Amphibious Aircraft Manufacturing from Carbon Graphite (Manufacturing and Maintenance issues) Avana Industries Ltd. April 11th 2012 Dósa János

Transcription

1 Amphibious Aircraft Manufacturing from Carbon Graphite (Manufacturing and Maintenance issues)

2 Mission In 2008 Avana Industries Ltd was founded to concentrate on the production of tooling and limited production of parts for aerospace and ground transport. Our goal is to provide the best environment for composite part developments in Central and Eastern Europe.

3 Location On a 1 hectare site the company currently occupies 1500 sqm of manufacturing space, expandable on demand. In 2008 the company acquired over 11 hectares of space in Somogy county, about 100 miles southwest of Budapest close to Lake Balaton.

4 Budapest Location Our Budapest location is based on an ex-military airport with 2500m x 60m runway. 20 minutes drive from downtown.

5 Somogyvár Facility Our Somogyvár location is about 90 minutes drive from Budapest on highway.

6 Somogyvár Facility - Artwork

7 Major Customers Civil sector NABI - Steel and Composite Buses. Bombardier Rail (via subcontractor) Hirschler windscreen Diamond Aircraft Defense sector BAE Systems - UAV Augusta Westland (via subcontractor) BHE Bonn Hungary - UAV In many cases Avana is 2nd tier supplier.

8 Work references transport industry Composite Bus for LA

9 Work references Transport Industry Composite Bus for LA

10 Work references Transport Industry Intercity Bus ULEV Diesel based on MAN undercarriage

11 Work references Transport Industry Urban Bus ULEV Diesel based on MAN undercarriage Avana was involved with over 12 bus projects tooling and production.

12 Work references Rapid prototypes Detroit Car Show Lamborghini concept car Michelin Design Contest Medical Devices Rapid prototypes Stereolitography

13 Current Project Avana Larus turboprop amphibious aircraft

14 Current Project Avana Larus turboprop amphibious aircraft

15 Avana Larus initial project goals Spacious - modern design to fit current people Long range high speed High altitude pressurized cabin Amphibious design to be able to land anywhere Turboprop engine - jetfuel capable Modern avionics - glass cockpit All weather

16 Avana Larus preliminary specification 240 kts / 444 km/h speed 2400km range 1350 kg empty weight / 1350kg useful load Pressurized Cabin m 8000m cruising altitude Short take-off and landing capability Safe water operation. Saltwater operation Very low maintenance

17 Avana Larus Material selection E-glass - low cost, readily available, low stiffness, flutter issues Kevlar absorbs moisture, low compressive strength Carbon higher cost, high strength, good stiffness. Epoxy high strength, readily available, suitable for Pre-Preg, VARTM, hand layout Vinylester was not considered due to drawbacks

18 Prototype was made and tested in the air,

19 ...and on the water.

20 Problems started to happen Saltwater related corrosion was underestimated Galvanic corrosion was underestimated Some aluminium alloys dissolved in seawater in two-three weeks. Fastener and hardware selection had to be reconsidered. Carbon shatters sharp blades forms potential danger for crew. It was time to go back to the design sheets.

21 Back to the drawing board Carbon was reselected, switched from 3K to 12K on most structures Fastener was switched to titanium or stainless steel to avoid corrosion Magnesium alloys were discarded. This led to a situation that there were no off-the-shelf parts. All parts had to be reengineered.

22 Reengineering.

23 and reengineering.

24 and reengineering.

25 The building process started

26 And continued...

27 And got close to the finish...

28 The next challenge... Finish the test flying program until Start the EASA/FAA certification in the new production facility.

29 New facility opens in Composite Machining: CNC 5 axis milling 15m x 5m x 1.2m (45ft x 15 ft x 4 ft) CNC 5 axis milling 12m x 5,5m x 1.3m (36ft x 18ft x 4.3ft) CNC 8 axis milling machine 30m x 6m x 3m (90ft x 20ft x 11 ft) w / waterjet head The second machine is equipped with scanning instruments. Composite Processing: Autoclave 12m x 3,5m 20 bar 600KW Autoclave 6m x 2m Electric Machining. CNC Metal tooling aluminum and steel -1100x380x380mm- work area. Welding. MIG/TIG/AWI 3D waterjet and plasma cutter.

30 For more information on how Avana Industries can help you with your development, tooling, rapid prototyping or limited production requirements, please contact: Janos Dosa Avana Industries Kft H-8698 Somogyvar PO Box. 33 Tel: Fax: Thank you for your attention!