Available Processes

PERMANENT FASTENING

- Installation of hi-locks
- Riveting
- TIG welding of steel, aluminum and titanium alloys
- Gas welding of aluminium alloys
- Coated-electrode arc welding of steel
- Resistance welding of steel, aluminum and titanium alloys

SHEET METAL FORMING

- Sheet metal forming carried out on rubber pad or membrane forming presses
- Sheet metal bending using press brakes
- Numerical controlled cutting 
- Stretch forming of sheet metal and profiles 
- Sheet metal forming using triple rollers
- Sheet metal straightening using levelling machine
- Double-action press forming
- Manufacture of parts carried out on hydraulic presses, eccentric presses for cutting, punching, trimming, bending, etc.

   

 

MACHINING

- Turning carried out on regular and numerically controlled lathes
- Integrated turning and milling carried out on CNC centers
- High precision milling of elaborate shapes with high surface quality, carried out on CNC 3D, 4D and 5D machine tools which ensures full repeatability of shapes and dimensions; 
- Precision grinding carried out on flat surface, internal and cylindrical grinders 
- Honing carried out on vertical and horizontal honing machines 
- Gear manufacture by hobbing carried out on regular and CNC gear hobbing machines 
- Deep drilling carried out on barrel piercing machines 
- Precision machining of holes carried out on jig grinders and drilling machines

 

HEAT TREATMENT

- Heat treatment of steel, copper, aluminum and titanium alloys

   

 

MANUFACTURE OF COMPOSITE STRUCTURES

Composite Shop is currently equipped with the infrastructure necessary to carry out the following processes:
 
1. Manufacture of main rotor blades, tail rotor blades and horizontal stabilizers for W-3, SW-4, Kania helicopters as well as for the manufacture of composite liners:
 
- dryers for composites ( max. temperature: 220°C, max. dimensions: width: 2800mm x height: 2200mm x length: 8500mm, with computer  recording of polymerization parameter),
- 115 sq.m painting shop.
   
 
2. Manufacture of composite structures in clean room:
 
- 3 clean rooms (the largest is 630 sq. m in size),
- VIRTEK 10-head laser projection system,
- 2 CNC cutting machine for prepreg cutting: LECTRA, HUMANTEC,
- 5 autoclaves (the largest with a diameter of 3500mm, 10000mm long),
- 9 cold rooms.
 
 
3. DT and NDT inspection:
 
- UT Pulse Echo ASCAN manual inspection of the monolithic structures, 
- UT Through Transmission ASCAN manual inspection of sandwich and bonded structures, 
- UT Through Transmision C-SCAN automatic inspection  of the monolithic, sandwich and bonded structures  (flat and slightly curved parts),
- UT Through Transmision NU-SCAN automatic inspection  of the monolithic, sandwich and bonded structures  (parts with complex 3D curvature).  
   
 
4. Machining:
 
- 5-axis CNC milling centers by JOBS - JOMACH 146®  (with overall dimensions worktable X: 6000 mm, Y 4000 mm, Z: 2000) and  JOBS - JOMACH 156® (with overall dimensions worktable X: 4800 mm, Y 3200 mm, Z: 2000 mm),
- 3-axis milling machine (plus indexed axis C) 4030 NOVA 3X with vacuum table with dimensions of 3m x 4m.
   
 
5. Design, simulation and manufacture of bonding tools:
 
- design and simulation, carried out with up-to-date CAD/CAM tools (Catia, NX, AutoCad), 
- fiber development and nesting (Magestic software),
- manufacture of metal tools, composite tools using wet lay-up, pre-preg,  infusion or pattern plate technology,
- tools refurbishment
 
 

 

SURFACE TREATMENT

The Coating Shop incorporates a fully automated line for chromic acid anodizing and chromating. The capabilities of the line are as follows: non-destructive tests, vapour degreasing, sodic deoxidizing surface preparation, chromic anodizing, sealing, chromating treatment with Alodine 1200.
The following processes are accredited by Nadcap: passivation of stainless steels, sulfuric acid anodizing of titanium, manganese phosphating, chromating, chromic acid anodizing.

 

Surface treatment of aluminum and its alloys

 

Engineering Process Type of treated materials Component Dimensions (m)
Chrominh acid anodizing Aluminium and its alloys 9.5 x 2.0 x 1.0
Chromating (Alodine treatment)
9.5 x 2.0 x 1.0
Sulfuric acid anodizing 5.8 x 0.6 x 2.4
Chemical milling 6.5 x 0.7 x 1.6
Hard anodizing 1.0 x 0.7 x 1.6

 

 

Surface treatment of steel, copper alloys and titanium

 

Engineering process Type of materials Max. Component Dimensions
Technical chromium plating Low-and medium- alloy steel, copper, copper alloys

1.9 x 0.6 x 1.0

1.4 x 0.6 x 1.0

Decorative chromium plating Low - alloy steels, copper and copper alloys

1.9 x 0.6 x 1.0

1.4 x 0.6 x 1.0

Cyanide-alkaline and amino-chloride Low - and high - alloys constructional steel

1.4 x 0.6 x 0.8

1.9 x 0.6 x 0.8

Passivation of stainless steels (Low - and high - alloys) Stainless steels 1.1 x 0.7 x 0.8
Anodising of titanium Titanium and titanium alloys 0.7 x 0.6 x 0.7
Silver plating Copper, copper alloys, stainless steel 0.9 x 0.6 x 0.7
Zinc phosphating

Low and medium alloy steels, constructional steel

(less than 6% Ni+Cr+Mo)

1.4 x 0.6 x 0.7
Manganese phosphating constructional steel 1.4 x 0.6 x 0.7

 

 

Spray painting:  max. dimensions of parts [m]  10x4x1,

 

TEST AND MEASURING

PZL-Świdnik S.A. offers the following tests carried out by the following laboratories:


- Metallurgical Lab
- Chemical Lab
- Length and Angle Measurement Lab
- Temperature and Humidity Lab
- Electrical Lab

 

 

0