construction (EPC) service provider for full-

spectrum construction engineering sector. AVIC CAPDI has

always vigorously devoted to investment, planning and

construction of aeronautical & aerospace, energy &

environment, civil buildings, pharmaceutical engineering

and other fields, inherited abundant experience and

obtained fruitful achievements.

In the past 60 years, AVIC CAPDI has delivered full-service

planning, consultancy, investment, financing, geographical

survey, design, construction, equipment general

contracting and consequent evaluation solutions for its

worldwide clients on the passion and vision of its talented

multi-disciplinary team.

One of the many CAPDI projects includes Zhuhai Aviation

City, which is located in Sanzao Town, Zhuhai. The project

provides general aircraft assembly, aircraft maintenance,

aircraft parts processing and manufacturing, general

operation and service, aviation logistics, aviation exhibition,

and aviation culture and education, and will grow into a

new international general aviation city featuring

international competitiveness, production, teaching and

research integration serving the whole value chain.

CAPDI also has devoted to promote use of environmental

energy in China through several engineering sectors such

as Solid Waste Management Engineering, Water

Treatment Engineering, Flue Gas Desulphurization &

Dedusting and Gas Turbine Combined Cycle Power Plant.

Notable projects for each sector are respectively Beijing

Liujiashan Waste Classification and Incineration Power

plant, Chifeng Water Supply &Water Plant, Boiler

Desulphurization and Dedusting for China Flight Test

Establishment and Zhejiang Jingxing Natural Gas

Combined-cycle Power Plant.

AVIC CAPDI’s Visit to AVICAST

Figure 2. Civil Aviation Project: Xuzhou Guanyin Airport Terminal

Figure 3. Planning Project: Zhuhai Aviation City Planning Figure 1. Group Photo of AVICAST and AVIC CAPDI Executives

A TASTE OF ENGINEERING EXCELLENCE | Issue 10

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1. Introduction

The first blind fasteners were introduced in 1940 by the Cherry

Rivet Company (now Cherry Aerospace) and the aviation industry

quickly adopted them in a wide range of airframe assembly

applications. The past decades have seen a proliferation of blind

fastening systems based on the original concept, which consists

of a tubular rivet sleeve incorporating a protruding (universal) or

countersunk (flush) rivet head and an internal mandrel or stem.

Installation consists of inserting the blind rivet into a prepared

hole, engaging the serrated end of the stem with a pulling tool

and pulling the stem into the sleeve to expand the sleeve on the

back or blind side of the sheet assembly to fix the rivet in place.

These rivets were designed to be used in blind applications where

there was limited or no access to the “blind” of the assembly,

such as the closing side of a box structure.

2. Types of Blind Rivets

Although rivet manufacturer’s produce blind rivets in a wide

range of variation each with specific properties and applications,

there are essentially five (5) basic types of blind rivets used in the

aircraft industry:

Self-Plugging, Mechanically-Locked Spindle, Rivets, with an Expandable Wire Draw Shank – Procurement Spec NAS1400 (Standard Sheets NAS1398/NAS1399)

Hollow, Pull-Through, Non-Structural rivets – Procurement Spec NASM8814 (Standard Sheets NASM20604/20605)

Self-Plugging, Mechanically-Locked Spindle, Rivets, Bulbed Shank – Procurement Spec NAS1740 (Standard Sheets NAS1738/1739)

Self-Plugging, Mechanically-Locked Spindle, Rivets, Bulbed Shank, Nominal and 1/64” Oversize Diameter – Procurement Spec NAS1686 and NAS1687 (Standard Sheets NAS9300 Series)

Mechanically Expanded, Self-Plugging, Mechanically-Locked Spindle, Rivets, Bulbed Shank, Nominal Diameter – Procurement Spec NAS1900 (Standard Sheets NAS1919/NAS1921)

3. Self-Plugging, Mechanically-Locked Spindle Rivets, Expandable Wire Draw Shank – Procurement Spec NAS1400

Procurement Specification NAS1400 establishes the requirements for procurement of self-plugging blind rivets, with a mechanically locked spindle, which can be installed in assemblies or construction where access to only one side is available. These rivets are intended for use in aircraft structural or similar applications.

Self-plugging mechanical-locked spindle blind rivets were developed to prevent from problems of losing the stem due to vibration and cyclic loading. This rivet incorporates a ring or sleeve on the stem which is formed into a groove on the stem during installation to lock the stem in place. The end of the rivet stem incorporates a “wire draw” mandrel which expands the rivet shank to form the top head and, as the stem is drawn into the shank, expands the shank to fill the hole, “drawing” or reducing the diameter of the mandrel until the break groove in the stem is flushed with the top of the rivet, the lock ring is set and the stem breaks off flush with the rivet head.

These rivets are called up by the part numbers listed on standard sheets NAS1398 for Protruding Head Rivets and NAS1399 for 100° Flush Head Rivets. They are available in 3/32” to 1/4" diameters in normal size only. The rivets are available in Aluminum, Nickle-Copper (Monel) and A-286 CRES alloys. As the wire draw action creates high compression forces on the blind head side, these rivets are not suitable for use in thin sheets, soft material or double dimple applications. Rivets incorporating a driving anvil, code “AB” in the part number can be installed using Non-Shifting type installation tools. Rivets with a “-“ or “A” code in the part number, denoting a partial or fully serrated spindle, will require shifting type installation tooling to set the lock ring in place. Shifting type tooling is 3 to 4 times more expensive than non-shifting type and is subject to a high degree of wear in use. Refer to figure 1. for a general description of an NAS1398 protruding head “AB” code, (non-shifting), wire-draw type blind rivet.

This article is continued as “Introduction to Blind Rivets – Part 2” in the next issue of AVICAST Newsletter. Please stay posted.

Disclaimer Avicast does not guarantee any results and does not incur any liability with regards to the information provided in this article. Avicast cannot and does not warrant the accuracy, correctness or completeness of the information and interpretation in this article.

Introduction to Blind Rivets – Part 1 - By Bruce McDonald

Figure1. – NAS1398 “AB” Code, Wire Draw, Blind Rivet Source: http://thumbs.ebaystatic.com/images/g/kwcAAOSwT6pVnzHF/s-l225.jpg

A TASTE OF ENGINEERING EXCELLENCE | Issue 10

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1. Introduction

The use of advanced composite materials on aircraft

structures has dramatically increased over the past 10 to

20 years. Although composites have been in use for more

than 50 years, the initial growth has been conservative and

more evolutionary than revolutionary, especially in the

area of commercial aviation. Military applications have

always included significant use of composites for many

years but with the introduction of the Boeing 787 and the

Airbus A350, the use of composites in primary structural

elements on commercial aviation aircraft has dramatically

increased and gone the next step. This trend will continue

onto more and more platforms.

2. The Growth of Composite Materials spanning different industries

One of the main reasons for this now revolutionary growth

has been the development of automation processes which

have increased efficiency, reduced the costs, and improved

the overall quality assurance of the layup processes

involved with making large and complex parts such as

fuselages and wings. With automation, the aerospace

industry has taken a significant turn and the use of hand lay

up for large structures has all but disappeared.

The automated techniques are not limited to tape laying

and fiber placement machines. There are newer

technologies including resin infusion and the emergence of

3D printing or additive processes which are also gaining

significant traction and will be further used and developed.

The use of robotics will also increase and the composites

factory of the future will look quite different from the

typical composite shop of today. Automation is not just

limited to layup techniques. It is already heavily used for

drilling, routing, and machining, bonding, not to mention

various inspection methods. There is room for more

growth within these processes as well.

Predictably, the increased use of composites is spreading

into other manufacturing sectors. Significant

developments are also occurring in the automotive

industry. Auto makers such as BMW, Mercedes-Benz, and

General Motors, among others, are significantly ramping

up their use of composites for part weight reduction

leading to improved fuel economy, optimized weight

distribution, improved fatigue resistance and higher

performance through improved mechanical properties.

Marine and other transportation industries are also

increasing the use of stiffer and stronger composites and

as the raw material price drops. Penetration of composites

into other markets will also increase.

Composite Materials – Where are we headed? - By Spyro Cacoutis

Figure 1. The TORRESFIBERLAYUP automated fiber placement machine used to fabricate high contour carbon fiber aircraft components.

Source: M.Torres Diseños Industriales SAU

A TASTE OF ENGINEERING EXCELLENCE | Issue 10

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In the automotive industry, the targeted price for

composite raw material is approximately $5 per pound for

high performance carbon-epoxy material, a price which is

very low compared with materials traditionally used within

the aerospace industry. Since projected material usage

and volumes of potential parts production are so great, the

world’s biggest aerospace raw material suppliers are now

showing a high interest in automotive applications and are

furiously working on high performance carbon materials

which can cure in as little as 5 minutes, which is unheard of

in the aerospace industry. Resin system developments are

not just limited to epoxies. Polyurethane and various

cocktail resin mixes are also being evaluated and

developed for use in a variety of processes aimed to

increase production rates by reducing cure cycle times.

These exciting developments will drive demand, growth,

and usage of composites. And while there will always be

part applications and technologies uniquely suitable to

either the aerospace or automotive industries, the path to

many commonly used material and process applications

has begun and will continue. This synergy will further drive

down the cost of raw materials which will in turn again

make the use of composites even more attractive and more

profitable.

As the usage continues to grow, so too will the requirement

for spinoff technologies. Viable repair processes and

procedures have been an area of great concern in the

aerospace industry for quite some time and are also now a

priority in the automotive industry since repair procedures

are complex and require special skills and techniques.

Training and certification of repair personnel and facilities

will become key for the success of composites in future

applications across all industries.

With such large volumes and material usages increasing,

the recycling of both raw materials and finished goods is

also becoming a major issue. Environmental concerns, the

development and use of “green” bio material products

generated from other industries are also important and

taking on greater significance and emphasis.

3. Conclusion

All in all, it is an exciting time to be involved in the new and

emerging composites technologies and spinoff activities.

Avicast will be discussing these developments and the

challenges associated with the ever growing use of

composites in upcoming editions of our newsletter. Please

stay tuned!

Disclaimer: Avicast does not guarantee any results and does not incur any liability with regards to the

information provided in this article. Avicast cannot and does not warrant the accuracy, correctness

or completeness of the information and interpretation in this article.

Figure 2. FACC fabrication of prototype OOA wingbox components for the Irkut MS-21, using dry fiber layup and infusion technology.

Source: FACC AG (Ried im Innkreis, Austria)

Figure 3. The chassis for the Lamborghini Aventador supercar produced by Lamborghini's ‘RTM-Lambo’ resin transfer moulding (RTM) process

Source: Automobile Lamborghini S.p.A.

A TASTE OF ENGINEERING EXCELLENCE | Issue 10

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1. Introduction

Picker to stock is a general term that refers to the approach

by which people move to locations where the stock is

located or stored. This would include both primary and

secondary (overflow) locations. While the term is picker, it

should also be interpreted as put-away and other

warehouse functions such as stock checks and cycle counts.

People frequently have some tools and equipment to help

them to carry out their task in the warehouse. This can be

the same equipment that is used in the dock zone (Please

refer to page 4 of AVICAST January 2016 Newsletter: issue

9 for information on Dock Zone), such as carts, pallet jacks

(walkies), forklifts, and/or more specialized equipment

such as straddle trucks, side loaders and turret trucks.

2. Picker-to-Stock System

The picker may have various activities to perform at the

pick-face (storage location). For picking, it could include the

activities listed:

Opening cases;

Counting out the pieces required possible by hand or a portable scale (referred to as split at pick-face);

Labelling picked items;

Packaging or repackaging picked items;

Recording what was picked or moving case to a separate splitting/repackaging area.

If other tasks are being performed, it could also include

stock rotation, counting of total pieces, and verification of

stock available at that location.

For some warehouses, a picker can be a hybrid system. An

example would be a pick to light system where the picker

would only move a limited distance in the pick to light area.

Therefore, the stock replenishment to this primary

pick/storage area is done from behind or at alternate time

from the pick time. Another hybrid system would be using

an AGV (automated guided vehicles) to deliver or remove

picked stock from a zone that would have a person picking

in that zone or doing put-away in a specific area.

3. Conclusion

Regardless of the tools and equipment used for picker to

stock, the most important aspects for stock picking are

accuracy, timeliness, and recording of stock information.

This concept will be explored in a future article.

Disclaimer: Avicast does not guarantee any results and does not incur any liability with regards to the

information provided in this article. Avicast cannot and does not warrant the accuracy, correctness

or completeness of the information and interpretation in this article.

Picker to Stock - By Clive Priggen

Figure 1. Raymond 9000 Reach Truck Source: http://forklifts.axlegeeks.com/l/488/Raymond-9000

Figure 3. A Picker Selecting and Putting Stock into the Container Source: http://www.ovguide.com/the-pick-operating-system-9202a8c04000641f80000000165d7da7

Figure 2. Swisslog Hybrid Automated Guided Vehicle Source: http://www.swisslog.com/en/Products/WDS/Automated-

Guided-Vehicles/AGV-Hybrid

A TASTE OF ENGINEERING EXCELLENCE | Issue 10

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We hope you found this newsletter

interesting and are confident that

you have lots of interesting stories

and/or great ideas to share. Share

those ideas with the aviation

industry throughout China, Europe

and North America by getting them

published in our upcoming

newsletter.

AVICAST would love to hear from its

readers and share their stories in

the future editions. Please send us

your stories at this email address:

weiwang@avicast.com

Follow us on LinkedIn!

Click here to follow us on LinkedIn

through the AVICAST Inc. Page.

Get your stories published by sending them to the following email address:

Editor: Wei Wang Email: weiwang@avicast.com Web: www.avicast.com

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