TABLE OF CONTENTS

1. SUMMARY 2. DESCRIPTION OF THE COMPANY 2.1Company Name 2.2Company Location 2.3 Shareholder of TAI 2.4Organization Chart 2.5 History of Company 2.6 Number and duties of engineers employed 2.7 Main Area of Business 2.8 Capabilities of TAI 2.8.1 Design and Engineering 2.8.1.1 Product Integrity 2.8.1.2 Flight Systems Design and Testing 2.8.1.3 Concurrent Engineering 2.8.1.4 Structural Design 2.8.1.5 Avionics and Electrical Systems 2.8.1.6 Manufacturing Engineering 2.8.1.7 Product Development Programs 2.8.1.8 Unmanned Aerial Vehicles and Satellite Programs 2.8.1.9 Structural Programs 2.8.1.10 Modernization Programs 2.8.2 Tool Design and Manufacturing 2.8.2.1 Tool Engineering 2.8.2.2 Tool Manufacturing Planning 2.8.2.3 Tool Manufacturing 2.8.3 Machining and NC Programming 2.8.3.1 Conventional, Manual and Semi Automatic Equipments 2.8.3.2 NC Programming 2.8.3.3 Sheet Metal and Tubing Competency Center 2.8.3.3.1 Sheet Metal and Extrusion Part Fabrication Shop 2.8.3.3.2 Tube Bending Shop 1 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

2.8.3.3.3 Welding Shop 2.8.3.4 Composite and Metal Bonding 2.8.3.4.1 Composite and Metal Bonding Facility 2.8.3.4.2 Manufacturing Activities 2.8.3.4.3 Material and Process Technology Laboratory 2.8.3.5 Electrical Assembly 2.8.3.6 Wire and Sleeve Preparation 2.8.3.6.1 Coaxial Cable and Harness Manufacturing 2.8.3.6.2 Harness Braiding 2.8.3.6.3 Panel Assembly 2.8.3.6.4 Harness and Panel Test 2.8.3.7 Maintenance, Repair and Overhaul 2.8.3.7.1 Turkish Military Maintenance Center C 2.8.3.8 Integrated Product Support 2.8.3.8.1 Aims of Integrated Product Support 2.8.3.8.2 Logistics Support Analysis 2.8.3.8.3 Customer Support 2.8.3.8.4 Technical Documentation 2.8.3.8.5 Integrated Logistics Support Management 2.8.3.8.6 Spare Part and Ground Support Equipment 2.8.3.9 Quality Systems 2.8.3.9.1 Process Control 2.8.3.10 Quality Assurance 3. INTRODUCTION 4. REPORT 4.1 CAMB Building 4.2 Composites General 4.2.1 Production Composite Material 4.2.2 Advantages of Composites 4.2.3 Disadvantages of Composites 4.3 Fiber Properties 4.4 Fabrics 4.5 Manufacturing Technology in TAI 2 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

4.6 Main Areas of the CAMB Facility 4.7 Machine Tools & Equipment Available in the TAI CAMB Facility 4.8 Some Definitions or explanations of composite terms
4.9 Composites by fibers- vacuum bag- autoclave

4.10 Manufacturing 4.11 Mechanical Test Laboratory 4.12 Mechanical Tests 5. CONCLUSION 6. APPENDIX

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1. SUMMARY
I spent 5 weeks in TAI to fulfill my summer practice and to improve and develop my materials science knowledge especially composite skills. Moreover I learned how projects are hold and followed by every instruction by technicians and engineers with their responsibilities. Every process has instruction sheets and technicians and engineers have to follow them step by step. Then I learned how tools are made and their importance materials and some specific properties. And I have chance of seeing computer programs and avionics systems are made and the importance of materials for aircrafts. I learned the work discipline in TAI and there are TVs that are showing the importance of work by color and every technician and engineers should follow these instructions on that TVs. In TAI I try to learn processes and engineering applications as much as possible and it was a beneficial summer practice for me.

2. DESCRIPTION OF THE COMPANY

2.1 Company Name
TAI ( TURKISH AEROSPACE INDUSTRY, INC.)

2.2 Company Location

ADRESS: Fethiye Mahallesi, Havaclk Bulvar No:17 TRKYE Tel : +90 312 811 1800 Fax: +90 312 811 1425 06980 Kazan-ANKARA /

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TAI Teknokent TAI AR-GE Binas ODT Teknokent, ANKARA Tel : +90 312 210 18 57-58 Fax: +90 312 210 18 57-58

TAI Free Zone stanbul AHL Serbest Blge b.Md.l Plaza Depo, No: 301 Marketing: marketing@tai.com.tr Procurement:procurement@tai.com.tr

2.3 Shareholder of TAI

TAI (TURKISH AEROSPACE IND. INC.)

Turkish Armed Forces Strengthening Foundation % 54.49 Under secretariat for Defense Industries % 45.44 Turkish Aeronautical Association Others % 0.0003 % 0.06

2.4 Organization Chart

In appendix, Figure 1 and 2, the organization charts can be found.

2.5 History of Company

TUSA Aerospace Industries, Inc. (TAI), the center of technology in design, development, manufacturing, integration of aerospace systems, modernization and after sales support in Turkey, was established on 15 May 1984. The Turkish Aircraft Industries, Inc. (TUSAS) and TUSAS Aerospace Industries, Inc. (TAI) merged under the roof of TAI on 28 April 2005. The shareholders of the Company are: Turkish Armed Forces Strengthening Foundation (TSKGV), under secretariat for Defense Industries (SSM) and Turkish Aeronautical Association (THK).

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The Company has a modern aircraft facility furnished with high technology machinery and equipment that provide extensive manufacturing capabilities ranging from parts manufacturing to aircraft assembly, flight tests and delivery. Quality system of the Company meets the stringent world standards including NATO AQAP-110, ISO9001:2000 and AS EN 9100.

TAI's vision is to attain the capabilities to design, manufacture and provide services for all kinds of aerospace vehicles, and thus become a globally recognized brand.

TAI's mission is to develop the technology and capability, as well as the design capacity, to meet both the military and commercial aerospace vehicle and space system requirements of Turkey and its foreign customers; to increase its share in the market subject to global competition through continuous improvements; and to create values for the benefit of the country, customers, shareholders, suppliers and employees.

Vision of TAI

In the 100th anniversary of the Republic of Turkey; TAI, by possessing indigenous/codesigned aircraft and satellites; seizing modern high technologies in modification, modernization and production, and attaining global competitive power, will become a world brand company with its devoted employees. Mission of TAI

With our great leader Atatrk's vision: "The Future is in the Skies" and our nation's eagerness to "Build its own aircraft"; TAI has dedicated itself to be in the skies and space and be pioneers in developing Turkey's aviation and space industry.

2.6 Number and duties of engineers employed

TAI has more than 3350 highly motivated employees And 1250 of whom are engineers and the number of personnel is increasing or decreasing related with the projects. And about; Engineer: Mechanical Engineer:

530 6

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Aeronautical Engineer: Industrial Engineer: Electrical Engineer: Metallurgical Engineer: Others:

425 90 95 45 65

Note: Uur Baydur (Training Chief) said that about 5% of the engineers are metallurgical and materials engineers and most of them are graduated from METU and they play a critical role and do crucial processes in TAI.

2.7 Main Area of Business

Fixed and Rotary Wing Aircraft Manufacturing Product Development Avionic systems Aerostructures Embedded software systems Modification, Modernization, Systems Integration and After Sales Support Maintenance, Repair and Overhaul Information Systems

2.8 Capabilities of TAI

TAI has expensive tools and machines and I observe that number of them increasing day by day. TAI has the capability of non-destructive testing methods which is related with my department and I have chance of seeing them. And the manufacturing capabilities are Aerostructure & Satellite Design & Development Integrated Helicopter Systems Design & Development Tool Design And Manufacturing NC Programming Metallic Parts Production 7 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

Composite Part Production Paint and Chemical Surface Treatments Electrical Harness Quality Inspections Quality Systems Maintenance, Repair And Overhaul

And I spend my most of my times in tool designing, aerostructures metallic parts production, composite parts production, quality inspections, quality systems, maintenance and repair of metallic parts and composites.

TAIs modern aircraft facilities, located in Aknc-Ankara, is furnished with high technology machinery and equipment that provide extensive manufacturing capabilities ranging from parts manufacturing to aircraft assembly, flight tests and delivery. Core Competencies: Design, Modernization, Production & Support of: Fixed and Rotary Wing Air Platforms Unmanned Aerial Vehicles Satellite 2.8.1 Design and Engineering The Design and Engineering Directorate realizes its activities with Structural Technologies, Avionics and Electrical Systems, Manufacturing Engineering, Product Development Programs, UAV and Satellite Programs, Structural Programs and Modernization Programs managements and Product Integrity, Flight System Design and Testing and Concurrent Engineering chieftaincies. 2.8.1.1 Product Integrity

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There are 4 main branches in Product Integrity which are engineering process assurance. Airworthiness and Certification, Reliability/Maintainability/Testability, Flight/System, Safety

2.8.1.2 Flight Systems Design and Testing Flight Sciences: The external geometry of an air platform is designed to meet the regulations and the requirements of the customer. Following the determination of the loads, flight performances and the flying qualities of the configuration, the database is formed using computational, emprical and experimental means. Wind tunnel and flight test needs are also determined and the test results are evaluated. Aircraft Systems: The design and analysis of all the systems except the avionics and electrical systems are realized. Mechanical systems such as flight control system and landing gears, fluidic systems such as environmental control, fuel, hydraulic and oxygen systems as well as aircraft ground equipment for both manned and unmanned aircraft are included in this context. Flight Operations: Necessary plans and procedures required for flight tests, which are the final phase of all modernization and indigenous design programs, are prepared in accordance with the standards and design. The results of the flight tests are reported. Ground handling and flight operations support is also given. 2.8.1.3 Concurrent Engineering Necessary infrastructure activities for the formation of design data in accordance with one target solution by different disciplines and people are performed. The department is responsible for developing and implementing tools for product design processes. 2.8.1.4 Structural Design Structural Design: The structural design alternatives are established in the early stages of design and updated throughout the design phase within a concurrent engineering environment taking into consideration the cost, material alternatives, manufacturability, maintainability, supportability and accessibility aspects. 9 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

Structural Analysis: Static, dynamic, aero elastic, fatigue and damage tolerance analyses are performed to demonstrate the compliance with design and certification requirements. Weight and Balance: Weight and Balance activities, required in all phases throughout the design phase up to final delivery of the aircraft. Material and Process: During the product design, in addition to performing material selection, characterization and determining material properties to be used in structural parts; process and test requirements of which the structural parts will be subjected to in the manufacturing process are also specified. Structural Tests: Coordination and Management of Static and Fatigue Verification and Certification Tests are realized for both metallic and composite components which are analyzed within the product design cycle. Material Review Board: Following the review and evaluation of all nonconforming material detected on raw material, detail part, subassembly, component or aircraft which are listed in the Quality Assurance Reports, engineering solutions are developed.

2.8.1.5 Avionics and Electrical Systems Avionics Tests: Research, analysis, design, development, integration, verification and management of laboratories and test setups, which are used for Avionics and Space Systems activities, are realized. Avionics Systems: Analysis, design, development, integration, tests and verification activities related to Avionics and Space Systems are performed. Avionics Software: Avionics and Space Systems Software analysis, design, coding, test and verification activities are performed according to flight safety standards. Electrical Systems: Analysis, design, development, integration, test and verification of electrical power generation, power distribution, signal distribution and lighting systems are carried out for Avionics and Space Systems.

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2.8.1.6 Manufacturing Engineering Manufacturing Engineering, which is responsible from the preparation of all technical data that forms the basis of a proposal during development process, is responsible from generation of assembly concept, analyzing manufacturing capabilities, determination of tooling requirements, creation of detail and assembly manufacturing work instructions, and maintaining per changes and requests coming from customer, coordination of design problems with design owner, determination of aircraft function tests in the design and production process of a product. Configuration Management: From the technical and administrative point of view; the Configuration Management, which identifies and documents the physical and functional characteristics of the product, controls the changes to the product, and defines the principles and methods of reporting and records the changes applied to the product. 2.8.1.7 Product Development Programs This is the management that is responsible for the Primary and Basic Trainer Aircraft (HRKU) and Light Commercial Helicopter products. 2.8.1.8 Unmanned Aerial Vehicles and Satellite Programs This is the management that is responsible for Unmanned Aerial Vehicles (tactical, medium altitude), Target Drones, and Reconnaissance/Observation Satellite products. 2.8.1.9 Structural Programs This is the management that is responsible for A400M fuselage, wing parts, lightingwater/waste systems as well as B787 parts and Airbus fuselage components. 2.8.1.10 Modernization Programs This is the management that is responsible for the modernization of helicopters, transport aircraft, Maritime Surveillance and Maritime Patrol aircraft as well as training aircraft. 2.8.2 Tool Design and Manufacturing

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Tool Design and Manufacturing Department, located in the Main Factory Building, is responsible for the design and manufacture of all tools required by the production units. Functions of this department can be grouped under three headings: 2.8.2.1 Tool Engineering Design and drawing of all the tools and equipments and required parts for fabrication and assembly are prepared in this unit. This section has all the necessary equipment and experienced manpower, to accomplish: design of jigs and fixtures, cutting, bending and drilling dies, fiberglass tools, 3, 4, 5 axis CNC and conventional milling dies; MSLO drawings; preparation of periodic inspection sheets; integration of tool designs furnished by the customer into production; preparation of PMMR kit documents and development and design of standard design systems. Tool Design Section is equipped with Computer Aided Design (CAD) systems, CATIA and unigraphics both to produce designs and to provide data flow in the computer media. 2.8.2.2 Tool Manufacturing Planning All preliminary activities aimed at preparing tools and fixtures for the assembly work before production is performed. Preparation of operation sheets for tool details and estimating processing schedules, control and ordering of tool materials; preparation of tool manufacturing documents and specifications; estimating man-hours for entire tools, workloads of shops and shop processing tool details are among the activities of this unit. 2.8.2.3 Tool Manufacturing Jig and Fixture Manufacturing: Includes all kinds of large or medium scale assembly tools. Assembly is conducted with 0.002 precision optics and laser equipment. Tool and Die Manufacturing: Includes all kinds of cutting, bending, drilling, milling, welding and manufacturing of small scale assembly tools. 0.0001 precision micrometers, 0.001 precision compasses, surface tables, blocks and sine tables are used in the manufacture of these dies and tools.

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Form Tool Manufacturing: Includes plastic or non-plastic surface forming draw dies manufactured by stretching and dropping (by drop hammer) methods. These are generally the outer surface part dies of the aircraft and can all be manufactured at TAI. Foundry: 6500-lb capacity, suitable for aluminum, lead and kirksite casting. Plaster Die Manufacturing: Includes manufacturing of outer or inner surface part and casting models by using plaster templates. Fiberglass Tool Manufacturing: Includes tools which are made of two-compound resins cured at room temperature at a specific time. These are generally the models made for intermediate transfers with routing and drilling tools of parts which have contours and that require models. Template Manufacturing: Manufacturing of all kinds of templates including plaster models. Composite Tool Manufacturing: Includes the manufacturing of all kinds of tools made of composite material in connection with the process requirements of composite and metal bonded parts manufacturing. The Company has the capability to manufacture tools with high heat-resistant resin via hand-impregnation method and with prepreg material. Form Block Manufacturing: Includes the manufacturing of tools which require contoured bending. Welding Shop: MIG, TIG and AC/DC ARC welding are performed at this shop where automatic wire-fed welding machines are available. Painting Operations: Identification of tool manufacturing color codes and painting of the tools are performed at this shop. Photographic Reproduction: Transfer of drawings can be made directly either on lightsensitive film coated aluminum or on Mylar. For this reproduction process, which facilitates tools manufacturing, CROWEX processor with 36 continuous-feed and lighting table in 48x144 dimensions are utilized. TAIs Tool Design and Manufacturing Department has the knowledge and experience for tool design and manufacture which is applicable to production in aerospace and other industries. 13 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

2.8.3 Machining and NC Programming Aircraft and helicopter structural detail parts, large-dimensioned and complex tooling parts, molds and dies are machined in the Machining Facility. Not only aluminum, steels and titanium, but also castings and forgings are machined at the facility. Our diverse machining and metal-cutting capabilities encompass CNC machining and turning centers, conventional and manual milling, drilling, grinding machines, and cutting and finishing and deburring machines. Cutter grinding/re-sharpening and tool preset shops support machining. 2.8.3.1 Conventional, Manual and Semi Automatic Equipments 5 Universal milling machines 4 Universal turning machines 6 Jig borers 1 Jig mill 1 EDM (electrical discharge machine) 1 Centerless grinder, 1 internal grinder, 1 universal grinder, 1 surface grinder 16 Various cutter, drill, reamer grinding and re-sharpening machines 1 Honing machine 2 Tool preset machine 1 Shrink fit machine 3 Vibratory finishing machine 1 Deburring machine PLC controlled 1 Plate saw 3600mmx1800mm travel 1 Skin milling machine 3600mmx1200mm travel 6 Vertical and horizontal band saws 3 circular cut-off saw 2 Shear -3600mm 1 Flame and plasma cutting machine 2.8.3.2 NC Programming Our experienced CNC programmers use PC workstation with "Unigraphics (16 license), Catia (4 license), Esprit (3 license) and Vericut (8 license) CAD/CAM systems to

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produce CNC machining instructions. The produced instructions are stored in secure central server and transmitted to the appropriate machine via DNC system at just the right time. 2.8.3.3 Sheet Metal and Tubing Competency Center There are three main activities in this facility, where 95 employees are working under the supervision of a chief and three process leaders. 2.8.3.3.1 Sheet Metal and Extrusion Part Fabrication Shops This shop, where aircraft detail parts are fabricated from aluminum, titanium or stainless steel sheets or extrusion material, is composed of four main cells: Flat Sheet Parts Manufacturing: Prior to forming processes, flat development part routing and deburring of aluminum sheets are performed here. Steel and titanium parts can also be cut by a CNC Punch Press. Forming: In addition to forming capabilities by means of sheet stretching, stretch drawing, roll forming, drop hammer forming and deep draw forming processes are performed. Lockheed Martin's assignment of TAI as the single source manufacturer of 92 items of F-16 parts under Chem-Mill Program proves that the workmanship quality of this shop conforms to worldwide standards. The Flex-forming (Fluid Cell) Presses, used in hydropress forming of medium size aircraft parts, are currently the highest pressurized hydraulic presses in Turkey. Extrusion Parts Manufacturing: Aircraft detail parts, which are made of L , Z or T section extrusion material, are formed by stretching, stretch drawing or roll forming. Joggling or other cold forming of extrusion parts are also accomplished here. In addition to these, routing to net sizes and drilling holes are also realized in this manufacturing cell. Routing and Finishing Sheet Metal Parts: Prior to paint, after being routed and/or drilled to net dimensions, the deburring of edges and surface of semi finished parts are performed at this area. A 5-axis CNC Skin Router with flexible tooling POGO system has also been in service since the second half of 2005. Burnishing and polishing are also performed on skin quality parts. 2.8.3.3.2 Tube Bending Shop

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In this shop, bending, swaging, flaring etc. of all kinds of tubing, in accordance with furnished drawings and sample, is accomplished. Precision bending of steel and aluminum tubing is performed on numerical controlled machines and three-dimensional forms are produced according to designs. High pressure leakage tests are also realized upon completion of tubes. In order to program 3D bending and control of parts after bending, a new Tube Data Measuring Center was also put in service. The shop is exceptional in terms of not only its machinery, but also technology and work performed. 2.8.3.3.3 Welding Shop The operations realized in this shop consist of two main phases: "Preparations for Welding" and "Welding." Here, mostly welding of aluminum, nickel alloy stainless steel and low alloy steel material is performed. In the shop, where Tungsten Inert Gas (TIG) welding method is used in fabrication of parts, the welding of high precision aircraft parts, under Argon gas, is also accomplished. Ability to make spot welding of various materials has been achieved in 2006. Furthermore, large size machined part surfaces can be conditioned (stress relieved and hardened) by a shot peening machine within international aeronautic standards. 2.8.3.4 Composite and Metal Bonding Composite and Metal Bonding (CAMB) Facility, covering an area of 10.500 square meters, started operating in 1994 to manufacture composite and metal bonding of CN-235 Light Transport Aircraft and of other products in future. Because of the increase in the workload, facility expansion activities were also started. With approximately 80 highly skilled personnel in the CAMB Facility, TAI is not only unique with its composite capabilities in Turkey, but it is also at the same level with foreign companies in this field. Quality Assurance System of the CAMB facility complies with AQAP-110, ISO-9001:2000 and AS EN 9100 standards. The activities implemented at the CAMB Facility are summarized as follows: 2.8.3.4.1 Composite and Metal Bonding Facility

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Composite manufacturing methods implemented at TAI comprise autoclave moulding, vacuum moulding and wet lay-up. To ensure the required quality in autoclave moulding, which is a main process in CAMB, the composite raw materials (prepregs, film adhesives, fillers, etc.) are laid-up in the Clean Room, where temperature, humidity and dust particles are continuously controlled in a class 100.000 environment per FED-SPEC.209. The prepregs are cut in CNC ply cutting machine and laid-up to the moulds under vacuum bagging and manufactured parts are cured in autoclaves and/or oven. Water jet machine and solid carbide or diamond coated routers are used in trimming of the cured parts. In addition, for sandwich parts, various types of metallic and non-metallic honeycomb cores are cut and milled by Core Milling Machine. After cleaning, they are sent to Clean Room for lay-up. All laminate and sandwich parts are passed through automated or manual ultrasonic and/or Xray inspection. In Metal Bonding, following the surface preparation of the aluminum details (phosphoric/chromic acid anodizing/FPLH processes), non-corrosive primer is applied and the materials are sent to Clean Room for lay-up cycle, which is similar to composite manufacturing.

2.8.3.4.2 Manufacturing Activities All the composite and metal bonding parts of CN-235: control surfaces, wing and tail tips, doors, leading edges, fairings, fins, window panels of the passenger cabin, ceiling and floor panels, tail cone, engine cowling parts, landing gear doors and various large and small parts were manufactured. Air intake, all floor panels, engine cowling parts, sliding cowling parts, cargo doors, blisters of Cougar AS-532 helicopters have also been completed; the engine cowling parts and rear doors of Eurocopter EC-135 helicopters; the horizontal stabilizers of Sikorsky S-76, S70 and CH60 helicopters, all the composite parts of main fuselage of MD-902 helicopters, various aircraft parts for Airbus and Boeing are being manufactured.

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The flaperons of F-16 aircraft, consisting of aluminum skin and honeycomb (sandwich structure), were manufactured by metal bonding technique. All types of repairs of damaged composite parts for various kinds of aircraft and helicopters are also accomplished in the CAMB facility. In the A400M Aileron and Spoiler Program, in addition to detail parts manufacturing, the assembly operations of composite parts are also performed at CAMB Facilities. 2.8.3.4.3 Material and Process Technology Laboratory Composite technology is a continuously developing technology which requires materials and processes to be well known. Developing and staying abreast of technology is vital to success in this field. In the Material and Process Laboratory, established for this purpose, physicochemical test equipment, mechanical test devices that are used in all kinds of static and dynamic tests at low and high temperatures, freezer, vacuum oven, NC specimen cutting machine, climatic chamber, microscope, and a sampling and prototype preparation clean room of 100.000 classifications are available. 2.8.3.5 Electrical Assembly The Electrical Assembly Shop, reporting to the Assembly Management, under the Directorate of Production, was established in 1987 on an area of 1,500 square meters under roof. Let alone an air conditioning system that enables air circulation for six times an hour, the shop also has a lighting system that enables a 100 ft/candle of brightness. The employees of the shop are certified on subjects such as Crimping Electrical Terminals, Hot Air Soldering and Hand Soldering. Complying with ISO-9001:2000, AQAP 110, AQAP 120, D6-82479 and AS-9100A quality standards, the shop has the capability to manufacture the electrical harness and panels for all military and commercial types of both fixed and rotary wing aircraft. Existing and completed projects are: The Electrical Assembly Shop consists of the following sections:

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F-16 Fighting Falcon, SF-260D Primary Trainers, CN-235 Light Transport Aircraft, Cougar AS-532 Helicopters, B737 aircraft Flight Deck Panels, Wing Tips, Wing Let and Strobe Light harnesses NATO Airborne Early Warning & Control (AEW&C) aircraft E54 and E56 cabinet harnesses, wire mod. Kits Turkish Airborne Early Warning & Control (AEW&C) aircraft wire mod. kits and some panels Meltem II modification program harness and panels, Yarasa II modification program harnesses Sikorsky CH60 harnesses, A400M all fuselage and FTI harnesses 2.8.3.6. Wire and Sleeve Preparation After being cut and marked, the wires and sleeves are prepared for assembly. The wire and sleeve cutting and marking is realized by the following equipment: Laser Wire Marking Machine (ULYS 220): The NdYAG type, computer controlled laser marking machine can mark wires between 6-26 AWG in 6-40000 inch length up to 40 meters per minute speed. Eubanks Autotab Wire Marking System (Model 77600): The computer controlled, hot stamp wire marking machine can mark wires between 6-26 AWG. Raychem TMS System 90 Printing Equipment: With this system, marking is performed on stickers or shrinkable sleeves via the help of a printer. Tyco Thermal Transfer (Series T400) Printers: With these printers, marking is performed on labels and wire marker sleeves.

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2.8.3.6.1 Coaxial Cable and Harness Manufacturing Coaxial and tri-axial cables and harnesses are manufactured with visual aids and engineering documents by electrical assemblers that are certified for crimping, hot air-soldering and handsoldering operations. 2.8.3.6.2 Harness Braiding A nomex or metal thread is braided over harnesses to protect them against chafing or electrical interference in an anechoic chamber. Three kinds of braiding machines with 24, 32 and 48 carriers (New England Butt and Spiraltex machines) are used for this operation. 2.8.3.6.3 Panel Assembly Cables and some components such as relays, lamps, circuit breakers and diodes are installed and terminated into the metal chassis assemblies using crimping and soldering methods. 2.8.3.6.4 Harness and Panel Test The testing operation is performed to find the faults on the harnesses and panels with three kinds of computer controlled testers. Two of the testers have 2000, whereas the other has 1000 test points. All conductors are checked for continuity endpoint to endpoint, and dielectric tests are performed to find the leakages. 35 Mohm and 500 VDC dielectric test is performed for coaxial, tri-axial and multiplex wires. Furthermore, functional tests are performed for the panels to check components such as relays, lights, switches etc.

2.8.3.7 Maintenance, Repair and Overhaul TAI offers the Maintenance, Repair and Overhaul (MRO) capabilities of the Turkish Armed Forces (TAF) to the world market. These capabilities constitute maintenance, repair, and overhaul calibration of air platforms, engines, miscellaneous aircraft systems, units and ground support systems. Additionally, structural repairs, structural upgrades and wiring harness revisions are also realized by TAI within the capacity of TAF. Under MRO activities, in which three MRO contracts for C-130 aircraft were successfully accomplished and overhaul of several S-70 Blackhawk components were completed, the engine revision activities of J-85 and J-69 are ongoing.

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During the utilization of the capabilities of 5th Main Maintenance Center (MMC) and Air Force Supply and Maintenance Centers (ASMC) of the Turkish Armed Forces, TAIs prime responsibilities such as:

Program Management Material Procurement Support Quality Assurance Support will assure; Responsive Approach Lower Administrative Costs Industrial Benefit or Offset Crediting Opportunities for the Customer. o Marketing o Proposal Preparation o Contract/Program Management o Material Acquisition o Transport/Customs/Insurance o Subcontract Management

2.8.3.7.1 Turkish Military Maintenance Center Capabilities Presented to Global Market by TAI

Fighter Aircraft Depot Level Maintenance Helicopter Depot Level Maintenance Military Transport/Training Aircraft Depot Level Maintenance
o o o o o o o o o o o o

Non-Destructive Inspection Paint Stripping/Painting Metal Parts Manufacturing (Airframe, Engine) Composite Parts Manufacturing/Repair Hydraulic, Pneumatic and Mechanical Systems Maintenance/Testing Avionics Maintenance/Testing Structural Repair Canopy/Windshield Overhaul Harness Manufacturing/Testing Gun Maintenance External Fuel Tank Manufacturing/Maintenance Fuel Pressurization Testing 21

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Aircraft Engine Depot Level Maintenance

o o o o o o o o o o o o o o

Turbofan Engines Turbojet Engines Turboprop Engines Turbo shaft Engines Piston (Reciprocating) Engines Gas Turbine Compressors and Starters Measurement Non-Destructive Inspection Cleaning/Stripping Conventional Repairs High Technology Repairs Painting Balancing Functional Test

Accessory Depot Level Maintenance

o o o o o

Hydraulic and Servo System Elements Electrical Power System Elements Oil/Fuel System Elements Brakes and Landing Gears Pneumatic System Elements

Avionics Depot Level Maintenance

o o o o o o

Flight Control System Elements Fire Control System Elements Navigation/Communication System Elements Engine Electronic System Elements Optical System Elements Printed Circuit Boards

Precision Measurement Equipment Calibration Ground Support Systems Manufacturing/Depot Level Maintenance Propeller Maintenance and Repair Radome Test Facilities Conventional and CNC Machining Parachute Manufacturing 22

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Aircraft Drag Chute Manufacturing Ballistic Vests Troop and Pilot Helmets Aircraft Modernization
o o o o o o

Systems Integration Laboratory Flight Test and Measurement Structural Analysis Operational Software Electrical/Structural Design Harness Manufacturing Test

2.8.3.8 Integrated Product Support Integrated Product Support Management, which was established in 1999 under the Programs Directorate, provides support to air platforms like F-16, CN-235, AS-532 Cougar, Peace Eagle AEW&C, A400M, MELTEM II, YARASA and Unmanned Aerial Vehicles (UAV) manufactured or being manufactured by TAI. Since the life cycle of air platforms are generally long (average 30 years) and operating & support costs for this period are equal to almost twice of the research & development plus procurement/production costs, after sales support for aerospace industry is extremely important. With the reasons stated above, integrated management of technical and logistic disciplines regarding the planning, development and provision of the support resources, needed for customer requirements, in a cost effective manner is a must. 2.8.3.8.1 Aims of Integrated Product Support

To bring the systems design properties and planned logistics resources to a state that would support the systems operational and utility requirements,

To define the support resources like supply support, support equipment, technical publication, training and training equipment, facilities, manpower and personnel, PHS&T

Provision of the required support resources in a cost effective manner.

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In order to perform Integrated Product Support activities, there is a need for an integrated process called the Logistics Support Analysis (LSA) which uses a standardized single data base. 2.8.3.8.2 Logistics Support Analysis Considering MIL-STD-1388-1A main tasks defined below, the Logistics Support Analysis can be applied to programs within the scope of Customer and Contractor agreed main tasks. In the cases, where defining supportability parameters are realized without performing Logistics Support Analysis, these parameters can be reached more economically depending on the requirements of the program by using Maintenance Allocation Charts (MAC). 2.8.3.8.3 Customer Support Within the scope of Customer Support activities, Integrated Product Support Management acts as focal point for the follow-up of the end item, spares and support equipment for the warranty period, and provides support during the period defined in the contract. In addition to this, taking action to all of the customer requests, collection and review of operation data within and out of warranty period is under the responsibility of the Management. Besides planning and coordination of trainings for pilot and maintenance personnel of the customer as defined in the contracts, management of technical representatives located in bases for long periods in the fields of mechanics, avionics/electronics are among the responsibilities of Customer Support Activities. 2.8.3.8.4 Technical Documentation Technical Documentation of air platforms that will be delivered to the customer are prepared by using the Logistics Support Analysis Records, results of Maintenance Task Analysis, and other Design/Procurement/Sub-contracts vendor documents. Depending on the program and Customer requirements, Technical Documentation of air platforms, not less than the ones listed below, that will be delivered to Customer are prepared by the Integrated Product Support Management;

Operations Manual 24

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Maintenance Manual Illustrated Parts Catalogue Fault Isolation Manual Flight Manual Weight and Balance Manual Pilots Manual/Pilots Check List Wiring Diagrams System Schematics

Moreover, customer requests regarding technical documentation are reviewed and necessary activities/updates are realized. For the time being, the software that are necessary for the preparation of technical publications are as follows: Peace Eagle Program: For the Maintenance Manual, design source data/LSA is converted into SGML format and Arbortext Epic software is used. For the Illustrated Parts Catalogue CATIA, Corel Draw 12 together with Linkone is used and Xyvision Content@ is used for the publishing system. Meltem II Program: THALOG/BALAD software and ILS Maintenance Manual Preparation software developed by TAI are used. Yarasa Program: For the text MS Word and for the drawings UG and Corel Draw 12 are used. Depending on the program requirements, Technical Publications can be developed in ATA iSpec2200 and ATA 100 formats. 2.8.3.8.5 Integrated Logistics Support Management During TAI proposal preparation activities before the contracts signature, not only customer ILS requirements are reviewed but pricing data is supplied together with manpower and other requirements as well. Additionally contracts negotiations with customer and vendors for ILS activities are carried on.

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Following the affectivity of the contracts, ILS Program Plan is prepared and submitted to customer for his approval. The preparation of ILS schedules of the effective programs, as well as program management of Logistics activities per ILS schedule is performed. 2.8.3.8.6 Spare Part and Ground Support Equipment With the use of Maintenance Task Analysis outputs, depth and range of spare parts and ground support equipment pertinent to the related air platform are determined. Standardization is the main goal in this analysis. Integration, test and evaluation activities to provide compatibility between main elements of system and support elements (material, software, personnel, and procedures) are also realized. Packaging, handling, storage and transportation activities for the spare parts and ground support equipment are planned for the life cycle of the system. Spare parts and ground support equipment are delivered to customer within the contract schedule. 2.8.3.9 Quality Systems TAI Calibration Laboratory occupies an indoor area of 1,000 square meters, which is preserved by means of continuous temperature and humidity, dust, vibration controls, etc., conforming to International Metrology Norms. The periodic calibration of over 6.000 Test and Measurement Equipment that are used at TAI is performed here with more than 400 advanced technology calibration standards and accessories. In addition, calibration services are provided for about 120 companies throughout the country. Dimension Calibration: All kinds of instruments that measure length, angle, flatness, straightness and squareness are present. Caliper, micrometer, dial indicator, height gage, gage block, ring gage, plug gage, V-block, steel rule, tape rule, precision pin, precision ball, 3-wire set, precision square, protractor, sine plate, cylindrical square, granite square, precision level, Coordinate Measuring Machine, CNC machine, durometer, coating thickness instrument and foils, hardness tester and blocks, granite and cast-iron surface plate are among the parameters that are calibrated in the dimensional area.

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Pressure Calibration: All kinds of gas or oil manometer, barometer, differential pressure gage, pressure sensor, altimeter etc. The oxygen cleaning system is used for oxygen gages.

Gas Flow Calibration: The rotameter or flow sensor is used for measuring air, nitrogen or oxygen flow.

Torque Calibration: All kinds of torque wrench, torquemeter, torque screwdriver, torque gun and torque tester are calibrated.

Optic Calibration: All kinds of theodolite, collimator, telescope, jig transit, tilting level, optic scale and optical wedge are calibrated.

Temperature Calibration: All kinds of thermometer, temperature bath, RTD sensor, thermistor, temperature calibrator, controller, recorder or indicator and sensor on the heat treatment furnace, autoclave, refrigerator, deep freezer, chemical bath are calibrated. Additionally, the temperature uniformity survey in the process volume is controlled using Data-Logging instrument.

Mass - Force Calibration: Precision electronic scale, force gage, cable tensiometer, load sensors, tensile testing machine etc. are calibrated.

Stripper-Crimper Calibration: All kinds of stripper and crimper are controlled using precision go-no gages. Cable-terminal connections are also checked for load and voltage drop tests.

Voltage-Current-Resistance Calibration: All kinds of AC, DC voltage and current instrument, digital and analog multimeter, ohmmeter, galvanometer, DC power supply, current supply, decade box, resistance, capacitor, inductance instrument are calibrated.

Phase Angle Calibration: Phase Angle Voltmeter and similar instruments are calibrated.

Oscilloscope Calibration: Using the related standard instruments, all kinds of oscilloscope are calibrated.

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Frequency-Time and RF Signal Calibration: Frequency counter, frequency generator, pulse generator, signal generator, attenuator, receiver, chronometer, timer and distortion analyzer are calibrated.

Microwave Calibration: Microwave counter, directional bridge, coupler filters, attenuators, modulators etc. are calibrated.

Vibration Transducer Calibration: Accelerometers and velocity meters are calibrated up to 10 KHz. 2.8.3.9.1 Process Control

TAI Process Control Laboratory occupies an indoor area of 1,000 square meters. In the laboratory, processes and production are controlled through chemical, metallurgical and mechanical tests, using approximately 100 items of equipment. The capabilities of the Process Control Laboratory are: Mechanical Tests: Tensile and compression tests and hardness measurement are performed for strength control.

Solution Analysis: The solutions of the chemical dip tanks, where surface treatment is accomplished, are kept constant in terms of chemical concentration through analysis.

Contamination Tests: Aircraft fuel and hydraulic oil are tested for particle contamination and impurity.

Corrosion Tests: The effectiveness of surface treatment processes is ensured by accelerated corrosion tests in salt fog and high humidity conditions.

Optic Tests: Optic inspections are performed to determine structures of materials at micro and macro levels.

Liquid Penetrant Test Systems: Used for the determination of cracks which occur during machining, forming or welding operations.

X-Ray Inspections: X-Ray inspection is applied to Foreign Object Damage (FOD) and void controls, composite parts and some welded parts. 28

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Chemical and Composite Material Tests: Non-metallic materials, such as paint, sealant, prepreg, film adhesive, solvent, lubricant, compound, acid etc. are tested for receiving and shelf life extension inspection purposes. 2.8.3.10 Quality Assurance Quality Inspection functions from fabrication of detail

parts, aircraft harness, subassembly/assembly parts and components to aircraft delivery are carried out systematically and effectively by Quality Inspections Management.

Tool Verification/Proof Load: Proof loading of manufactured tools is realized to determine whether the produced end items conform to engineering requirements or to ensure detected deficiencies are corrected and product quality is guaranteed from the beginning.

Portable Coordinate Measurement Machines (CMMs) and Laser Tracker Systems: These equipment are used for the verification of detail part, assembly and tools. All detail parts, assemblies, tool details and tool assemblies can be verified by the combination of both systems.

Interchangeable / Replaceable Parts Inspection (I-R): I-R parts such as; doors, covers, control surfaces, which need to be changed with each other without any problem, are tested when they are first produced. Later, these parts are periodically tested on various aircraft for verification of I-R requirement. In case of nonconformance, installation of these parts on aircraft is prevented and necessary corrective actions are initiated.

Part, Component and Aircraft Inspections: Required visual, dimensional and non destructive inspections such as fluorescent penetrant, eddy current and tap inspection, are performed in all stages of the production and modification activities in order to ensure product quality.

Harness Board Inspections: Harness boards used in electrical harness fabrication are controlled at the manufacturing stage, ensuring that all engineering and production requirements are met.

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Pre-Flight/Post-Flight Inspection: Pre-Flight inspection of aircraft released for flight and post-flight inspection of aircraft that have completed their flights are conducted and detected deficiencies are corrected.

Acceptance Inspection: Due to various reasons such as maintenance, repair and modification, the condition of the aircraft, received at TAIs facilities, is determined by acceptance inspection and correction of deficiencies is performed in coordination with the customer.

Final Inspection of the Completed Aircraft: Final inspection is performed on aircraft which have completed test flights and are ready for delivery, to ensure defectfree delivery to the customer.

Time Compliance Parts: Follow-up, control or replacement of time-compliance parts on aircraft are performed to ensure flight safety.

Special Inspections: Special inspections of aircraft such as bore sight adjustment, weight and balance measurement, fuel operations, symmetry control, compass swing, engine run inspection, control of fuel and oxygen before loading, One-Time Inspection (OTI) and Foreign Object Damage (FOD) Control are performed.

Composite Part Inspections: Dimensional and non destructive control of composite and metal bonding parts are realized.

Ultrasonic Inspections: These inspections are performed to control delamination, debond, foreign material, void and bonding effectiveness especially in composite manufacturing parts. The Automated Ultrasonic Squirter System of 12 m inspection length is used.

Liquid Penetrant Test Systems: Used for the determination of open surface cracks on metal parts which occur during machining, forming or welding operations.

Eddy Current Inspection: Used for not only the determination of open and under surface cracks around fastener holes of aircraft parts, but also the measurement of coating thickness and conductivity of the parts.

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Magnetic Particle Test Systems: Used for the determination of open and under surface cracks of ferromagnetic parts which occur during machining, forming or welding operations.

Photogrammetry System: A new optical measurement technology is used in the dimensional inspection of components and aircraft.

Dimensional Inspection Systems: Most of the detail parts are verified by using Coordinate Measurement Machines (CMM). Parts with a larger size than CMM capabilities are verified by the combination of Portable CMM and Laser Tracker Systems.

3. INTRODUCTION
It is important that summer practice is an important chance for students to combine their theoretical knowledge with the practical one. I learned the importance of materials and the properties of them which are mainly density, cost, toughness, and its using time. Management and work discipline was another thing that I learn in TAI and every project should be done in importance order and finally this summer practice will play an important role in my career.

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4. REPORT
4.1CAMB Building
During my summer practice I spend my most of time in CAMB building in TAI since it is the most related area to my department. And I reinforced my theoretical knowledge with practical one.

The idea of having CAMB facility at TAI started with the introduction of CASA CN235 Light Transport Aircraft Project. By entering into CAMB investment, TAI made a decision for the improvement of its technological capacity and capability in aerospace industry.

4.2 Composites - General

As in the world, in TAI as possible as composites are used. As plastics thermosets are preferred and the most important thing is that high strength to weight ratio

4.2.1Production Composite Material

Unlike metals, whose properties can be known independent of the structures in which they are used, composite properties are to a significant extent determined as they are manufactured into a structure. the ratio of fiber and resin, orientations of fibers the ply schedule, the selected fabrication process parameters all have their effect on the ultimate performance, which cannot be known until the part is cured and subsequently tested. Historically, this fact has made the process of qualifying a composite material system for use on aircraft much more time consuming, difficult and expensive than qualifying metals. Each aircraft manufacturer had to conduct its own qualification process. Even if a new composite material was identical to one already approved for use on an aircraft built by another company, the fabrication techniques and testing processes used for the previous aircraft application were unknown and, therefore, 32 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

could not be duplicated. The company was required to develop its own procedures for structural testing, manufacturing control and repair- a process that could consume up to five years and cost millions of dollars. And TAI had taken the project of Boeing 787 dream liners elevator.

4.2.2Advantages of Composites
o Produced as it can be complex o High resistance to corrosion o Using less detail parts o High strength, toughness and pressure values can be calculated as desired o High strength to weight ratio o Excellent chemical resistance against acids, chemicals etc. o Excellent weather/water resistance. Material has almost no corrosion, takes on little water which leads to low maintenance cost especially on the long run. o Composites have excellent RAM features (Radar absorbing materials). It's also possible to make special laminates which are radar and sonar transparent. o Excellent impact habits o Excellent electrical habits, concerning isolation but also conduction, dielectric habits, EMS shielding etc. Structures can be tailored on RF transparency but can also be made RF reflecting. Great for telecom especially UMTS frequencies. o Great thermal isolation habits, and high temperature performance.

4.2.3Disadvantages of Composites
Expensive There is no standard quality of the composites and it depends on the workers ability. It is difficult to repair them Composites have short time life material properties diminish quickly as angles of fibres increases 33 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

Therefore, careful analysis must be performed to confirm component has sufficient strength in all directions

4.3 Fiber Properties

Please look at Figure 3

As it can be seen in the graph, Carbon fibers have less elongation due to stress and they are used for more critical projects (F-35) but they are much more expensive than Aramid and Eglass.

4.4 Fabrics
A fencing material made from wire helically wound and interwoven in such a manner as to provide a continuous mesh without knots or ties except in the form of knuckling or of twisting the ends of wires to form the selvage of the fabric.

Please have look at Figure 4.

4.5 Manufacturing Technology in TAI

Hand Lay-up/Contact molding: The successive plies of reinforcing material or resin impregnated reinforcement are placed and worked on/in a mold by hand. Cure takes place at room temperature by applying a catalyst-promoter or heat in oven. Vacuum-Bag Molding: The sheet of flexible transparent material is placed over the lay-up on the mold and sealed. Autoclave-Bag Molding: Bagged lay-up is placed in autoclave and both pressure and heat are applied to cure the resin-impregnated materials

One of the most important subsystems in an autoclave is the part vacuum supply. Vacuum is applied to the parts during curing in order to provide vacuum for removal of volatiles and for compaction of laminates. Structural Bonding: 34 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

Bonded structure is a composition that uses a structural adhesive as the primary means of attachment, or assembly, without having with honeycomb core.

The following bonding processes are applied successfully in this facility: Metal to metal (in air cure and in autoclave), Metal to honeycomb core (Sandwich Structure), Composite to honeycomb core (Sandwich Structure), Composite to Composite Laminates, Composite to Metal Bonding.

4.6 Main Areas of the CAMB Facility

In CAMB building, everything should be proper, and there are some obligatory rules. The temperature, humidity & dust are controlled at 21 3 C , 45 10 %R.H. And 10 micron maximum, respectively. And the main areas are; Process Line (Cleaning & Anodizing) and Priming Area: After cleaning & anodizing, aluminum sheets are primed in the priming area by having a water curtain and filtered down draft airflow Prefit Area: In this area, the metal parts to be bonded are subjected to the prefiting, operation prior to the conditioning or preparation of the surfaces. Curing Area: The area has an autoclave with auxiliary utilities and a cure oven. A certain amount of land is reserved to be able to install a second autoclave. Demolding Area: The area is furnished with all auxiliary tools to demold the already cured parts taken out of the autoclave and/or cure oven. The application of mold releasing agent to the tools to be sent back to clean room is carried out to this area. Routing & Trimming Area: Routing & Trimming operations of the composite and metal bonding parts are done in this area. Core Machining Area: First cut and finish operations of metallic and non-metallic cores are performed in this area Core Cleaning Room: The cleaning operations for non-metallic cores are made in this core cleaning room by applying filtered air before lay-up operation. An air blowing and

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sucking system is used in this area for holding the particles in the ambient air during honeycomb cleaning operations. Assembly: Some detail parts are assembled in this area after curing operations. Miscellaneous cutting and fastening elements are used depending on the type of the assembly work. Non-Destructive Inspection Area: available for non-destructive testing and dimensional measurement of composite and bonding parts. Also some destructive tests are applied in the separate Process Control Lab. by Quality Control Department.

4.7 Machine Tools and Equipment Available in the TAI CAMB Facility
The main equipments and machine tools available in the TAI and CAMB building are namely autoclave, cure oven, CNC ply cutter, and core milling machine, abrasive water jet cutting machine, freezer and refrigerator. Autoclave: Curing is closely controlled in a temperature, pressure and vacuum cycle adapted to the type of material. Cure Oven: It is utilized to perform curing of some of the parts, which do not require autoclave curing CNC Ply Cutter: It is used to cut brood goods plies of Kevlar / Epoxy, Graphite / Epoxy and Fiberglass / Epoxy composite materials into the engineered shapes for composite parts Core Milling Machine: The core milling machine is intended for milling close tolerance parts from aluminum, nomex and fiberglass core materials. Freezer: The freezer is used to store materials like prepregs and adhesives which require certain storage conditions (-180C). Refrigerator: The temperature of the refrigerator is kept at + 4 C

4.8 Some Definitions or explanations of composite terms

Fabric: They are glass fibers, carbon and aramid became a bunch. A Fabric ply is different weave styles. Prepregs: Fabrics are made like textiles. Then they homogenously absorbed with resin then they became prepreg. 36 St. No:1630391 METE 300 SUMMER PRACTICE REPORT

Honeycomb: It can be aluminum, nomex, paper or fiberglass. Its hexagonal structure gives anisotropic strength it has high durability for vertical loads. Please have a look at figure 5 and figure 6. One of the most important things is that honeycombs are stronger with lamina structures. Vacuum Bag: They prevent the air exits when vacuuming process is done. Sealants: Sealants seal the vacuum bag and tool to prevent some gas exits. Please have a look at Figure 7. Breathers: When prepreg is under compression or in autoclave, air breathers help absorbing more air and resin to obtain optimum structure. Pell Plies: They protect the prepregs surface from dust or the other things.

4.9 Composites by fibers- vacuum bag- autoclave

The method of lay up is used in clean room. Release film air breather and vacuum bags are put and repeated in every 6th or 7th floor. Then they are sent to autoclave.

Please have a look at figure 8

4.10 Manufacturing
First of all prepregs and film adhesives are used in permitted tolerances. And prepregs and adhesives should be compatible with each other.

4.11 Mechanical Test Laboratory

Mechanical Testing Laboratory is equipped with 3 universal testing machines with capacity to 300 kN and temperature capabilities from -150 to 350 C and 1 impact testing machine with capacity 0.6 to 840 Joules and at temperatures from -70 to 130 C. Besides the mechanical test laboratory is capable of designing and manufacturing necessary test jigs, tools, and fixtures for mechanical test applications.

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With up to date technical equipment, software and experienced employee, performing all kinds of standard and non- standard static/dynamic tests of metallic/non-metallic materials are within the capabilities of mechanical test lab.

4.12 Mechanical Tests

Mechanical tests are listed below with some of the related Standards, Mechanical tests for metallic and non-metallic materials are performed using the standards; ASTM, ISO, MIL, SAE and various company specifications: Tension Tests Compression Tests Fatigue Tests Flexure Testing Sandwich Flexure In-plane Shear Inter-laminar Shear Lap Shear Floating Roller Peel Sandwich Shear Tension/Compression Sandwich Peel Flatwise Sandwich Tensile Test Low Velocity And High Velocity Impact Tests, Charpy, Izod Impact Tests Barcol Hardness Durometer (Shore A, D) Hardness Compression After Impact

CONCLUSION

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In my summer practice I have a chance of seeing the processes and with my knowledge and the courses that I have taken in METU I improve my theoretical knowledge with practical one and seeing the importance of materials and choosing a proper and right material is so much critical in aerospace industry.

In TAI I had a chance of seeing expensive tools, machines and products. Moreover I had chance of seeing how these expensive machines works and how these expensive products are made. It is important for engineering candidates seeing the processes step by step and the relations between chiefs, specialists and technicians, I learn that how should behave engineers and obeying the rules are crucial for fulfilling responsibilities.

This summer practice was enjoyable for me and I had chance of seeing and sometimes asking questions to engineers and technicians about processes and material scinence. It was a good experience for me to full fill my summer practice in TAI. And I believe that this summer practice will play an important role and will become a significant key for my career.

APPENDIX

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Figure 1- Organization Chart

Figure 2

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Figure 3-fiber stress strain graph of Carbon Aramid and E-glass

Plain

Basket
Figure 4-fabrics

Twill

Satin

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Hexagonal

Ox

Flex

Figure 5- Cores

Figure 6- how cores are made

Figure 7- sealants

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Figure 8- Lay up

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