Contour cutting and punching of MPCM sheets by all applicable methods was done in serial production. The metallographic research of work zones was done by diverse tools and methods: hand shears, hack-saw, file, milling, laser, carving out, and punching. The peculiarities of these kinds of machining at the stage of structural elements production and assembling stage are analyzed. The comparative tests of sample items after guillotine cutting, milling, and laser cutting were conducted. It was observed that the best results are received at milling with sharp-edge finishing.

The work justifies the application of metal polymer composite materials (MPCMs) for leading-edge assembly of An-124-100 airplane in relation to frequent vibroacoustic damages of airplane skins and framework of D16ch-ATV aluminum alloy. Fourteen full-size segments of three types of wing leading-edges were produced in serial production and such comparative endurance tests were executed in SibNIA. The advantages of structures of ALOR MPCM were registered: at acoustic loads - by 3 times, at repeated-static and acoustic loadings-by 20-27 times. Mass reduction: 8.2%. The in-flight check in 1994-2000 time range confirmed the running time increase of wing leading-edge panels by 11 times compared to metal structures.

The production technology of prepregs from woven filling compounds with asymmetrical application of modified FPR-520 binding agent was described. The technological characteristics of resulting prepregs and the description of the draw die are included. It was confirmed that asymmetrical application of binding agent makes it possible to increase the cohesive strength of three-layered honeycomb panel skins without increasing the quantity of binding agent.

The work describes x-ray dosimetry method of continuous monitoring of mass percentage of binding in prepregs in the production process. ISS-1003M computerized installation was developed and produced on the basis of this method. The peculiarity of the installation is the use of radio channel for data transmission from sensors to a remote computer. That made it possible to eliminate long connecting high-voltage cables, and that significantly increased the levels of reliability and fire-safety of the installation. The practical use of the installation showed that root-mean-square error in mass percentage binding measurements makes no more than ±1% in 0-75 percent range.

The work examines formation peculiarities of large-dimension MPCM sheets, including surface preparation of aluminum alloy sheets, autoclave formation conditions, structural changes in metal-composite interface, distribution of residual stresses and their alteration techniques in the formation process and after it, as well as the impact on mechanical properties and fatigue life. The tests of corrosion resistance of sheets and cracking susceptibility of films of sulfuric-acid and chromate anodizing under deformation were performed.