EU Projects

„Additive Manufaturing Processes and Hybrid Operations Research for Innovative Aircraft Technology Development”

 

Polskie Zaklady Lotnicze Sp. z o.o.

 

In cooperation with:

 

Wroclaw University of Technology, Kielce University of Technology, Lublin University of Technology

and Pabianice Tool Factory PAFANA

 

 

Under The Innolot Program is currently implementing:

 

„Additive Manufaturing Processes and Hybrid Operations Research for Innovative Aircraft Technology Development”

 

Financed by National Center for Research and Development

and European Union

 founded by European Regional Development Fund

under the Operational Program Innovative Economy

 

 

This project will conduct research into the most ground breaking manufacturing technology since the advent of numerical control machinery: Additive Manufacturing. Research will explore product applications such as casting/forging replacement, part simplification through part consolidation using novel design approaches, and reconstructive repairs. Material property and process parameter data for several additive techniques will be gathered as well as design guidelines that leverage the many opportunities additive processes will create for engineers of the future.

 

www.europa.eu

www.poig.gov.pl

www.ncbr.gov.pl

 

Contact person:

 

Janusz Mądry, tel. +48 725 257 092, e-mail:

Justyna Skiba, nr tel. +48 17 743 1373, e-mail:

 

 

„Block Structures - Mechanical joining innovations to replace conventional fasteners in aerostructures”

 

 

Polskie Zaklady Lotnicze Sp. z o.o.

 

In cooperation with:

 

Lublin University of Technology, P. P. U. H. BRYK WITOLD BRYK

and WIT Composites

 

 

Under The Innolot Program is currently implementing:

 

„Block Structures - Mechanical joining innovations to replace conventional fasteners in aerostructures”

 

Financed by National Center for Research and Development

and European Union

 founded by European Regional Development Fund

under the Operational Program Innovative Economy

 

Project implementation period: 2013-2018

 

This program will provide Polish industry a unique capability: simplification of complex aerostructures with a one step assembly approach called Block Structures. By creating mating surfaces that “clip” together, part counts and costs can be reduced dramatically with no loss of functionality or performance. The types of structures addressed in this effort are semi-monocoque parts with thin gages. The materials to be studied include metals, composites, and metal/composite hybrids. Each application will have a unique “clip” geometry that will accomplish joining without fasteners or adhesives.

 

 

www.europa.eu

www.poig.gov.pl

www.ncbr.gov.pl

 

Contact person:

 

Karol Padykuła, tel. 17 743 1220, e-mail:

Magdalena Rzeszutek, tel. 17 743 1730, e-mail:

 

„Advanced techniques for the fabrication of airframe structures using innovative friction stir welding (FSW) technology”

 

 

Polskie Zaklady Lotnicze Sp. z o.o.

 

In cooperation with:

 

Czestochowa University of Technology, P. P. U. H. BRYK WITOLD BRYK

and Chirmed

 

 

Under The Innolot Program is currently implementing:

 

„Advanced techniques for the fabrication of airframe structures using innovative friction stir welding (FSW) technology”

 

Financed by National Center for Research and Development

and European Union

 founded by European Regional Development Fund

under the Operational Program Innovative Economy

 

 

The aim of the project is to develop aerostructures joining technology using innovative method of joining i.e. friction stir welding (FSW) by conducting industry research. Friction stir welding is a solid state joining process that reduces errors and manufacturing costs by eliminating fasteners. The program will create an extensive material property and joint performance database.  Parameters and tooling for continuous and spot welding processes will be developed for thin to thin and thin to thick materials. Design guidelines and quality control techniques will be validated with small and large scale specimenculminating with development and testing of representative aerostructure demonstrators.

 

www.europa.eu

www.poig.gov.pl

www.ncbr.gov.pl

 

Contact person:

 

Karol Padykuła, tel. 17 743 1220, e-mail:

Monika Serafin, tel. +48 17 743 1295, e-mail:

 

 

 

 

Innovate technologies on M28 aircraft

 

At PZL Mielec, a Lockheed Martin Company, has been conducted a flight test with composite engine nacelle on M28 aircraft. The design of the composite engine nacelle, manufactured from innovative technologies is developing by eight entities Consortium as part of SAT-AM project (More Affordable Small Aircraft Manufacturing) with European Commission co-financing.

 

On December 2020, PZL Mielec successfully completed flight test with composite engine nacelle on M28 aircraft. It was a very important milestone in the Clean Sky 2 project, which aim is to develop innovative technologies for the manufacturing of the aircraft structures.

 

Earlier, at the beginning of 2020, PZL Mielec and their Consortium Partners, conducted a static test of the first composite engine nacelle. After that, Zakłady Lotnicze Margański & Mysłowski has produced the second copy dedicated for flight test stage.

 

The successfully completed flight test, confirmed the project assumptions and the suitability of the developed solutions for future structural changes in aviation. Research and development activities are carried out under CLEAN SKY 2 program financed by European Commission. The goal of performing activities is to develop innovative design processes and manufacturing technologies in order to increase aircraft flight safety while reducing manufacturing costs. The new, composite engine nacelle, developed as part of SAT-AM project, could replace the traditional metal structure, thus reducing the weight of current design by at least 10 %.

 

As part of project activities, a full scale ground demonstrator of M28 aircraft cabin was built and assembled with use of innovative technologies, such as: friction stir welding, additive manufacturing (aka 3D printing), block structures, high speed machining, out of autoclave composites and superhydrophobic coatings. Application of above-mentioned technologies, results in reduction of parts used by about 35%, reduction in the number of joints, what will cause the significant lead times reduction of production and assembly.

 

Total project budget is over €9m of which funding from European Commission amounts to €6m. 

 

Deadline of project is planned for the end of 2021 and will be preceded by detailed analysis of performed researches and further activities related to the optimization of design and technological processes of composite engine nacelle.

 

Watch the video:https://www.youtube.com/watch?v=NtZ241C0vaw

 

 

***

 

The SAT-AM project Consortium is composed of eight entities including Sieć Badawcza Łukasiewicz – Instytut Lotnictwa, Polskie Zakłady Lotnicze Sp. z o.o., Eurotech, Szel-Tech,  P.W. "Metrol”, Ultratech, Zakłady Lotnicze  Margański & Mysłowski and Italian Aerospace Research Entity (CIRA).

 







 
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