Installed on Test Stand 3E at GE Aviation’s Peebles Test Operation in Ohio, PANACHE is demonstrating the capabilities of Nexcelle’s advanced thrust reverser configuration for its IPS, including the one-piece composite O-Duct that replaces a traditional thrust reverser’s two-piece “D” doors; new kinematics in which the entire O-Duct moves aftward to the reverse thrust position; and the integration of an electrical thrust reverser actuation system (ETRAS).

I was on-site at Peebles this week with Nexcelle President Huntley Myrie to see PANACHE in operation. We had the opportunity to watch a 1.5-hour test, during which PANACHE was cycled every few minutes at varying engine power levels – replicating its thrust reverse deployment in situations that varied from normal operation during landing to conditions that would be encountered in aborted landings and aborted takeoffs.

As one test engineer described it, PANACHE and its CFM56-5C demonstrator engine was the primary propulsion system to be “singing” at the 7,000-acre Peebles facility that day, generating a steady flow of digital data from its highly instrumented set-up on Test Stand 3E.

The PANACHE validations are off to an excellent start, as shown by the uninterrupted long-duration test that Huntley and I witnessed at Peebles – which is another demonstration of Nexcelle’s technology roadmap maturing for its Integrated Propulsion System.

Michel Abella
Director of Programs – Nexcelle

This video clip from Test Stand 3E at Peebles shows one of the PANACHE thrust reverser deployment cycles. It begins with the CFM56-5C demonstrator engine in a ready mode, followed by the aftward movement of PANACHE’s translating cowl O-Duct to the reverse thrust position (beginning at 00:55 seconds). The cycle is completed as the O-Duct returns to its stowed position (01:49).

At Nexcelle, we are living this moment now as the new thrust reverser configuration for our next-generation Integrated Propulsion System (IPS) has completed its initial validation and is ready for the first test bench engine runs.

The new nacelle demonstrator, called PANACHE (Pylon And Nacelle Advanced Configuration for High Efficiency), was put through its initial paces at the Le Havre, France and Baltimore, Maryland plants of Nexcelle’s Aircelle and Middle River Aircraft Systems parent companies. The PANACHE demonstrator is now in the U.S. for installation on a test stand at GE’s Peebles, Ohio facility.

This advanced thrust reverser incorporates a cornerstone element of Nexcelle’s vision for Integrated Propulsion Systems of the future: a one-piece composite O-Duct, which replaces the two-piece “D” doors on a traditional thrust reverser. With the O-Duct’s continuous composite structure, the IPS’ thrust reverser benefits from reduced weight, while also eliminating the D-doors’ bifurcation in the flow-path – increasing the thrust reverser’s efficiency.

Another unique characteristic is the new thrust reverser’s kinematics, in which the entire O-Duct moves aftward to the reverse thrust position, deploying blocker doors into the engine’s secondary airflow – thereby eliminating the need for drag links in the secondary flow-path.

Added to these advantages is our application of the electrical thrust reverser actuation system (ETRAS), a major improvement that employs electrically-operated actuators instead of the hydraulic system actuators used in current-generation engines. Benefits of ETRAS include enhanced reliability, reduced weight, and improved maintainability.

Pierre Hurpin
Technical Director – Nexcelle

As this session was my first PRM as Nexcelle’s president, I also used the opportunity to conduct a team assimilation session and review some of the key elements of our company’s value proposition, which is becoming a reality as we execute on the technology roadmaps for a new generation of integrated propulsion systems.

Nexcelle is demonstrating that by uniting the capabilities and processes of Aircelle and Middle River Aircraft Systems is a winning formula, benefitting from their respective expertise in design, development, production and support. Bringing together the major components of a propulsion system as a truly optimized system can be achieved.

This value proposition will soon be showcased for the first time as our PANACHE demonstrator begins its test stand evaluations at Peebles, Ohio.  PANACHE – which stands for Pylon And Nacelle Advanced Configuration for High Efficiency – will validate many of Nexcelle’s key features for integrated propulsion systems, including the innovative embedded O-Duct technologies.

Huntley Myrie
President – Nexcelle

One of my trips was to China, where I participated in a program review meeting along with our customer – CFM International – for the C919 jetliner’s LEAP-1X engine. I saw the energy and the working relationships that have been built up, and was pleased to see the interaction between the co-located teams in China.

I then headed to the facilities of our Aircelle parent company – beginning with stopovers at Aircelle’s headquarters and main production center in Le Havre, France, as well as its plant in Casablanca, Morocco. This was followed by meetings at the manufacturing site in Burnley, England.

My travels then took me to Nexcelle’s other parent company, Middle River Aircraft Systems in Baltimore, Maryland.

During these visits, I was impressed by the strong commitment, consistent processes and teamwork. It is evident that teams are passionate about the Nexcelle programs, and they are readying for the next phase – delivering the first hardware for development testing and ramping up for production activities.

Next on my travel schedule is Nexcelle’s upcoming quarterly Program Review Meeting (PRM) in Toulouse, France – which will be my first as the company’s President. I also will use the opportunity to visit Aircelle’s facility in Toulouse.

Huntley Myrie
President – Nexcelle

I am very excited about the opportunity to lead Nexcelle into the next phase, which includes a focus on testing, the manufacturing of development and production hardware, and validation of the IPS concepts.

Having participated in Nexcelle’s most recent quarterly Program Review Meeting (PRM), I was impressed by the spirit of teamwork that has been forged by all of those involved at Aircelle and Middle River Aircraft Systems – with the focus on leveraging the strengths from these two parent companies in delivering on our promises to the customers.

During the first quarter of 2012, I will put my emphasis on spending time with the Nexcelle teams, our parent companies, along with the key partners, stakeholders and customers, including a trip to China this month for meetings on the C919 program.

I will work diligently to maintain the momentum that Steve Walters has achieved in bringing Nexcelle to where it is today, and I will continue to provide my inputs on this blog – which will be supplemented by postings from other members of the Nexcelle team.

Huntley Myrie
President – Nexcelle

Since then, Nexcelle’s evolution has been truly remarkable, as the market clearly recognized the value proposition of this integrated system approach.  Our joint venture scored back-to-back major program wins, and stood up its operations for the successful development and implementation of our committed technologies.

I have had the pleasure of leading Nexcelle since 2009, and the time has come to hand off these responsibilities to its new president, Huntley Myrie, as I become the Product Leader for all of GE Aviation’s nacelle and aerostructures activities.

In reflecting on Nexcelle’s achievements, three keywords come to mind: culture, collaboration and flexibility.

Nexcelle takes best practices from CFM International, which was created by Safran and GE Aviation 37 years ago, and is applying the same culture of working together that has made CFM International the industry reference for successful joint venture operations.  This culture is evident across Nexcelle’s daily operations, with teams from Middle River Aircraft Systems and Aircelle having forged the excellent relationships that are allowing our company to effectively evolve the technology and deliver on its program commitments.

We also have demonstrated on a daily basis our commitment to what I’ve been calling Nexcelle’s “flexible and collaborative perimeter” approach in our relationships with the airframe manufacturers.  This reflects Nexcelle’s willingness to share responsibilities appropriately with our airframe partners, establishing mutually-agreed upon lines of ownership according to their wishes in such areas as the integrated propulsion system’s pylon, engine inlet or exhaust nozzle.  Such an approach brings multiple benefits, including the reduction of development risks, while ensuring that the expertise of each of the partners is utilized to achieve the best possible product for the market.

In completing my last blog posting for Nexcelle, I want to acknowledge the dedication, commitment to excellence, and hard work of everyone at Middle River Aircraft Systems and Aircelle who have contributed to our company’s success, and to thank the customers for their confidence in us.

Nexcelle is in very good hands with Huntley Myrie, who will continue the blogging tradition on these pages.

Steve Walters
President – Nexcelle

In attending NBAA 2011 with Mike Long, Nexcelle’s Customer Support Director, we’ve come to understand how important lifecycle management and service coverage is for business jet operators.  It is clear that their needs and requirements involve a wide scope of all processes involved in operating an aircraft, including just about everything from financing and arranging insurance coverage to handling the claim process for maintenance.

This opens up much broader opportunities for supplier services than typically applied to the airline industry, and is fully aligned with Nexcelle’s approach to integrated propulsion systems in the broadest sense – which includes more integration in the customer support and product support offerings as well.

For our role on the GE Passport 20 business jet engine, Mike already has been coordinating his teams at Nexcelle parent companies Aircelle and Middle River Aircraft Systems, along with GE Aviation as the powerplant manufacturer, to ensure our services package for the Bombardier Global 7000 and 8000 fully responds to the expectations of their future throughout the aircraft’s lifecycle.

• See the video interview with Mike Long at this week’s NBAA’s annual meeting in Las Vegas for his perspective on Nexcelle’s customer support advantages in the business aviation sector.

Our presence at NBAA is allowing Nexcelle to highlight some of the technologies that will be applied in the nacelle and thrust reverser we are developing for the GE Passport 20 engine, which is to power the Bombardier Global 7000 and 8000 business jets.

This new integrated propulsion system includes such features as the Directed Flow Nozzle deicing system – which requires less mass flow and brings significant weight savings, along with a laminar flow inlet to improve aerodynamics and reduce weight.

Another key technology being applied to the Passport 20 is the thrust reverser’s moveable kicker plate – which smoothes the airflow during forward flight, improving specific fuel consumption while maintaining excellent reverse thrust performance.

Another area of focus is the application of composite materials, with the content increasing to some 75 percent in the nacelle.  In addition to conventional graphite epoxy, we are now working to introduce new materials that could include new high temperature-resistant composites.

Nexcelle is on track with our technology roadmaps as we move ahead with GE Aviation in developing the Passport 20 integrated propulsion system for the business aviation market.

• My video clip from the NBAA exhibit floor highlights Nexcelle’s presence at the show.

With Nexcelle as the nacelle and thrust reverser supplier, the Passport 20’s development takes full advantage of benefits from the common technology development processes, program processes and operating practices utilized by Nexcelle and GE.

In practical terms, the aerodynamic design of the engine and the nacelle’s inner flow lines are done from one operation within GE Aviation, facilitating tradeoffs and optimization – as the same team “owns” performance on both sides.  This has helped drive technologies that are being developed in the Passport 20’s nacelle and thrust reverser, including optimizing flow paths, removing steps and gaps, and expanding the application of composites.

It also extends to the single supply chain shared by our co-parent company, Middle River Aircraft Systems, which is part of GE Aviation.  Material planning, sourcing and quality are all shared on both the engine and nacelle sides.

I will be leading the Nexcelle team attending NBAA, and look forward to meeting my industry colleagues – as well as future operators of the Bombardier Global 7000 and 8000 – on the GE Aviation exhibit stand, Booth #N1833.

Steve Walters
President – Nexcelle

Their global network of facilities was further expanded with this month’s opening of a new facility in Xi’an, China, created through the SAVI joint venture of Aircelle and the Chinese AVIC Group’s XAIC (Xi’an Aircraft International Corporation) subsidiary.

The new SAVI installation has a direct relationship to Nexcelle’s supplier role for the nacelle and thrust reverser on the Chinese C919 jetliner’s integrated propulsion system, as this facility will provide the final assembly of many of the major nacelle and thrust reverser systems on the C919.

Initially, SAVI will be involved in certain major legacy programs for Aircelle and Middle River Aircraft Systems. Production of subsystems for these programs will help establish procedures and methods in advance of C919 nacelle work being assigned to the Xi’an facility.

The current SAVI installation at Xi’an covers more than 7,000 sq. meters on three floors, with workshops and production areas representing over 5,000 sq. meters of the total area. And this is simply the first step, as expansion plans include facilities that more than double this space.

SAVI reflects the importance that Aircelle, Middle River Aircraft Systems and their parent organizations – Safran and GE Aviation – place in building relationships in the Chinese market.

I was pleased to attend the SAVI grand opening event at Xi’an. I also had the opportunity to meet with many of the members of the SAVI leadership team who already are on location to develop the facility’s operations. Having known SAVI General Manager Gerard Lavigne through a prior business relationship, I have great confidence this will be a world-class operation.

I look forward to seeing the first production assemblies being delivered from SAVI in Xi’an!

Steve Walters
President – Nexcelle