Astronautics Selected by Nova Systems for Secure Airborne Mission System

Astronautics Corporation of America’s AeroSync Max, a wireless air-ground communications system (AGCS), has been selected by Nova Systems for more than 20 additional installations on its airborne C4ISR mission systems solution for Leonardo AW139/189 and Sikorsky S-92 helicopters deployed in a search and rescue (SAR) role with customers in Europe.

For the Nova Systems application, Astronautics’ AeroSync Max acts as a secure data gateway that within seconds captures, filters, and converts mission system data into data formatted for the aircraft’s flight management system (FMS), acting as a secure pipeline towardsthe FMS.  Similarly, AeroSync Max acts as an avionics data gateway between surveillance equipment and the mission system.

“Astronautics is proud to continue supporting Nova Systems with a tailored AeroSyncMax solution that enhances mission capabilities for the C4ISR system on Leonardo AW139/189 and Sikorsky S-92 helicopters,” said Matt Frei, Astronautics’ director of connected aircraft solutions. “The AeroSync Max will provide critical and timely mission data and security needed to support life-saving SAR efforts.”  

Astronautics and Nova Systems first partnered on an airborne C4ISR mission system solution for operational service with Leonardo AW139 helicopters deployed on a SAR and airborne law enforcement role with a European customer. 

Lincoln Electric Launches Sprinter 180Si 

Lincoln Electric introduces the Sprinter 180Si stick welder. This versatile machine delivers superior arc performance for stick welding combined with advanced TIG functionality, all wrapped up in a portable, lightweight package, thanks to the newest inverter technology. 

The 180Si is designed with a maximum output of 180 amps to enable exceptional stick welding quality. Operators can weld up to 5/32-inch electrodes (6010/7018) and can even choose a dedicated 6010 mode for cellulosic stick electrodes. 

But the 180Si is more than just a stick welder. It also delivers 200 amps for TIG welding and offers a variety of advanced TIG features: 

  • Pulse mode with options ranging from .1-100 pulses per second 
  • A choice of high-frequency or lift start options at the push of a button 
  • TIG-ready capabilities with an 8-pin connector for foot pedals, hand amptrols and other devices  

The 180Si is also portable and versatile. Weighing in at less than 20 pounds, it goes anywhere easily and the dual-input voltage enables the operator to plug into any common power supply. Once it’s up and running, the simple user interface provides an easy-to-read seven-segment display and easy push-button controls. And it all packs up neatly in an ergonomically designed case with a handle and shoulder strap that make it easier to carry and move – around the shop or to any location. 

Stick or TIG, in the shop or on the move, the Sprinter 180Si is ideal for welders of every kind – home hobbyist, professional, or both. And it’s ready for every type of work – maintenance and repair, farm, light industrial, shipbuilding and more. 

Get out and run with the Sprinter 180Si stick welder. 

Zulu Pods Awarded Phase 2 Contract by U.S. Army to Continue Development of its Loss of Lubrication Technology

Zulu Pods has been awarded a Phase 2 contract from the U.S. Army Aviation and Missile Center (AvMC) via FirePoint Innovations Center. The award will continue the partnership between ZPI and the Army focusing on further development of ZPI’s novel loss of lubrication pod technology, the ZPod, aimed at enhancing rotorcraft combat survivability during loss of lubrication events for the next generation of military helicopters.

In Phase 1, ZPI conducted instrumented tests on its internal high-speed rig that culminated in the successful validation of its technology through a simulated loss of lubrication event. The tests demonstrated mitigation of bearing failure and performance degradation by delivering minimum oil over time through a static ZPod, upgrading the technology readiness level to TRL 5.

In Phase 2, ZPI will work closely with two major aerospace engine OEMs to continue lubrication testing on bearing hardware, begin digital product integration through engine interface design, and deliver an engine ready prototype for testing and evaluation by the end of 2024.

The ZPod serves as a small decentralized, self-contained, and self-energized emergency oil system independent of the oil pump’s ability to adequately circulate oil to critical mechanical components, thus offering pilots the necessary time to carry out evasive landing maneuvers to safely land the rotary wing aircraft in the event of loss of lubrication.

Aurion Develops Clean-Tech Machining

Aurion Machining Technologies has developed new technology using ionized air as a trailblazing clean-tech alternative for metal working fluids and emulsions in parts manufacturing. Ionized air helps achieve high quality machining results — and it is safe for employees and environmentally friendly
Aurion technology is fully compliant with modern sustainability regulations which require end-to-end clean-tech solutions. Aurion says the technology is the response to increasing concern that metalworking fluids contribute significant carbon emissions on global basis

Disposal of used cutting fluids causes environmental contamination. Global annual consumption of cutting fluids is estimated to exceed two billion liters — although the actual amount of cutting fluids waste is assumed to be up to 10 times higher, as most fluids are diluted before their use. Cutting fluid treatment and their release to the environment leads to significant oxygen depletion and nutrient destruction in surface waters.

Aurion Technology

The core of the Aurion technology is in the ionized air which generates an electrochemical process resulting in electron loss and atomic level transformation of Aurion gas medium at the cutting surface. The electrochemical process acts as a dry lubricant in the cutting process, penetrating the cutting zone and optimising the interaction between the tool edge and the workpiece. This process accelerates oxide layer formation and significantly reduces the friction, thermal stress and tool wear.

The Aurion system consists of three components – ionizer, controller and air-cooling unit. The system is connected to the factory compressed air network and machinery CNC. There is no need for any special safety precautions as ionized air pressure remains at 2 – 3 bar and temperature in the -10°C to +10°C during machining operations.

Aurion technology is the result of years of industrial research and development work. Its technical properties have been proven in thorough tests conducted by authoritative institutions and industrial partners. Most recently the respected Advanced Manufacturing Research Centre (AMRC) of the University of Sheffield in England achieved excellent results in titanium milling trials.

Economically Compelling Solution

Aurion reduces manufacturing costs and cutting lead times in workshop processes. Thousands of validation runs have proven that Aurion technology delivers at least the same machining quality and performance as cutting fluids – measured by cutting speed, tool life and surface quality. Ionized clean air is safe for its operators and the relevant machinery and meets the highest standards for workpiece residuals.

Easy to Use and Integrate

Aurion technology is suitable for all machining applications and materials. It is easy to integrate to both existing and new machines, either by using the external piping to the cutting zone or by using existing coolant channels in standard toolholders and tools.

High integration flexibility and the possibility to use existing machine tool features minimises the up-front investment and limits the transition costs for introduction of the Aurion technology. The payback for the Aurion system is typically three to six months.

Aurion adaptation is moving to full industrial scale – Join for the journey

Following years of development work, Aurion is now ready for full scale industrial use. Attracted by the recent positive tests and validation runs, a number of high-quality manufacturers are engaged as partners in the next steps of the Aurion journey to transform their profitability and accelerate their carbon net zero plans.

PPG Adds Two Adhesives to Aerospace Product Portfolio

PPG announced that it has added two adhesives to its aerospace portfolio: PPG PR-2940 epoxy syntactic paste adhesive (ESPA) for bonding the internal structures of an aircraft; and PPG PR-2936, an adhesive that incorporates the properties of a shim and sealant for attaching the outer skin of an aircraft to the internal structures.

“We are excited to add these adhesive technologies to our product offering,” said Sean Purdy, PPG global director, coatings and sealants, Aerospace. “They will provide our aerospace customers with significant performance benefits as well as sustainability advantages through lightweighting.”

PPG PR-2940 ESPA adhesive is a lightweight potting compound used by both original equipment manufacturers (OEMs) and maintenance, repair and overhaul (MROs) customers on secondary aircraft structures. It fills and reinforces the honeycomb structures used to manufacture an aircraft’s internal components, including the inner wing structure, galley, lavatories, overhead bins and flooring.

PPG PR-2936 adhesive is used by OEMs to attach the metallic or composite skin of an aircraft to the internal structures of the fuselage, tail assembly, wings and stabilizers. This epoxy-based adhesive cures at ambient temperatures and is designed to fill gaps or irregularities between the surfaces of the primary and secondary structures. It combines outstanding mechanical strength with flexibility and microcracking resistance across a wide operating temperature window.

“Sustainability is a key priority across PPG, including new product innovations,” said Daniel Sydes, PPG global product manager, adhesives, Aerospace. “These new adhesives offer improved chemistries and low-density properties while maintaining a high strength-to-weight ratio that aids in increasing the fuel efficiency of aircraft.”

Airbus UpNext Flight Demonstrator Successfully Executes AI-based Navigation and Cooperative Control Using CoreAVI’s SafeAI Software Suite

Airbus has announced a successful flight test of their Auto’Mate (autonomous in-flight refueling) demonstrator utilizing CoreAVI’s GPU accelerated AI software stack, including VkCore SC and ComputeCore. The Airbus Auto’Mate represents a significant industry milestone by demonstrating Autonomous Assets Air to Air Refuelling operations flying with three manned drones Airbus DT-25s, and two more digital twins, under the control of an A310 MRTT tanker using an advanced navigation suite, including AI-based detection and cooperative control technologies.

Designed from the ground up for safety certification, CoreAVI’s Safe AI software suite includes
ComputeCore as well as VkCore SC. VkCore SC is a Vulkan SC implementation enabling
low-level high-performance compute acceleration, and ComputeCore is CoreAVI’s AI/ML
acceleration library providing APIs for BLAS, FFT, and a neural network inference engine
implementing The Khronos Group’s NNEF format. The building block nature of CoreAVI’s tools
and libraries provide scalable performance and capabilities making it easily expandable to meet
a wide range of compute algorithms.

“This Auto’mate flight demonstration marks a major success milestone for the growing
partnership between CoreAVI and Airbus for paving the future of AI-based airborne product
developments and certifications. This is the first time that Airbus has ever executed an AI flight
test that’s using a fully certifiable stack for autonomous air-to-air refuelling based on controlling
and guiding multiple drones from the Multi Role Tanker Transport aircraft,” said Dan Joncas,
deputy CEO at CoreAVI. “The value of Safe AI to airborne platforms cannot be overstated as it
enhances safety, reliability, efficiency while reducing pilot workload, training costs, and
ensuring more effective operations, especially in situations with low visibility. We’re happy to
work with a future-focused technology leader like Airbus to ensure the best in AI technology is
available to all integrators of safety critical systems.”

“Bringing state-of-the-art GPU compute capabilities to our product portfolio will allow us to
evolve and create new capabilities that put us on the forefront of military aviation technology,”
said David Pérez Amenabar, air refueling software innovation manager at Airbus Defence &
Space. “This successful technology deployment paves the way for a future where parallelization
enables numerous new data intensive applications. AI technology will be quintessential in the
future of our industry and CoreAVI’s SafeAI stack has proven to be an exceptional enabler for
these integrations. This particular iteration demonstrates our commitment to the future mosaic warfare and unmanned/manned aircraft teaming; we are ready for Autonomous Operation and
committed to developing the most capable interoperable system of systems for air
dominance.”

Service Electrical Vehicles Safely with the New Electric Vehicle General Maintenance Kit from Snap-on Industrial

The new Electric Vehicle General Maintenance Kit from Snap-on Industrial provides technicians with all the hand tools they need to service electric vehicles safely and reliably.

The Electric Vehicle General Maintenance Kit (EVTECHCARTO) contains an assortment of 270 hand tools, which are composite in design to prevent electricity from reaching the technician’s hand, ensuring excellent protection without compromising on performance. Composite tools are IEC60900 compliant; composite sockets and extensions are UL rated. 

The kit also includes a toolbox and tool control foam. The Electric Orange Roll Cart (KRSC46HPJK) comes with six 35” wide drawers and a top compartment housed in a one-piece fully welded box designed to hold 120 pounds per drawer (240 pounds with double sides). The top compartment stores a battery charger and can be used as a charging station while locked. Additionally, every tool has a specific place in the box, thanks to pre-cut foam for maximum organization, tool identification, inventory, and storage. 

Tool assortment includes:

  • Composite 3/8” metric sockets from 8mm to 19mm
  • Chrome 6-point 1/4″ sockets, shallow and deep from 4mm to 15mm
  • Chrome 6-point 3/8” sockets, shallow and deep from 6mm to 21mm
  • Composite ring- and open-ended wrenches from 6mm to 19mm
  • Flank drive 12-point combination wrenches from 6mm to 23mm
  • Composite pliers
  • Composite hex keys from 3mm to 12mm
  • 1/4″ torque wrench rated from 15-300 in-lbs.
  • Digital hybrid multimeter
  • 12V DC circuit tester

Jelmar Launches New Industrial-Strength Cleaning Solution Delivering Advanced Results

Jelmar, maker of CLR Brands, CLR PRO and Tarn-X, announced the launch of a new industrial cleaning product CLR PRO MAX Industrial Descaler. The cleaner is specifically engineered to deliver faster, deeper results and dissolve and eliminate scale and rust build up from drains and industrial equipment that heats and cools liquids.

“In independent laboratory testing, the proprietary patent pending CLR PRO MAX Industrial Descaler was found to outperform all competitive products, some by as much as two times greater descaling power,” according to Rafael Ortiz, director of research & development at Jelmar.

The increased cleaning power and speed of CLR PRO MAX Industrial Descaler delivers improved operational efficiency of industrial equipment, resulting in overall improved energy consumption and utility savings. It achieves this by reducing buildup, which, if present, is known to block water flow, cause pressure drops, and reduce heat transfer efficiency, resulting in the equipment working harder for longer. CLR PRO MAX Industrial Descaler boasts the capability to help restore equipment to peak condition, ultimately preserving and prolonging the lifespan of costly industrial machinery.

“The innovation of CLR PRO MAX Industrial Descaler is in direct response to our customers expressing their need for more power, efficacy and speed in their industrial-strength cleaners,” said Dan Bucci, director of B2B sales at Jelmar. “While our CLR PRO line is optimal for routine industrial cleaning, the new CLR PRO MAX offering delivers greater efficiencies for our customers operating equipment and facilities at major size and scale.”

The product is suitable for a wide range of applications from heat exchangers, cooling towers, die cast lines, quench tanks, evaporators, chillers, wastewater buildup, radiators, dishwashers and urinals. It will be available starting February 1, 2024, through B2B distributors and wholesalers.

Jelmar says it will continue to release new products alongside the new CLR PRO MAX Industrial Descaler in 2024 and beyond to build a CLR PRO MAX product portfolio with cleaning solutions made to tackle tough, heavy-duty industrial cleaning challenges.

Reliable Robotics Awarded Military Airworthiness Approval for a Commercial Autonomous Flight System

Reliable Robotics announced that it has received military airworthiness approval to begin flight testing and operational missions of its remotely piloted Cessna 208 Caravan for the U.S. Air Force. This approval signifies a deeper level of engagement with the Department of Defense (DoD) by enabling Reliable to demonstrate dual-use automated flight capabilities for military use cases, including cargo missions.

“Nothing compares to showcasing how our autonomous flight capabilities will immediately enable new ways for the U.S. Air Force and other departments of the military to lead with innovation, improve safety and project power across the globe,” said Dr. David O’Brien, Major General (Ret.), and Senior Vice President of Government Solutions at Reliable Robotics.

DoD airworthiness policies require all aircraft and air systems owned, leased, operated, used, designed, or modified for Air Force applications complete an airworthiness assessment in accordance with Air Force standards. In order to meet these requirements, Reliable completed a comprehensive safety analysis, maintenance and operational evaluations and testing of the automated flight technologies. This airworthiness achievement was a key milestone of Reliable’s Phase III Small Business Innovation Research (SBIR) contract.

“Our AFWERX partners are developing exciting automation technologies through robust engineering and flight test campaigns,” said Hank “Hog” Griffiths, AFWERX airworthiness and test lead. “The technology is maturing rapidly and this airworthiness approval for a certified aircraft retrofitted with an autonomous flight system provides significant opportunities for the military.”

Reliable’s collaboration with the Air Force Research Laboratory (AFRL) and AFWERX began in 2021 and includes SBIR awards, as well as a large aircraft automation study. In 2023, Reliable demonstrated automated flight for distinguished military personnel as part of the Golden Phoenix exercise at Travis Air Force base.

Air Industries Group Receives Two Strategically Important New Contracts from New Customers

Air Industries Group, an integrated Tier 1 manufacturer of precision assemblies and components for mission-critical aerospace and defense applications, and a prime contractor to the U.S. Department of Defense, announced that it has received two separate strategically important contracts, both from new customers.

Air Industries has received an initial order for structural engine nacelle components for the new CH-53K Heavy Lift Helicopter. This initial order is for just under $1 million, but is the first release against an anticipated five-year order expected to be in excess of $12 million.

Separately, Air Industries has received an order from a major landing gear manufacturer for actuator subassemblies on a developmental aircraft. This initial order is modest at approximately $1 million, but this award concludes what has been a multi-year effort to establish a relationship with this large and important customer. When the program enters the production phase, the anticipated order value increases exponentially.

Lou Melluzzo, CEO of Air Industries, commented: “These awards are very satisfying and result from our increased investment and efforts in business development. Air Industries is focused on increasing its workshare on the Sikorsky CH-53K. This new contract from a new customer furthers that goal.

“The second contract is also from a new customer and is significant to Air Industries, as it represents an important first step from a large OEM in establishing a relationship that will grow materially. The order is for a developmental aircraft. Producing new, prototype product requires a high level of expertise, and considerable concurrent engineering skill. It is a tribute to Air Industries that this World Class OEM has placed its trust in us. We anticipate additional substantial orders in the coming months.”