DESIGN & MFRS OF NON METALLIC AND METALLIC PARTS FOR AEROSPACE APPLICATIONS

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1 DESIGN & MFRS OF NON METALLIC AND METALLIC PARTS FOR AEROSPACE APPLICATIONS

2 INDIGENOUS INNOVATIONS OF ELASTOMERS FOR AEROSPACE AND FLUID POWER SECTOR 17 & 18 TH JUNE 2016 AT SATISH DHAWAN AUDITORIUM IISC CAMPUS, BANGALORE

3 CERTIFICATES

4 AWARDS ` NATIONAL AWARD FOR DEFENCE TECHNOLOGY ABSORPTION

5 Polymers can be classified into: POLYMERS Thermoset - are those elastomer materials which does not melt when subjected to heat. Thermoplastic - are those elastomers which melt when heated.

6 Polymers Thermoset Thermoplastic Natural Rubber Synthetic Rubber EPDM FKM FSE CR NBR SILICONE etc., POLYCARBONATE POLYACETAL etc.,

7 CLASSIFICATION OF RUBBERS Though there are many kinds of rubbers available for the various applications. Rubber is basically classified into two types. Natural Rubber Synthetic Rubber

8 NATURAL RUBBER Natural rubber is obtained through the latex produced by rubber-tree. It has very high elasticity, good tensile strength and good abrasion resistance. SYNTHETIC RUBBER These are mainly polymers synthesised from petroleum by-products, Silica, etc., There are many types of synthetic rubbers used in the world. Synthetic rubbers are selected based on their application.

9 Rubber Property Application Styrene Butadeine Rubber (SBR) Nitrile Rubber (NBR) Butyl Rubber (IIR) Chloroprene Rubber (CR) Ethylene propylene Rubber (EPM) TYPES OF SYNTHETIC RUBBER Good Abrasion & Ageing Resistance Better Oil resistant Properties Excellent air retention & good fatigue Properties Better Ozone and weather resistance Better heat, ozone and weather resistance Used widely in pneumatic tires, shoe heels and soles, gaskets. Non-latex gloves for the healthcare industry, hoses, O rings, gaskets, oil seals, V belts. Used for the inner liner that holds the air in the tire Moulded goods, cables, transmission belts, conveyor belts, profiles etc., Window seals, Gaskets, Cable insulations.

10 Rubber Property Application Polyurethane (PU) Silicone Rubber (VMQ) Fluoro Carbon Rubber (FKM) Fluorosilicone (FVMQ) TYPES OF SYNTHETIC RUBBER High Performance materials Excellent high as well as low temperature, weather resistance Very high heat stability & excellent oil resistance Excellent fuel & compression set resistance and high temperature stability. Rigid and hard plastics. seals, sealing membranes, electric connectors. O ring seals in fluids, lubricants & hydraulic systems, shaft seals, fuel injector orings,diaphragms Aircraft fuel systems o-rings, rubber seal for extreme temperature application

11 TYPES OF SYNTHETIC RUBBER Rubber Property Application Hydrogented Nitrile Rubber (HNBR) Hypalon (CSM) High heat resistance & excellent resistance to oxidized fuels Outstanding oxygen, ozone and weather resistance & excellent abrasion resistance Host of dynamic and static seals, hoses, and belts, industrial sealing for oil field exploration Automotive hoses, and floor tiles, coatings, gaskets, flexible tubes, diaphragms and lining for chemical processing equipment. Acrylic Rubber (ACM) Outstanding oil and heat resistance shaft seals, adhesives, beltings, gaskets and O-ring, hoses.

12 LIST OF RUBBER SPECIFICATION USED FOR AEROSPACE APPLICATIONS Rubber Nitrile Rubber Chloroprene Rubber Fluoro Carbon Rubber Silicone Rubber Fluorosilicone Rubber Styrene Butadiene Rubber Specification NFL A7/21A6, NFL B7, NFL A- 21B6/21A9, DTD560 GR C Q/P, DTD458A GR A GR 1, DTD560 GR B Q/P, DTD458A GR B GR 1, MIL-R-6855 CL.I GR60 NFL A-31B4/31B5/31B6/31B8,DTD 5514B GR60, MIL-R CL.II GR60 MSRR9450, MSRR9451,60C7,AMS7276 A, DTD5613 GR80,HM4920,64C8. NFL D5/50D6, NFL A-50D7, DTD5582A GR50, DTD5531 GR50, HM4922, HM4923 NFL B-61D6, MIL R 25988B CL.I GR60 MIL-R-6855 CL.III GR60

13 DRDO APPROVAL FOR FSE RUBBER - AE MIL-R B CLASS I GR60

14 DRDO APPROVAL FOR FSE RUBBER - AE MIL-R B CLASS I GR60

15 LIST OF APPROVED COMPOUNDS FOR AEROSPACE APPLICATIONS SL# COMPOUND REFERENCE BASE MATERIAL SPECIFICATION DETAILS APPROVAL REFERENCE APPLICATIONS 1 AE 4934 Nitrile Base Rubber HM 4934 Issue A Approved by CEMILAC (DRDO) TA AE 4934 Nitrile Base Rubber Lucas Standard Approved by CEMILAC (DRDO) TA 1483 Approved by CEMILAC (DRDO) PC NO. 3 AE 20A6 Nitrile Base Rubber NFL B-20A6 12/ AE 21A6 Nitrile Base Rubber NFL A-21A6 Approved by CEMILAC (DRDO) PC No.13/ Nitrile Base Rubber MIL-P-25732C Approved by CEMILAC (DRDO) AE-MIL-P-25732C PC.No.16/2014 Approved by CEMILAC (DRDO) PC- 6 AE 21B6 Nitrile Base Rubber NFL A-21B6 19/2014 Compatible with variety of lubricants & Hydraulic fluids from a temperature of -30 deg. C to +125 deg. C 7 EE 560 Gr. A Qly. R Nitrile Base Rubber DTD560 Gr. A Qly. R Approved by CEMILAC (DRDO) TA EE 560 Gr. B Qly. P Nitrile Base Rubber DTD560 Gr. B Qly. P Approved by CEMILAC (DRDO) TA Elastonitrile -01 Nitrile Base Rubber DTD560 Gr. C Qly. P Approved by CEMILAC (DRDO) TA EE 458A Gr.A Gr.I Nitrile Base Rubber DTD458 A Gr. A Gr. I Approved by CEMILAC (DRDO) TA Elastonitrile -02 Nitrile Base Rubber MIL-R-6855C Class I Gr. 60 Approved by CEMILAC (DRDO) TA EE 4885 Nitrile Base Rubber LUCAS Standard Approved by CEMILAC (DRDO) TA EE 4885 Nitrile Base Rubber NFL A-21A9 Approved by CEMILAC (DRDO) TA 1176 For making Gaskets, Sheets, Diaphragms, Bushes, Seals, Packings and other rubber parts which are resistant to aromatic fuels, ester base lubricating oils etc., Can be used in the temperature of -60 deg. C to +125 deg.c 14 EE 4885 Nitrile Base Rubber HM 4885 Issue 'C' 15 EE 4885 Nitrile Base Rubber MSRR EE 3826 Nitrile Base Rubber Russian Specn (TY & TS/IND/61/14/AML1) Approved by CEMILAC (DRDO) TA 1176 Approved by CEMILAC (DRDO) TA 1176 Approved by CEMILAC (DRDO) TA 1116

16 17 EE 21A7 Nitrile Base Rubber NFL A7 18 EE 20B9 Nitrile Base Rubber NFL B9 19 EE 24B7 Nitrile Base Rubber NFL B7 Approved by CEMILAC (DRDO) TA 1275 Approved by CEMILAC (DRDO) TA 1333 Approved by CEMILAC (DRDO) TA 1274 For making Gaskets, Sheets, Diaphragms, Bushes, Seals, Packings and other rubber parts which are resistant to aromatic fuels, ester base lubricating oils etc., Can be used in the temperature of -60 deg. C to +125 deg.c 20 AE 61D8 Fluoro Silicone Rubber NFL B-61D8 21 AE 61D6 Fluoro Silicone Rubber NFL B-61D6 RCMA (F&F)/314/145/PC Extn-08/2014 Dtd Approved by CEMILAC (DRDO) TA 1672 Can used in various Aeronautical applications like fuel systems, Hydraulic systems, Solvent resistance, Engine sealing applications used in the temperature range of -45 deg. C to +200 deg. C 22 AE MILR-25988B Class I Gr EE 61D6 Fluoro Silicone Base Rubber MIL-R-25988B Class I Gr. 60 Approved by CEMILAC (DRDO) TA 1665 Fluoro Silicone Base Rubber NFL B-61D6 Approved by CEMILAC (DRDO) TA 1170 EE-MIL-R Gr.60 Fluoro Silicone Base Rubber MIL-R-25988B Class I Gr. 60 Approved by CEMILAC (DRDO) TA 1276 To make rubber parts to use with Petroleum fuids, Hydraulic fluids, lubricants Diester lubricants, fuels, etc., Temperature rane -55 deg. C to +200 deg. C 25 AE 31B3 Polychloroprene (Neoprene) Rubber 26 AE 31B4 Polychloroprene (Neoprene) Rubber 27 AE 31B5 Polychloroprene (Neoprene) Rubber 28 AE 31B6 Polychloroprene (Neoprene) Rubber 29 AE 31B8 Polychloroprene (Neoprene) Rubber NFL A-31B3 NFL A-31B4 NFL A-31B5 NFL A-31B6 NFL A-31B8 RCMA (F&F)/314/145/PC Extn-09/2014 Dtd RCMA (F&F-FOL)/314/145/2013/PC Extn- 15/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 16/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 17/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 18/2014 Dtd Compatible with variety of lubricants & Hydraulic fluids from a temperature of -40 deg. C to +100 deg. C Compatible with variety of lubricants & Hydraulic fluids from a temperature of -40 deg. C to +100 deg. C

17 30 EE 31B4 31 EE 31B6 32 EE 31B5 33 EE EE Polychloroprene (Neoprene) Rubber NFL A-31B4 Polychloroprene (Neoprene) Rubber NFL A-31B6 Polychloroprene (Neoprene) Rubber NFL A-31B5 Polychloroprene (Neoprene) Rubber DIN Polychloroprene (Neoprene) Rubber DIN AE 4922 Silicone Base Rubber HM 4922 Issue 'C' 36 AE 4922 Silicone Base Rubber NFL D5 37 AE 4922 Silicone Base Rubber DTD 5531 Gr AE 4922 Silicone Base Rubber MSRR AE 4922 Silicone Base Rubber DTD5582A Gr AE 4923 Silicone Base Rubber NFL D6 41 AE 4923 Silicone Base Rubber BACE AE 4923 Silicone Base Rubber DTD5582A Gr AE 4923 Silicone Base Rubber DTD5531A Gr AE 4923 Silicone Base Rubber HM 4923 Issue 'B' 45 AE 5531 GR 70 Silicone Base Rubber DTD 5531 GR AE 50D7 Silicone Base Rubber NFL A-50D7 Approved by CEMILAC (DRDO) TA 1173 Approved by CEMILAC (DRDO) TA 1175 Approved by CEMILAC (DRDO) TA 1277 RCMA(F&F)/PC Extn-02/314 Dtd RCMA(F&F)/PC Extn-03/314 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 11/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 11/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 11/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 11/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 11/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 12/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 12/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 12/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 12/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 12/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 13/2014 Dtd RCMA (F&F-FOL)/314/145/PC Extn- 14/2014 Dtd To make rubber parts to use with Petroleum lubricants, Turbine Oil, Piston engine oil etc., This is having good ozone resistance. Can be used in various Aeronautical applications like fuel systems, Hydraulic systems, Solvent resistance, Engine sealing applications used in the temperature range of -15 C to +200 C For making components required for various aeronautical application including Aeroengines used in the temperature of -55 C to +250 C. This have excellent Ozone Resistance.

18 47 AE EMS Silicone Base Rubber EMS AE MSRR 9492 Silicone Base Rubber MSRR 9492 RCMA (F&F-FOL)/PC.No.14/2014 RCMA (F&F-FOL)/PC.No.15/2014 For making components required for various aeronautical application including Aeroengines used in the temperature of -55 deg. C to AE-AMS3195 Silicone Sponge Rubber AMS 3195 RCMA(F&F)/314/145/PC-27/2014 dt; For making components required for various aeronautical application including aeroengines used in the temperature of -75 C to +205 C 50 AE-ERP1078 Nitrile Base Rubber ERP 1078 RCMA(KPT)/PC/15003 DTD: For making Gaskets,sheets,Diaphragms,Bushes, Seals,Packing and other rubber parts which are resistant to aromatic fuels can be used in the temperature of -45 c to c 51 EE 4922 Silicone Base Rubber NFL D5 52 EE 4922 Silicone Base Rubber DTD 5531 Gr. 50 Approved by CEMILAC (DRDO) TA 1171 Approved by CEMILAC (DRDO) TA EE 4922 Silicone Base Rubber MSRR EE 4922 Silicone Base Rubber DTD5582A Gr EE 4922 Silicone Base Rubber HM 4922 Issue 'C' 56 EE 4923 Silicone Base Rubber NFL D6 57 EE 4923 Silicone Base Rubber BACE EE 4923 Silicone Base Rubber DTD5582A Gr. 60 Approved by CEMILAC (DRDO) TA 1171 Approved by CEMILAC (DRDO) TA 1171 Approved by CEMILAC (DRDO) TA 1171 Approved by CEMILAC (DRDO) TA 1167 Approved by CEMILAC (DRDO) TA 1167 Approved by CEMILAC (DRDO) TA 1167 For making components required for various aeronautical application including Aeroengines used in the temperature of -55 deg. C to +250 deg. C. This have excellent Ozone Resistance.

19 59 EE 4923 Silicone Base Rubber DTD5531A Gr EE 4923 Silicone Base Rubber HM 4923 Issue 'B' 61 EE 5531 Gr. 70 Silicone Base Rubber DTD5531 Gr EE 50D7 Silicone Base Rubber NFL A-50D7 Approved by CEMILAC (DRDO) TA 1167 Approved by CEMILAC (DRDO) TA 1167 Approved by CEMILAC (DRDO) TA 1168 Approved by CEMILAC (DRDO) TA 1441 For making components required for various aeronautical application including Aeroengines used in the temperature of -55 deg. C to +250 deg. C. This have excellent Ozone Resistance. 63 AE-3784 Ty.1 Gr. B PTFE Sheets BS 3784 Ty. 1 Gr. B RCMA (F&F)/314/145/2013/PC Extn-14 Dtd For making PTFE components for the purpose of dimensionally stable, heat resistant for Hydraulic & Pneumatic systems. 64 EE -Fluoroplast PTFE Sheet Fluoroplast Grade 'O' Gost CRE(N)/L-101/12/98/1191 dtd For fabrication of aircraft parts 65 AE 6564 PTFE Sheets BS 6564 Part 2:1991 Gr. A1 & A1E, Grade A & AE, Grade B RCMA (F&F-FOL)/PC No. 11/2012 For use in AL31FP series Engines. 66 AE 4920 Fluorocarbon Rubber HM 4920 Iss. A 67 AE 1698 Fluorocarbon Rubber TY AE-MIL-R-83248C CL1 TYI AE-MIL-R-83248C CL1 TYII AE-MIL-R-83248C CL2 TYI AE-MIL-R-83248C CL2 TYII Flurocarbon Rubber Compound Flurocarbon Rubber Compound FlurocarbonRubber Compound Flurocarbon Rubber Compound 72 AE 4921 Fluorocarbon Rubber HM 4921 Issue 'B' 73 AE 4921 Fluorocarbon Rubber NFL A-60C7 RCMA (F&F-FOL)/314/145/PC Extn-19 Dtd PC No. RCMA (KPT)/PC/12001 Dtd MIL-R-83248C CL1 TYI RCMA (F&F-FOL)/PC No. 02/2014 MIL-R-83248C CL1 TYII RCMA (F&F-FOL)/PC No. 03/2014 MIL-R-83248C CL2 TYI RCMA (F&F-FOL)/PC No. 04/2014 MIL-R-83248C CL2 TYII RCMA (F&F-FOL)/PC No. 05/2014 RCMA (F&F)/314/145/PC Extn-10/2014 Dtd RCMA (F&F)/314/145/PC Extn-10/2014 Dtd Can be used in variety of lubricants & Hydraulic fluids from a temperature of -40 deg. C to +100 deg. C For use in AL31FP series Engines. Can be used in various Aeronautical applications like fuel systems, Hydraulic systems, Solvent resistance, Engine sealing applications used in the temperature range of -55 C to C

20 74 AE 4921 Fluorocarbon Rubber MSRR 9450 RCMA (F&F)/314/145/PC Extn-10/2014 Dtd EE 4920 Fluoro Carbon (Viton) Rubber AMS 7276A Approved by CEMILAC (DRDO) TA EE 4920 Fluoro Carbon (Viton) Rubber AMS 7280C Approved by CEMILAC (DRDO) TA EE 4920 Fluoro Carbon (Viton) Rubber DTD 5543 Gr. E Approved by CEMILAC (DRDO) TA 1169 For making rubber parts Compatible withaeroengines, in contact with variety of lubricants & hydraulic fluids from a temperature of -20 deg. C to +260 deg. C 78 EE 4920 Fluoro Carbon (Viton) Rubber DTD 5612 Gr. 80 Approved by CEMILAC (DRDO) TA EE 4920 Fluoro Carbon (Viton) Rubber HM 4920 Issue 'A' Approved by CEMILAC (DRDO) TA EE 64C8 81 EE EE 4921 Fluoro Carbon (Viton) Rubber Fluoro Carbon (Viton) Rubber Fluoro Carbon (Viton) Rubber NFL C8 HM 4921 Issue 'B' NFL A-60C7 Approved by CEMILAC (DRDO) TA 1329 Approved by CEMILAC (DRDO) TA 1673 Approved by CEMILAC (DRDO) TA 1673 For making rubber parts Compatible with Aeroengines, in contact with variety of lubricants & hydraulic fluids from a temperature of -20 deg. C to +260 deg. C 83 EE EE-FKM-01 Fluoro Carbon (Viton) Rubber MSRR 9450 Approved by CEMILAC (DRDO) TA 1673 Fluoro Carbon (Viton) Rubber ERP-1305 & ERP-1287 Approved by CEMILAC (DRDO) TA EE 40B7 Butyl Rubber Compound NFL A-40B7 Approved by CEMILAC (DRDO) TA Elast SBR-01 Styrene Butadiene Rubber MIL-R-6855C Class III Gr. 60 Approved by CEMILAC (DRDO) TA EE R29 Sponge Rubber Sheet Sponge Rubber R29 TU , CMIII / SIII 88 EE 1847 Rubber Compound TU RCMA (N)/L- 100/02/98/1181 dtd RCMA (N)/L- 100/01/98/1180 dtd To make rubber sheets, 'O' Rings, Seals, Grommets, Chords, Beadings, Rubber Parts, etc., For the general use application, where resistance to oil & fuel and elemence are not required For sp ot vulcanization of flexible fuel tanks For fabricati on of aircraft parts like canopy seals etc.,

21 89 AE - PJ 01 Nitrile Rubber PJ 01 Approved by ELD HTCC / ASL 90 AE - PJ 02 Natural Rubber PJ 02 Approved by ELD HTCC / ASL 91 AE - PJ 03 Silicone Rubber PJ 03 Approved by ELD HTCC / ASL Neoprene + Nitrileblend Rubber 92 AE - PJ 04 PJ 04 Approved by ELD HTCC / ASL 93 AE - PJ 05 Fluoro Carbon Rubber PJ 05 Approved by ELD HTCC / ASL 94 AE - PJ 06 Nitrile Rubber PJ 06 Approved by ELD HTCC / ASL 95 AE - PJ 12 EPDM Sponge Rubber PJ 12 Approved by ELD HTCC / ASL 96 AE - PJ 13 Fluoro Silicone Rubber PJ 13 Approved by ELD HTCC / ASL 97 AE IND Nitrile Rubber 2025 IND Approved by ELD HTCC / ASL 98 AE 3012 IND Nitrile Rubber 3012 IND Approved by ELD HTCC / ASL 99 AE - AK 01 A Nitrile Rubber AK 01 A Approved by ELD HTCC / ASL 100 AE - AK 01 B Nitrile Rubber AK 01 B Approved by ELD HTCC / ASL 101 AE - AK 02 EPDM Rubber AK 02 Approved by ELD HTCC / ASL 102 AE - AK 04A Fluoro Carbon Rubber AK 04A 103 AE - AK 04B Fluoro Carbon Rubber AK 04B 104 AE - AK 04C Fluoro Carbon Rubber AK 04C Used in Missile & Defence applications 105 AE - AK 05 Natural Rubber AK 05

22 106 AE - Hella-N 38014/ AE - Hella-N 38014/ AE - Hella-N 38014/ AE - Hella-N 38014/ AE - Hella-N 38014/ AE - ABS 5846(EN 2259) Silicone Rubber Hella-N 38014/30-2 Silicone Rubber Hella-N 38014/40-2 Silicone Rubber Hella-N 38014/50-1 Silicone Rubber Hella-N 38014/50-2 Silicone Rubber Hella-N 38014/60-3 Silicone Rubber ABS 5846(EN 2259) Used in Civil Aircraft for Lightings,Interior & Cargo System. 112 AE - AMS 3325E Fluoro Silicone Rubber AMS 3325E 113 AE - AMS 3328B 114 AE - Hella-N 38014/40-6 Fluoro Silicone Rubber AMS 3328B Nitrile Rubber Hella-N 38014/ AE - PFLD - 24 FOAM Rubber PFLD -24

23 NON METALLIC COMPONENTS - COCKPIT (a) CANOPY SEAL Cockpit (a) canopy seals are used in aircraft & helicopters cockpit doors. They are used to maintain the inside cabin pressure and prevents the atmospheric air or pressure to enter inside the cabin.

24 NON- METALLIC COMPONENTS FIRE RESISTANT HOSES: Fire wall hoses are used in high temperature duct and engine areas for transfer of fluids. CONDUCTIVE BELLOWS Conductive Bellows conforming MIL-G allows the passage of current through bellows.

25 NON- METALLIC COMPONENTS The O-rings and seals are used in static applications and dynamic applications where there is relative motion between the parts. O Rings are manufactured in parting line based on 45 & 90 according to standards DIN,SAE,GOST,OST,MS etc.

26 NON- METALLIC COMPONENTS

27 NON- METALLIC COMPONENTS

28 NON- METALLIC COMPONENTS

29 HARNESS CLAMPS & ISOLATORS FIELDS OF APPLICATION: Used in all Aircraft & Helicopters for Electrical Circuit Lining purpose.(fluorosilicone, Nitrile, Neoprene) FIELD OF APPLICATION They are used in rockets to isolate an object from vibrations.

30 TOWARDS ACHIEVING

31

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