MS Composites is a composite materials company that specializes in aerospace, defense, energy, and medical industries. It has 250 employees across multiple sites in France and Morocco. In 2011, its revenue was 21.8 million euros, with 66% from aerospace. MS Composites has expertise in carbon fiber composite materials and processes like autoclave, press, and RTM. It supplies parts for aircraft like Airbus A320, A400M, and Rafale. It also works on defense projects, space antennas, medical imaging tables, and ballistic armor. MS Composites aims to support the aerospace industry with research on engine and airframe components made of composites.
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1. MS COMPOSITES
USINAGE COMPOSITES
ALBERT 23/10/12
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2. AD industries customers
AÉRONAUTIQUE DÉFENSE
& SPATIAL & SECURITE
AGUSTA HISPANO SUIZA DCNS MBDA
AIRBUS LATECOERE DGA ROXEL
AIRCELLE LIEBHERR AEROSPACE EADS SAGEM
AIRFRANCE IND. MESSIER BUGATTI EUROCOPTER SESM
AIRLIQUIDE MESSIER DOWTY NEXTER THALES
ALCATEL SPACE MICROTURBO
ASTRIUM RATIER
ATR SABCA
AVIO SNECMA
BOMBARDIER
DASSAULT
SNECMA SPS
SOCATA
ENERGIE
DRAGER AEROSPACE TURBOMECA
EADS TECHNOFAN
ESA TECHSPACE AERO
EUROCOPTER VOLVO AREVA GE POWER SYSTEM
GOODRICH ALSTOM POWER SCHLUMBERGER
DRESSER SGN
FLENDER SIEMENS
TECHNIP
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3. AD Industrie Group - Locations
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4. LES EXPERTISES ET LEURS COMPLEMENTARITES
Epsitech AEP / SETAM KALFA
15 M€ / 116 p 6 M€ / 32 p
CA 2011: 160 M€
Prototypes
Préséries
M ICRO M ECANIQUE
PYRENEENNE DESHORS ADI
14 M€ / 109 p 37 M€ / 249 p
Grandes
dimensions
- Bureau d'études
- Massification achats
Projet Perform'HA
- Lean manufacturing
Projet AD Lean
- Mutualisation F supports
- Partage bonnes pratiques
Moyennes
EXAM ECA dimensions
38 M€ / 340 p M ECALIM
16 M€ / 93 p
Petites
dimensions
DURUAL
10 M€ / 84 p
M EKAM ICRON
4 M€ / 23 p
M S COM POSITES
20 M€ / 220 p
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5. MS Composites Fields of activities
» Defence » Space » Aeronautics
» Industry & Railway » Medical
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6. 2011 Synthesis data
Total turn over: 21.8 Million Euro
Fields of acitivity share:
• 66 % Aerospace
• 12 % Defence
• 12 % Medical
• 6 % Space
• 4 % Various
Employees average number: 250
Budget 2012: 22.5 Million Euro
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7. Material & Processes
MSC master every technology dealing with the process of continuous and long
fiber composites with thermosetting and /or thermoplastic matrix with any
kind of resins and fibers such as
1-Resins 2-Fibres (woven and unidirectional, including hybrids)
Thermosetting
•Polyester •Carbon T300, T700, T800
•Vinylester •M46J, M55J, M60J
•Epoxies Other
•Phenolic •Aramid 49, 29, 129
•Cyanate Ester •Glass
•Polyethylene High Density (Dyneema, Spectra)
Thermoplastic •Bronze meshes
•PEI
•PEEK 3-Main processes
•PPS
Autoclave / Press / RTM / Injection
•PE low density
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8. Aeronautics
Outer Guiding Vanes (CFM 56-5A / 5B / 5C)
Airbus A319/320/321
25 000 parts per year
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9. Aeronautics
» A320 & A340 Family components
» Engines Pylon AFT structure
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10. Aeronautics
A400 M
» Engines fairings structure
-Monolitic and sandwich carbon parts
-Delivered to directely to assembly line
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11. Aeronautics
» Dassault – Rafale
Materials AS4/PEEK + Process
Manual /Cutting
Lay up
Autoclave
Mold Specific
Curing
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14. R&T
OBJECTIFS
Cône de soufflante - CORAC PICE
Medium part for cone link
and engine balance
(Inner Ring, Fwd-FAN)
Shroud, fwd-FAN
Techno MASCOT2
Forward spinner
Material : TA6V
(Platform support)
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15. R&T
Vane de Charge (VDB) – CORAC EPICE
Rôle : Optimiser les débits d’air entrée compresseur HP
Eviter le pompage
Eviter le risque d’ingestion dans le flux primaire
- Passage Métal -> Composites
Gain de masse
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16. R&T
Intermediate Case – CORAC EPICE
1. Etudes OGV composite non structural
Moteur monocouloir +100 places
=> tenue mécanique sur roue hybride
2. Etude OGV composite structural
3. Etudes structures innovantes
Carter intermédiaire et A frame
(2 cas : triple corps et double corps)
Carter intermédiaire et kit engine structural
Carter intermédiaire sur UHBR et propositions d’accrochage
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17. Space
Antenna Support
Yahsat 1B SSA
INTELSAT – 10-02
in integration
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18. Defense
Anti-Sand Avionic Bay
Tiger Helicopter or NH90 Sofrance
Night-Vision Goggles structure
Thales Angénieux
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19. Defense
Sonar 2087
Thales Underwater system
Deshors ADi
MSC / ADi
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20. Medical
Our range of products: X-Ray table top
-X ray tables top
-Mammography plates
-Accessories
-V-Arm
Technical features:
- Low X-ray absorption
Mammography bucky - High mechanical resistance
- Cosmetic finish
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21. Balistic Protection
Armoring systems for
- Rotorcraft armoring systems
- Land vehicles
- Individual ballistic protection
Technical Principles
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22. Ballistic Protection
A400 M Program
External and internal parts
Cockpit and Loadmaster locations
Cockpit protection
Tier one supplier (Design / Stress / Manufacturing)
1 000 kg high ballistic protection / aircratf
Fully Removeable (exterior & interior parts)
Delivery directly the FAL Sevilla
Loadmaster area
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25. Control laboratory
• Mechanical testing machine compression
200 KN with climatic chamber
Temperature: –40°Cto +250°C
• 1 Faro arm control
• Metrology - 3 threedimensional
equipments (Automatic & Manual)
• A curing simulator : Kinemat
• Non destructive ultrasonic testing
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26. Production equipment
• 3 workshops 7000 m2 (Liévin) ; 6000 m2 (Chavignon) 5000 m2 (Tanger-
Moroco)
• Controlled atmosphere lay-up rooms, including one class 100 000,
• Digital control prepreg cutting machine
• Water jet cutting machines
• 8 autoclaves, (dia. 3 m x 6 m, 20 bars, 420 °C)
• Presses of 40t to 360t for thermosets and thermoplastics
• 5 ovens (3m x3m x8m, 200° C)
• RTM equipment
• 2 painting qualified rooms for aerospace components
• 2 filament winding machines 4 and 6 axles
(Ø 500 x 3500 mm)
• 3 robotized milling machines 3 to 5 axles
(1500 x 3500 x 1000 mm)
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27. Production equipment
8 Autoclaves
0
Average size: 4m x2m
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28. Quality assurance
GENERAL CERTIFICATIONS :
• EN-9100
• ISO 9001 – 2000 (BVQI)
• PRI-Nadcap Composites (Lievin unit)
AERONAUTICS AND SPACE :
• PART 21-G (Production) (DGAC)
• PART 145 (Maintenance) (DGAC)
• AECMA-EASE / QUALIFAS
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29. Aeronautic – A350 Aerolia structure
A350XWB NOSE FUSELAGE INTERCOSTALS
Enjeu fort pour MSC
• 100 PN / aircraft
• Cadence de 10 AC/mois
=> 1000 usinage / mois
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30. Aeronautic – A350 Aerolia structure process
Problématique => conservation des repères d’usinage
+
Moule drapage métallique Cuisson pièce carbone à 180
Outillage d’usinage metallique
Mise en place insert pdt drapage
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31. Aeronautic – A350 Aerolia structure - Defects
Problème de qualité des usinages à résoudre
Plusieurs type de défauts apparaissent => FNC => Augmentation du COQ
Plis non coupés net
Ecaillage
But => limiter ces défaut par étude des vieillissement des outils coupants
Action préventives et non pas en curatives
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32. Aeronautic – A350 Aerolia structure - Challenge
Challenge de la montée en cadence A350
Les problèmes à résoudre sont
-Transfert Liévin – Tanger a assurer
-Modification des centre usinage
-Vérification de l applicabilité des procédure
-Vérification de l applicabilité des programmation
- Le Ramp-Up met en exergue l usinage comme un bottle-neck
- Optimisation des programmes
- Optimisation des paramètres d’usinage
- Optimisation des outils de coupes
Expertise de l’usinage de composites carbone
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