Civil aviation

Our global network provides the scale and capability to partner with our customers on long-term programmes and multiple projects simultaneously. As their platforms progress through product life cycles, our service offering and technical expertise advances with them, through changes in material utilisation as well as geographic shifts in production.

Further, our optimisation of processing parameters, use of materials, and equipment utilisation enables us to significantly reduce the carbon footprint of our customers, and support their sustainability targets.

Engine

Aircraft engines are designed and built to work in extreme conditions and meet ever-changing environmental legislations. Engine components frequently operate at temperatures approaching their melting point – the use of controlled thermal processing is a vital stage of manufacture that allows these parts to operate reliably at high temperatures for extended periods of time.

Thermal processes such as heat treatment, hot isostatic pressing (HIP), and surface technology all contribute in preparing the engine for its serviceable life. Bodycote’s services for engine components cover the supply chain from castings and forgings to finished engines, and aftermarket care.

The use of heat treatments and specialist technologies during original manufacture, and in repair and rejuvenation of used parts, contribute to a sustainable manufacturing lifecycle, by extending component lifetime, reducing overall waste, and reducing material required for component manufacture. Typically treated parts include:

• Front bearing housing
• Exhaust ducts
• LP turbine blades
• IP turbine blades
• HP turbine blades
• Turbine guide vane
• Aft fan case
• LPT stator
• Compressor assembly
• Main shaft
• Stub shafts
• Seals
• Bearings
• Air ducts
• Oil pipes

Landing gear

Critical landing gear must perform without fault every time the aircraft flies. The safety of the crew and the passengers depend on it. The nature and position of this critical component demands both strength and high resistance to wear and corrosion to fulfil design requirements.

Combinations of thermal processing techniques are used to ensure these characteristics are achieved. Heat treatment is performed to enhance the properties of the materials, allowing the parts to endure harsh in-service stresses. Bodycote uses more sustainable thermal spray processes such as HVOF, in replacement of traditional coating methods, to provide superior corrosion and wear resistance properties. Typical treated parts include:

• Trunnion
• Wheels
• NLG
• MLG
• Brakes
• Screw shafts
• Ball joints

Structure

The integrity of an airframe structure and its associated components is paramount not only for the protection of the passengers, but also to cope with the ever-changing environment for which they are exposed.

Corrosion resistant materials are used in areas where strength and resistance to the elements are mandatory. Aluminium and titanium are used in areas where strength and lightness is a priority. Heat treatment processes are carried out in order to fulfil the required material properties and design requirements.

Many precision airframe castings from alloys such as titanium, aluminium and steel are HIPed to ensure integrity, optimise mechanical properties and improve fatigue life.

• Airframe
• Horizontal stabiliser
• Wing keel
• Fan duct
• Side body
• Hinge
• Engine nacelle
• Engine mount
• Cowling
• Door locks
• Rivets

Actuation and control

The ability of a pilot to control and safely fly an aircraft relies on how the actuation and control system operates and allows the aircraft to respond to their commands. Due to the complex nature of the parts and the materials involved, some form of thermal processing is required.

The joining of intricate hydraulic pipes and actuators using thermal processes such as vacuum brazing and electron beam welding enables designers to utilise the latest technologies available to them when designing new components.

• Reverse thrust actuator
• Flap track
• Hydraulic pipe