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Expression of Interest (EOI)
Fabrication of Honey Comb Decks for
Launch Vehicles from Indian Work-Centre
Indian Space Research Organisation
Department Of Space
Government of India
Expression of interest
Table of Contents
Part I- Scope of Work
1. BACKGROUND
2. EXTENT OF WORK
3. STRUCTURES AND CRITICALITY
Basic construction of a honeycomb deck and realization strategy
Part II: Facility Requirements
1. HUMIDITY/TEMPERATURE CONTROLLED STORAGE FACILITIES.
2. MECHANICAL TEST FACILITY
3. FACILITY FOR DESIGNING, FABRICATING AND QUALIFYING OF
TOOLING FIXTURES AND TEMPLATES
4. MATERIAL CONTROL AND MANAGEMENT
5. OTHER MANDATORY FACILITIES
Part III: Applicable Documents
1. Applicable drawings for PSLV Honey Comb Deck Hardware- CCD/PSLV-68 Dt:
27-08-2015 (Issue-01)
[QMPG-CCD-DRG LIST-PUS-049; Dt: 03/09/2015
2. Process document for realization of metallic honeycomb sandwich deck plates
[VSSC/SDEG/HPDD/TM-02/2014; 29/05/2014]
3. Other applicable documents
Part I- Scope of Work
1. Background
In a launch vehicle, there are used many honeycomb deck plates of different size and
shapes. These deck plates are made out of aluminum alloy honeycomb core stuffed
with top/bottom plates. This is low weight- high strength constructions and that’s why it
finds applications in making aerospace packages platforms. This bonded metallic
honeycomb sandwich products are used as the platform on which, various electronic
packages, on-board computers, control and guidance systems as well as satellite and
payloads in the a launch vehicle. Realizing of such simple yet critical deck plates,
requires dedicated facility under organized set-up with all testing and qualifying
systems. With the increased demand of PSLV and GSLV, requirement of deck plates
has very significantly increased which is not actually being fulfilled with the existing
work-centres. Hence, to meet the huge demand for launch vehicles, Department is
willing to receive Expression of Interest from promising contractors to realize
Honeycomb Deck plates of aerospace quality.
2. Extent of Work
Each Polar Satellite Launch Vehicle (PSLV) requires 13 types of Honeycomb deck
plates of different shape and size. Whereas in GSLV, 7 types of deck plates are used.
These deck plates are of different thickness and size based on the application and
location. These are to be realized by bonding Aluminum skin sheets of AA 2014‐T6
material over Aluminum Honeycomb core using various Adhesive and potting
compounds and finally trimming to required size. The proposed work is for supplying 12
qualified sets of all required configuration for PSLV and at least 2 qualified sets for
GSLV flights every year with continued demand for 5 years or more.
The size of various configurations varies from sector dia 0.7M to 1.5 M (radial sector)
and thickness varies from 20mm to 110mm. For all different configuration of deck plates
and process plans for its realization, appicable documents may be referred. Raw
material being mostly aluminum alloys of aerospace quality, realization of such products
requires different advanced manufacturing processes at different stages.
3. Structure and Criticalities
A brief idea about the overall construction of a typical configuration and the critical
processes involved in the realization of deck plates with specific facility set-up required
is mentioned below.
Basic construction of a honeycomb deck
Basic construction of a honeycomb deck
Basic construction of a honeycomb deck
Various other configurations of Honeycomb structures
Structure Realization Strategy
� The performance of bonded metallic honeycomb sandwich products is highly fabrication
process sensitive and the process needs to be adhered with greatest care.
� An approved process document which describes the methods and practices involve
realization of metallic honeycomb structures shall be followed by the realizing agency.
� Design, realization and qualification of
the aluminum sheets and curing and bonding of decks shall be realized by the
prospective vendors.
� All AA components must
activities.
� Test coupons are prepared from the
extended portion as per drgs.
� Dimensional & geometrical parameter in
inspection equipments, 3D CMM
Various other configurations of Honeycomb structures:
Structure Realization Strategy:
The performance of bonded metallic honeycomb sandwich products is highly fabrication
process sensitive and the process needs to be adhered with greatest care.
An approved process document which describes the methods and practices involve
f metallic honeycomb structures shall be followed by the realizing agency.
Design, realization and qualification of templates, drilling and curing
the aluminum sheets and curing and bonding of decks shall be realized by the
All AA components must be Anodized for surface protection purposes before bonding
Test coupons are prepared from the actual flight deck plates by trimmed
as per drgs.
Dimensional & geometrical parameter inspection of final product
inspection equipments, 3D CMM, FBT equipment etc.
The performance of bonded metallic honeycomb sandwich products is highly fabrication
process sensitive and the process needs to be adhered with greatest care.
An approved process document which describes the methods and practices involved in
f metallic honeycomb structures shall be followed by the realizing agency.
curing plates for cutting
the aluminum sheets and curing and bonding of decks shall be realized by the
for surface protection purposes before bonding
trimmed-off from the
product using qualified
Part II: Facility Requirements
1. HUMIDITY/TEMPERATURE CONTROLLED STORAGE FACILITIES.
Room Conditions for adhesive bonding operations and post bonding processes,
storage of identified inserts, skin sheet, core and semi-finished deck plates while
fabrication): Environment should be contamination-free and should be controlled for
temperatures of 18 to 24°C, relative humidity of 40 to 65 % .
2. MECHANICAL TEST FACILITY
Strict compliance of raw material specifications, process control procedures, at every
stage of fabrication ensures suitability for good reproducible products. Various test
methodologies and detailed procedures of testing of Aluminium Skin sheets,
Honeycomb core and adhesives are to be followed. Work Centre shall generate and
maintain records and procedures in order to maintain traceability of raw materials,
process, coupons, tooling and instruments used during product realization. These
records shall be available for verification at any time. The tested coupons shall be
disposed only after VSSC review. All coupons shall have labels marked before
cutting and testing. Both sides of the lap shear coupons shall be labeled before
slicing.
3. FACILITY FOR DESIGNING, FABRICATING AND QUALIFYING OF TOOLING
FIXTURES AND TEMPLATES
Various steps are involved in this crucial phase of fabrication such as preparation of
core, preparation of skin sheets, preparation of inserts, preparation of adhesive
films, molding of panel, fabrication of test coupons, curing of the product, drilling and
potting of inserts, edge sealing of sandwich panel segments etc. These are
explained in detail in the process documents. Templates are prepared for curing and
drilling purposes and also to check the deck plates for proper alignment with the
interface. Surface of the templates are milled on both surfaces and sides to obtain
the correct dimensions. Holes are drilled on the templates for interfaces.
4. MATERIAL CONTROL AND MANAGEMENT
AA 2014‐T6 is used for making Aluminum skin sheets as well as Aluminum
Honeycomb core in HOBE form/ Expanded core form. Few examples of Potting
compounds, Adhesive film and inserts are given below for references; but for
detailed specification, process documents may be referred,
� Potting compounds:- Araldite-AV138IN, HV998;
� Adhesive film:- Redux 319A, 312;
� Aluminum inserts-Aluminum (B51 SWP/ AA6061 T6/AA 6351 T6);
� Primers- Redux 119, Redux 112;
� Helicoil- Stainless steel helicoils inserts (SS 304) and other various sealant.
All the above raw materials required for realization of honeycomb structures have to
be procured from reputed manufactures like M/s. Hexcell .
Specific storage condition is required for raw materials which is given in the process document. Specific requirements, if any, specified by the supplier of the raw material shall be implemented. 5. OTHER MANDATORY FACILITIES
Apart from above mentioned system, other important facilities like Clean Room for
carrying out bonding of Honeycomb decks, Chemical Etching, Surface Treatment
facilities are mandatorily required. Process equipments like autoclave, Potting Gun,
Fokker Bond Test equipment for NDT evaluation etc are also required.
Part III: Applicable Documents
Following process document and drawing list are applicable for PSLV Honey
Comb Deck Hardware realization.
1. Applicable drawings for PSLV Honey Comb Deck Hardware- CCD/PSLV-68 Dt:
27-08-2015 (Issue-01)
[QMPG-CCD-DRG LIST-PUS-049; Dt: 03/09/2015]
2. Process document for realization of metallic honeycomb sandwich deck plates
[VSSC/SDEG/HPDD/TM-02/2014; 29/05/2014]
Others applicable documents for quality control requirements are listed below:
1. General quality requirements and protocol for the realization of Launch Vehicle, light
alloy structures. MEE/QCI/43.86/14/2002 Feb.2002 (Issue-0)
2. Quality control requirements for storage, preservation and distribution of materials,
components and assemblies for Launch Vehicle Light alloy structures.
MEE/QCI/43.86/QCP/15/2002 Feb.2002 (Issue-0)
3. Quality control requirements for anodising aluminum alloy components for Launch
Vehicle structures. MEE/QCI/43.86/QCP/16/2002 March 2002 (Issue-0)
Note: All these documents shall be provided to the qualified party.