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The paper proposes a framework for the successful deployment of Industry 4.0 (I4.0) principles in the aerospace industry, based on identified success factors. The paper challenges the perception of I4.0 being aligned with de-skilling and personnel reduction and instead promotes a route to successful deployment centred on upskilling and retaining personnel for future role requirements.

The research methodology involved a literature review and industrial data collection via questionnaires to develop and validate the framework. The questionnaire was sent to a purposive sample of 50 respondents working in operations, and a response rate of 90% was achieved. Content analysis was used to identify patterns, themes, or biases, and the data were tabulated based on specific common attributes. The proposed framework consists of a series of gates and criteria that must be met before progressing to the next gate.

The proposed framework provides a feedback mechanism to review minimum standards for successful deployment, aligned with new developments in capability and technology, and ensures quality assessment at each gate. The paper highlights the potential benefits of I4.0 implementation in the aerospace industry, including reducing operational costs and improving competitiveness by eliminating variation in manufacturing processes. The identified success factors were used to define the framework, and the identified failure points were used to form mitigation actions or controls for inclusion in the framework.

The paper provides a framework for the successful deployment of I4.0 principles in the aerospace industry, based on identified success factors. The framework challenges the perception of I4.0 as being aligned with de-skilling and personnel reduction and instead promotes a route to successful deployment centred on upskilling and retaining personnel for future role requirements. The framework can be used as a guideline for organizations to deploy I4.0 principles successfully and improve competitiveness.

Castellated and cellular beams achieved the same strength as solid I-beams with the same depth, resulting in significantly lighter and more economical structures. The purpose of this study is to analyse the bending behaviour of I-beam steel sections with certain web openings by finite element analysis.

The accuracy of finite element results allows extensive numerical analysis of sections with web openings, concentrating on the web opening sizes and web opening positions. These assumptions can increase the induced section load with various shapes of web opening depth and web opening shapes of c-hexagon, hexagon, octagon, circular and square. This also includes spacing distances, with a 50-mm edge and 150-mm centre-to-centre distance and a section with a 100-mm edge and 200-mm centre-to-centre distance. Generally, the adjustment of the opening geometry (by reducing the angle of web pitch or reducing the opening depth depending on analysed parameters) may influence the bending behaviour.

Additionally, Model 2 was found to be the optimum model compared to Model 1, mainly in terms of bending. Moreover, the I-beam with a c-hexagon shape opening exhibited the lowest displacement compared to other sections with other web opening shapes. Section with a different arrangement of web opening, Type E shows the lower displacement while higher displacement is observed for Type A and also higher displacement considered for Type G. The optimum model is associated with Type E, followed by Type D, compared to other types of certain web opening and I-beam.

The use of sections with different arrangements of web opening improved the performance of the perforated section in terms of structural behaviour, compared to typical I-beam, thus leading to economic design.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

Automatic dependent surveillance-broadcast (ADS-B) is the foundational technology of the next generation air transportation system defined by Federal Aviation Authority and is one of the most precise ways for tracking aircraft position. ADS-B is intended to provide greater situational awareness to the pilots by displaying the traffic information like aircraft ID, altitude, speed and other critical parameters on the Cockpit Display of Traffic Information displays in the cockpit. Unfortunately, due to the initial proposed nature of ADS-B protocol, it is neither encrypted nor has any other innate security mechanisms, which makes it an easy target for malicious attacks. The system is vulnerable to various active and passive attacks like message ingestion, message deletion, eavesdropping, jamming, etc., which has become an area of concern for the aviation industry. The purpose of this study is to propose a method based on modified advanced encryption standard (AES) algorithm to secure the ADS=B messages and increase the integrity of ADS-B data transmissions.

Though there are various cryptographic and non-cryptographic methods proposed to secure ADS-B data transmissions, it is evident that most of these systems have limitations in terms of cost, implementation or feasibility. The new proposed method implements AES encryption techniques on the ADS-B data on the sender side and correlated decryption mechanism at the receiver end. The system is designed based on the flight schedule data available from any flight planning systems and implementing the AES algorithm on the ADS-B data from each aircraft in the flight schedule.

The suitable hardware was developed using Raspberry pi, ESP32 and Ra-02. Several runs were done to verify the original message, transmitted data and received data. During transmission, encryption algorithm was being developed, which has got very high secured transmission, and during the reception, the data was secured. Field test was conducted to validate the transmission and quality. Several trials were done to validate the transmission process. The authors have successfully shown that the ADS-B data can be encrypted using AES algorithm. The authors are successful in transmitting and receiving the ADS-B data packet using the discussed hardware and software methodology. One major advantage of using the proposed solution is that the information received is encrypted, and the receiver ADS-B system can decrypt the messages on the receiving end. This clearly proves that when the data is received by an unknown receiver, the messages cannot be decrypted, as the receiver is not capable of decrypting the AES-authenticated messages transmitted by the authenticated source. Also, AES encryption is highly unlikely to be decrypted if the encryption key and the associated decryption key are not known.

Implementation of the developed solution in actual onboard avionics systems is not within the scope of this research. Hence, assessing in the real-time distances is not covered.

The authors propose to extend this as a software solution to the onboard avionics systems by considering the required architectural changes. This solution can also bring in positive results for unmanned air vehicles in addition to the commercial aircrafts. Enhancement of security to the key operational and navigation data elements is going to be invaluable for future air traffic management and saving lives of people.

The proposed solution has been practically implemented by developing the hardware and software as part of this research. This has been clearly brought out in the paper. The implementation has been tested using the actual ADS-B data/messages received from using the ADS-B receiver. The solution works perfectly, and this brings immense value to the aircraft-to-aircraft and aircraft-to-ground communications, specifically while using ADS-B data for communicating the position information. With the proposed architecture and minor software updates to the onboard avionics, this solution can enhance safety of flights.

The purpose of this paper is to explore the emergence of innovation in smart service systems to conceptualize how actor’s relationships through technology-enabled interactions can give birth to novel technologies, processes, strategies and value. The objectives of the study are: to detect the different enablers that activate innovation in smart service systems; and to explore how these can lead dynamically to the emergence of different innovation patterns.

The empirical research adopts an approach based on constructivist grounded theory, performed through observation and semi-structured interviews to investigate the development of innovation in the Italian CTNA (Italian acronym of National Cluster for Aerospace Technology).

The identification and re-elaboration of the novelties that emerged from the analysis of the Cluster allow the elaboration of a diagram that classifies five different shades of innovation, introduced through some related theoretical propositions: technological; process; business model and data-driven; social and eco-sustainable; and practice-based.

The paper embraces a synthesis view that detects the enabling structural and systems dimensions for innovation (the “what”) and the way in which these can be combined to create new technologies, resources, values and social rules (the “how” dimension). The classification of five different kinds of innovation can contribute to enrich extant research on value co-creation and innovation and can shed light on how given technologies and relational strategies can produce varied innovation outcomes according to the diverse stakeholders engaged.

The lightweight design of aircraft seats can significantly improve fuel efficiency and reduce greenhouse gas emissions. Metal additive manufacturing (MAM) can produce lightweight topology-optimized designs with improved performance, but limited build volume restricts the printing of large components. The purpose of this paper is to design a lightweight aircraft seat leg structure using topology optimization (TO) and MAM with build volume restrictions, while satisfying structural airworthiness certification requirements.

TO was used to determine a lightweight conceptual design for the seat leg structure. The conceptual design was decomposed to meet the machine build volume, a detailed CAD assembly was designed and print orientation was selected for each component. Static and dynamic verification was performed, the design was updated to meet the structural requirements and a prototype was manufactured.

The final topology-optimized seat leg structure was decomposed into three parts, yielding a 57% reduction in the number of parts compared to a reference design. In addition, the design achieved an 8.5% mass reduction while satisfying structural requirements for airworthiness certification.

To the best of the authors’ knowledge, this study is the first paper to design an aircraft seat leg structure manufactured with MAM using a rigorous TO approach. The resultant design reduces mass and part count compared to a reference design and is verified with respect to real-world aircraft certification requirements.

Aerospace is a demanding technological and industrial sector. Several regulations and policies via innovative digital transformation have been integrated to impact production systems and supply chains, including safety measures. Studies demonstrated that the Fourth Industrial Revolution (4IR) technologies could enhance productivity growth and safety measures. The 4IR role in influencing airlines’ growth is yet to receive in-depth studies in South Africa. Thus, this study aims to investigate the role of 4IR technologies in influencing airlines’ growth in South Africa.

This research used a qualitative research method. Primary data were compiled via 56 face-to-face semi-structured interviews with major stakeholders. The study achieved saturation. A thematic method was used to analyse the collected data.

Findings reveal the nine major factors influencing South African airlines’ growth in the 4IR era. This includes investment in ergonomics applications and research, governance is driven by 4IR, collaboration and incorporation of 4IR concepts, partnership with drone technology and high precision and efficiency with 4IR. Others are reskilling and upskilling, investment in 4IR software, policies to promote 4IR usage in the industry and policies to reduce human interface.

Understanding the relative significance of 4IR technologies’ role in airlines’ growth can assist critical stakeholders in promoting innovative policies and regulations tailored towards digitalised aerospace. Thus, the study contributes to strategies to improve digital innovation, airline growth and safety as components of the air travel demands in South Africa.

Composite materials have revolutionized the aerospace industry by offering superior structural qualities over traditional elements. This study aims to focus on the development and testing of bamboo natural fiber-based composites enhanced with SiO₂ nanoparticles.

The investigation involved fabricating specimens with varying nanoparticle compositions (0, 10 and 20%) and conducting tensile, flexural, impact and fracture toughness tests. Results indicated significant improvements in mechanical properties with the addition of nanoparticles, particularly at a 10% composition level.

This study underscores the potential of natural fiber composites, highlighting their environmental friendliness, cost-effectiveness and improved structural properties when reinforced with nanoparticles. The findings suggest an optimal ratio for nanoparticle integration, emphasizing the critical role of precise mixing proportions in achieving superior composite performance.

The tensile strength, flexural strength, impact resistance and fracture toughness exhibited notable enhancements compared with the 0 and 20% nanoparticle compositions. The 10% composition showed the most promising outcomes, showcasing increased strength across all parameters.

This paper aims to focus on the research progress of intelligent self-healing anti-corrosion coatings in the aviation field in the past few years. The paper provides certain literature review supports and development direction suggestions for future research on intelligent self-healing coatings in aviation.

This mini-review uses a systematic literature review process to provide a comprehensive and up-to-date review of intelligent self-healing anti-corrosion coatings that have been researched and applied in the field of aviation in recent years. In total, 64 articles published in journals in this field in the last few years were analysed in this paper.

The authors conclude that the incorporation of multiple external stimulus-response mechanisms makes the coatings smarter in addition to their original self-healing corrosion protection function. In the future, further research is still needed in the research and development of new coating materials, the synergistic release of multiple self-healing mechanisms, coating preparation technology and corrosion monitoring technology.

To the best of the authors’ knowledge, this is one of the few systematic literature reviews on intelligent self-healing anti-corrosion coatings in aviation. The authors provide a comprehensive overview of the topical issues of such coatings and present their views and opinions by discussing the opportunities and challenges that self-healing coatings will face in future development.

Temperature anomalies in the upper troposphere have become a reality as a result of global warming, which has a noticeable impact on aircraft performance. The purpose of this study is to investigate the total air temperature (TAT) anomaly observed during the cruise level and its impact on engine parameter variations.

Empirical methodology is used in this study, and it is based on measurements and observations of anomalous phenomena on the tropopause. The primary data were taken from the Boeing 747-8F's enhanced flight data recorder, which refers to the quantitative method, while the qualitative method is based on a literature review and interviews. The GEnx Integrated Vehicle Health Management system was used for the study's evaluation of engine performance to support the complete range of operational priorities throughout the entire engine lifecycle.

The study's findings indicate that TAT and SAT anomalies, which occur between 270- and 320-feet flight level, have a substantial impact on aircraft performance at cruise altitude and, as a result, on engine parameters, specifically an increase in fuel consumption and engine exhaust gas temperature values. The TAT and Ram Rise anomalies were the focus of the atmospheric deviations, which were assessed as major departures from the International Civil Aviation Organizations–defined International Standard Atmosphere, which is obvious on a positive tendency and so goes against the norms.

Necessary fixed flight parameters gathered from the aircraft's enhanced airborne flight recorder (EAFR) via Aeronautical Radio Incorporated (ARINC) 664 Part 7 at a certain velocity and altitude interfacing with the diagnostic program direct parameter display (DPD), allow for analysis of aircraft performance in a real-time frame. Thus, processed data transmits to the ground maintenance infrastructure for future evaluation and for proper maintenance solutions.

A real-time analysis of aircraft performance is possible using the diagnostic program DPD in conjunction with necessary fixed flight parameters obtained from the aircraft's EAFR via ARINC 664 Part 7 at a specific speed and altitude. Thus, processed data is transmitted to the ground infrastructure for maintenance to be evaluated in the future and to find the best maintenance fixes.