The HAI's Composite Materials and Processes Laboratory (Part of company's R&D) operates within the Strategic Planning and Business Development Directorate of the company.

The main scope of the Department is to implement Research and Development programs concerning the design, manufacture, production and testing of structural aeronautical components/prototypes. The components are designed manufactured and evaluated by applying advanced methods, materials and processes in order to be used in Aerospace Industry and application.

OBJECTIVES of COMPOSITE MATERIALS DEPT.

- Applied & Product oriented Research.
- Development of new processes for the manufacturing aeronautical composite structures.
- Development of new NDI techniques.
- Development of advanced repaired methods in the scientific field of composite materials patch repairs.
- Transferring of know-how to the production.

MANUFACTURING CAPABILITIES OF COMPOSITE STRUCTURES FOR R&D PURPOSES

Existing Laboratory Scale Composite Facility in HAI.

The manufacturing area of composite structures operates within the lab facilities of Research and Development Department for the purposes of development of new products. This area of 500 sq. meters , consists of two individual sections which carry out:

Design Section

The section incorporates CAD-CAM-CAE capabilities, as follows:

     CAD – Unigraphics programme

     Structural design/analysis programme - PATRAN/NASTRAN

Laminate Modeler

Fatigue Analysis

     Composite DATA bank

Manufacturing section

The section is consisted by two separate areas of clean room and autoclave processing area

In this section structural components are fabricated by using composite materials and the following methods :

    Autoclave processing ,

    Limited size hot pressing ,

    Wet lamination – hand lay up and

   Resin Transfer Molding (RTM is in the development phase).



                  Autoclave

Repair section

Portable repair kits by using vacuum and heating blankets are used for the repair of composite structures.



Application of a Repair method using composite materials in sailplanes



                 Repaired components of Bombardier CL-215

Testing Station

    Mechanical testing

    Microscopic analysis

    Non Destructive Evaluations (Ultra-Sonics, Acoustic Emission, Eddy Current)

Microscope Press

TECHNOLOGIES & MATERIALS

The following advanced composite material systems are used:

   Reinforced materials with fibers (carbon, or aramide or glass, boron) and

      thermosetting matrix (3d woven , pre-pregs).

   Reinforced materials with fibers (carbon, or aramide or glass) and thermoplastic matrix.

   Honeycomb reinforced sandwich structures (nomex or aluminum).

   Metal to metal bonding.

RESEARCH PROJECTS

Current Projects - European Funded

Composite Material Repair for metalic structures of ageing commercial aircraft (COMPRES). European Project BRITE-EURAM BE-97 409

Partners: HAI (Co-ordinator), IAI, Alenia, CYTEC, OGMA, GMI, NTUA, Democritus Newclear Research Center.

Resin Transfer Moulding Techniques (EUCLID) - RTP 3.15

Partners: Daimler-Chrysler (DASA), DERA, HAI, Eurocopter, SONACA, Fokker, Baris, OGMA, TERMA

Technology application to the Near-Term Business. Goals & Objectives of the Aerospace Industry "TANGO", GROWTH Project.

Partners: Airbus Industry, Daimler-Crysler (DASA), Aerospatiale-Matra, CASA, Alenia, SAAB, IAI, SONACA, Fokker, HAI.

Development of a repair method for ageing aircraft using reinforced composite patches EPET National Project.

Partners: HAI (Co-ordinator), NTUA, Democritus Univercity of Thace, Univercity of Patras.

Targeted Research Action In Advanced Structural Efficiency (ADSTREFF). Thematic Network European Project.

Partners: BAe, Alenia, Aerospatiale, ICI, HAI, Univercity of Strathclyde, Dassault, SAAB, DLR, Daimler-Chrysler (DASA), DERA.

Completed Projects

Evaluation of the fatigue life limit of aerospace materials and components by Accoustic Emission. PAVE National funded project.

NDE-NDT for Maintenance of Stuctural Parts - Task: Ultrasounds BRITE-EURAM BE 58-79.

Diagnostics and Reliability of Composite Materials and Structures for Advanced Transportation Applications. HUMAN CAPITAL & MOBILITY - European Project.

Mechanical behavior and suitability study of advanced composite materials for use in primary aircraft structures. PAVE National funded project.

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