Hindustan Aeronautics Limited

Aircraft Division, Bangalore

A Presentation
on
HONEYCOMB/ METAL SANDWICH STRUCTURE &
HONEYCOMB REPAIR WORK
Presented by
Varun Kumar (SM-HC Shop) BE-Mech, MBA (IMI Delhi)
 Sandwich Structure

Highlights: Aircraft Division(BC) 2

 Types & Classification
Honeycomb Core

Types of Honeycomb Core

• Hexagonal Core

• Flex Core

• Ox core

Highlights: Aircraft Division(BC) 3

 Rudder Sandwich Structure

Highlights: Aircraft Division(BC) 4

 PROCESS FLOW: HONEYCOMB BONDING

INCOMING MATERIAL
TEST

Life control & Monitoring Test Coupons fabrication /

Testing

Lay Up of Parts

Detailed Parts Layup Test coupons Layup

Vacuum Bagging/ Leak Check

Curing Parameters Check

INSPECTION

DT/ NDT Check

Dimensional Check
( ILSS, Flexural, Tensile , FTT , ‘C’
( CMM, Laser Tracker )
Scan)
Painting / Final Tagging /
Acceptance
PROCESS FLOW: HONEYCOMB BONDING
 HONEYCOMB BONDING FACILITY

 The Honeycomb Shop is one among the few facilities in the world having unique capability in
manufacturing of metal to metal bonded structures of Honeycomb core.

 The facility caters to a variety of projects both Domestic and Exports.

Autoclave

C-Scan Ultrasonic Flaw Detector

C-Scan Ultrasonic Flaw Detector
 CHROMIC ACID ANODIZING
FACILITY

 The Shop has captive anodizing facility with tank capacity of 12,000 lts
each, which can accommodate Aluminium Alloy components of the size
8m X 1m X 4m.

CORE BONDING

 Application of adhesive film in between core and face sheet

 Application of prepregs between face sheet and composite material around the peripheral area.
  COLD STORES
(-18° C)

Challenges for Monitoring of life of prepregs :

• 24 x 7 monitoring of raw materials starting from manufacturing date, during transit and storage
in cold stores and deep freezers
• Review of shift based issues reported if any on daily basis based on the feedback by
duty officers and corrective action on priority

Highlights: Aircraft Division(BC) 9

 HONEYCOMB CORE MILLING
FACILITY

Core Milling Process :

 Rebate Milling,
 Chamfer Milling,
 Grove Milling,
 Step Milling
 CRITICAL FACTORS

Storage conditions & Shelf

Waiting Time between life of Prepregs
Stations affecting Tack life
and out life of prepregs
Good Layup Practices
Skill Level

Heating Rate (°C/min)

Dwell Time
Cooling Time
Mould Opening Temp (°C)
Vacuum bagging and
Vacuum (bar)
debulking process
 RAW MATERIALS USED: HONEYCOMB/ METAL
SANDWICH STRUCTURES

Unidirectional Prepeg Supplier: Hexcel Corporation, France

Carbon Prepeg, Carbon UD, Glass Prepeg, Kevlar
PREPREG
Prepeg
Bidirectional

Consumable Supplier: Cytec, USA

Film Adhesive Film, Foaming Adhesive,
Adhesives
Primer
ADHESIVES
Foaming Araldite & Hardner
Adhesive

Core Material Supplier: Hexcel Corporation, USA

Aluminum
Core Hexagonal Core: Aluminium (8 to 108 mm), Nomex

CORE (6 to 30 mm)
Flexible Core: Aluminium (15 mm), Nomex (15
Nomex Core
mm),Ox Core: 15 mm
 PREPARATION FOR HOT BONDING: VACUUM BAGGING

 Create vacuum around the bonding area during hot curing process

 Helps to avoids air bubble during Hot Curing Process

 Provides exit to the fumes generated during hot bonding process

HOT CURING WITH CONTROLLED PRESSURE
& VACCUME: AUTOCLAVE

Autoclave : Qty 2 nos.

Working Size :
 3.3 m x 7m, &
 1.2m x 3m
 Inspection and Testing Facilities

A-SCAN
Parts Inspection Techniques:
 A - Scan (De-bond check)
 C – scan (Ultrasonic Testing)
 Digital X-Ray Fluoroscopy

C-Scan Ultrasonic
Flaw Detector
Digital X Ray
 APPROVALS : HONEYCOMB PANEL BONDING

The Facility is approved by DGCA (Indian Civil Aviation Regulatory Authority) for manufacturing of sandwich
structures for :
 Civil ALH (35 parts), &
 Dornier (5 parts).
The Facility is approved by DGAQA (Indian Military Aviation Regulatory Authority) for Honeycomb parts
ALH, (35 items), LCH (74 parts), LUH (13 parts), Cheetah (1 part),
Chetak (5 parts), Hawk (8 items)

ALH: VERTICAL STABILIZER

JAGUAR: ALPHA BOX

HAWK: RUDDER
 HONEYCOMB/ METAL SANDWICH STRUCTURES

Helicopter Tailboom Top Shell

Size: 3500mmx 650mm

Helicopter Rear Floor Board Helicopter Front Floor Board

Size: 1500mmx 1200mm Size: 2500mmx 1500mm
 HONEYCOMB/ METAL SANDWICH STRUCTURES

Jaguar : Base Plate (3.5 X 1 m), Tail Plane Tip & Trailing Edge, Inboard &
out board flaps, Undercarriage door, Air-intake ducts, Rudder, Electrical Panels
Hawk: Aileron, Rudder, Over-wing panel, Vane Assembly

DORNIER: SEAT
ALH: Tail Boom, Floor Board (Center , Rear and Front), BACK REST ASSY
Crashworthy panel, Structural & Equipment panels,
LCH: Floor Board, Structural Panels
ALH : FUEL OPTIONAL

Jaguar : AIRDUCT

Jaguar :
Undercarriage Door
ALH : CRASHWORTHY PANEL
 Damage classification in
Honeycomb Structures

Types Of Defect
• Debond
Skin to Skin, Skin To Core

• Dent/Crack

• Minor/Major Honeycomb Core

Damage

• Bonded Skin Damage

Aluminium sheet, Prepreg

Highlights: Aircraft Division(BC) 19

 Defect Analaysis in Honeycomb
Structures

• Impact Load/ Dent in

honeycomb structure

• Water Ingress in the

honeycomb structure

Highlights: Aircraft Division(BC) 20

 DAMAGE AND REPAIR

WET REPAIR

REPAIR WITH HOT BONDING

CRACK REPAIR
Honeycomb Core
REPAIR
 Repair Scheme For IL-76 Air Brake

Highlights: Aircraft Division(BC) 24

 IL-76 Air Brake Panel

BEFORE

Highlights: Aircraft Division(BC) 25

 IL-76 Air Brake Panel

AFTER

Highlights: Aircraft Division(BC) 26

 Repair Scheme For IL-76 Air Brake

Highlights: Aircraft Division(BC) 27

 Repair Panels of IL-76

REWOKABLE

Highlights: Aircraft Division(BC) 28

 Repair Panels of IL-76

Non Reworkable

Highlights: Aircraft Division(BC) 29

 Repair Panels of IL-76

Non Reworkable

Highlights: Aircraft Division(BC) 30

 Repair Panels of IL-76

Beyond Economical Cost of

Recovery

Highlights: Aircraft Division(BC) 31

Highlights: Aircraft Division(BC) 32
END OF PRESENTATION
THANK YOU FOR YOUR ATTENTION