Empowering technologies

The production and application of composites is important today for a technological breakthrough in many industries. For the Russian economy, this is certainly one of the drivers of development, first of all for high-tech industries that produce products that are in demand on the world market.
7 september 2019

Since the middle of the last century, composites have become particularly popular in the aerospace industry and other high-tech industries. Today, the widespread use of composite materials based on carbon and fiberglass in the production of aircraft has become a global practice. In the aircraft industry is now actively replacing metal parts composite. Make composite elements of the fuselage, wings, center section, details of the tail, interior elements, etc. The effect — significant reduction of aircraft weight, reduction in the cost of its production. These competitive advantages for manufacturers, as well as the possibility of reducing operating costs of equipment by consumers, contribute to the increasing expansion of the scope of application of composites. It is now used in shipbuilding, automotive industry, rocket industry, gas and energy processing industry, machine tools, etc.

One of the first who started developing of production of polymer composite materials in the domestic aviation industry was "Voronezh Shareholder Aircraft-Building Society"  ("VASO"). Today, the company mastered the production of polymer composite products for the entire line of aircraft produced by. "VASO" and other Russian aircraft — Kazan Aircraft Production Association (“KAPO”), "Aviastar-SP" are made of composite materials mounted units: flaps, ailerons, interceptors, brake flaps, elevators and directions, various panels, hatches. AeroComposite Company, a member of the UAC, produced the so-called "black wing" of composite materials for the new medium-haul aircraft MS-21.

Despite the obvious demand for these innovative technologies, there are still very few engineering companies in Russia that can provide customers with their successful implementation. They include engineering-consulting company "Solver". The direction "Digital production of parts from composites" was first presented by the company in 2011 at the International aviation and space salon (MAX). By this point, Solver already had experience in promoting composite technology for various customers. The company has completed the work on the General contract in the interests of UAC and "VASO" for the supply of the first machine MAG Viper 1200 FPS for automated winding-laying out composites. At the exhibition "Metalworking-2012” the company "Solver" for the first time demonstrated a working prototype of modern manufacturing parts made of composite materials and plastics for the aerospace industry. The company's stand was deployed a comprehensive automated section: workplace design and technological preparation of production of composite parts based on FiberSim, Zund cutting machine for automatic cutting of the prepreg, laser projectors LAP and LPT for contour projection in the computation of the prepreg for tooling, industrial designs tooling for the manufacture of parts from composites in the aircraft industry, as well as auxiliary materials Airtech for temperature control of parts in the autoclave.

The degree of involvement of a state in aviation and space activities can be judged not only on the level of its socio-economic development, but also on the weight and position in the international arena. Aerospace industry reflects the general state of industry and economy. The competitiveness of the Russian aviation industry is largely determined by the use of innovative, competitive in price, quality and service life of materials. Components of aircraft made of composite materials are characterized by high strength, lightness, heat resistance, performance at high humidity, the ability to absorb radio emissions. Compared with traditional materials used in the creation of aircraft, composites have a number of advantages.

The main ones are lightness, high strength, wear resistance, stiffness, high temperature resistance, radio transparency (for fiberglass) and durability. In addition, composites have high resistance to corrosion. Moreover, these materials have a low percentage of thermal expansion — this is a very important quality in the manufacture of high-precision instruments, such as antennas for space communications. The use of composites also reduces the weight of various structures, resulting in, for example, reduced fuel consumption and increased maneuverability of machines. When creating products designed to save people in case of fire, composites with high heat and fire resistance are used. Some composite materials have properties that exceed in certain respects traditionally used materials: steel, aluminum and titanium alloys, wood and the higher the specific characteristics of the composite, the lighter or stronger the structure. The uniqueness of composites lies in the fact that it is possible to pre-design this material with specified physical and mechanical properties to give the final product the characteristics necessary for a particular application.

Production of components from composites is now part of a comprehensive offer of the company "Solver" domestic industry. The specialists of "Solver" have designed details of carbon fiber for aircraft Sukhoi Superjet 100, AN-148 etc. According to the details it was a complete technological preparation of production and implemented the process of automated production (with training and certification of personnel aviation companies). Today, the specialists of Solver are ready to take on the solution of a complex of tasks for the production of parts from composite materials: from the supply of automated systems for design and technological design and production to its own custom production of such parts at the established production base in Voronezh.