Helicopter

We offer a complete range of thermal processing services to the rotary aircraft industry, servicing the spectrum from commercial aviation to military requirements.

Engine

A helicopter turbine engine capable of providing in excess of 1500KW has many technically advanced components.  At Bodycote, we perform a variety of thermal processes providing essential thermodynamic characteristics for this complex, vitally important component.

The engine’s blades, combustion chamber and exhaust nozzles are all heat treated to resist high temperature and corrosion; additionally bearings and gears are heat treated for wear resistance. The main shaft is HVOF coated to increase tensile strength and extend its serviceable life.  Injectors and all supply circuit parts are brazed assembled for resistance whilst yielding a clean and light-weight component.  Typically treated parts include:

• Blades
• Injectors
• Combustion chamber
• Gears
• Main shaft
• Nozzles

Main gear box

The main gear box has to transfer the power from the engines to the rotors, whilst the tail gear box aids control and maneuverability.  In the gear box assemblies, all critical parts are designed for resistance to vibration, high pressure and temperatures  – typical military helicopter specifications require the main gear box to perform at full power for up to two hours without oil  – imagine doing that in your car!

Bodycote provides heat treatment processing on gears and bearings to improve high speed performance. Surface coating treatments are essential to high precision, hydraulic control components.  Typically treated parts include:

• Gears
• Bearings
• Housing
• Planetary satellite
• Carter

Main rotor

The rotor is one of the largest and most important components on the helicopter.  It must withstand centrifugal forces, vibration, abrasion, and corrosion, whilst turning the blades and providing essential inputs to flight control components.

A combination of thermal processing techniques is used to ensure desired material characteristics are achieved.  Nitriding is often employed on bearing surfaces, with additional HVOF coating to improve resistance.  Tail rotor blades receive surface coatings to improve their abrasion resistance. Typical treated parts include:

• Tail rotor blades
• Gears
• Bearings

Drive shaft

The helicopter drive shaft powers both the main and the tail rotors. The tail rotor and gearbox’s dependency on the main gear box requires the long drive shaft to be extremely strong, yet light-weight.

Bodycote employs many processes such as electron beam welding and HVOF coatings along with heat treatments to deliver the required resistance to corrosion and vibration.  Typically treated parts include:

• Gears
• Bearings
• Shaft

Flight control

Helicopter flight controls are essential to drive the speed and pitch of the rotor blades.  Bodycote aids the performance of flight control components by combining a full complement of heat treatments, surface technology, HIP and metal joining (EBW) to improve resistance, increase precision, while maintaining a light weight.  Typically treated parts include:

• Rods
• Bearings
• Hydraulic components
• Electro-mechanical assemblies

Landing gear

Helicopter manufacturers employ a wide array of landing choices.  Bodycote is able to provide a thermal processing solution regardless of the landing gear technology utilised.

On mechanical gear, Bodycote provides heat treatment of titanium, aluminium or stainless steel components; whilst thermal spray coatings are often employed for hydraulic jacks and cage bearings.  On non-mechanical gear, Bodycote provides heat treatments to minimise geometric distortions; whilst brazing and electron beam welding are employed to join different metals. Typically treated parts include:

• Hydraulic jacks
• Bearings
• Rails