Moss Vale Inc. Fabricators of tube assemblies

Transcription

1 Fabricators of tube assemblies Picture courtesy of Cirrus Design Corp. Guide to Products and Services FAA Repair Station No. M0OR914N FAA PMA No. PQ2593CED JAR Acceptance No. JAA.5365

2 Left: A bellow formed from 321 Stainless. Moss Vale has a full range of size capacity for bellows manufacturing. Right: This is a standard production Induction tube. Their manufacture involves cutting, coping, precision aligning, welding, bead blasting, heat treating and chemical Below: Moss Vale keeps an on hand supply of numerous sizes in Gamah, Deutsch, Flared and Flareless end fittings.

3 About Moss Vale Moss Vale, Inc. is a FAA/EASA* approved Repair Station and FAA PMA* approved PMA manufacturer. We repair, overhaul and fabricate tube assemblies and ducts. The strength of Moss Vale is its ability to support quick turns of repair parts. There are several companies who say they will work parts for an grounded (AOG) aircraft, but when Saturday comes, they are no where to be found. At Moss Vale we know what it is like for the inspection department to have a late inspection find for an airplane which is due to go back into scheduled service. We ll work your AOG parts. We ll work hard to get your airplane back in the air. There are some facts about many of the modern aircraft to consider: Many tubes and ducts are made out of titanium and is not as easily formed as the stainless steels and aluminums. When Boeing made the 737 they went to internal swaged fittings which require special tooling. Other manufacturers followed. With the advent of the 757 Boeing standardized with many tubes made out of 3.2AL 2.5v titanium with the end fittings welded on. The days of an A&P using a hand bender at his toolbox were gone. And let s face it, turbine engine tubes have never been simple. *FAA means Federal Aviation Administration, PMA means Parts Manufacturing Authorization which is a federal government approval to manufacture and sell aircraft parts to the general public.

4 About Moss Vale Located just outside Greater Cincinnati s I-275 beltway, in Fairfield Ohio, Moss Vale is a 10,000 square foot shop equipped with nine benders, associated deburr, cutting, flaring, presetting, testing and end forming machinery. The shop is equipped for medium size production runs, prototype and small run jobs. The strength of Moss Vale s size is that we are small enough to respond quickly. People answer the phones. At Moss Vale we use several of the tube and duct fabrication processes. We can bend using CNC tube benders and coordinate design systems. Sometimes it is better to use hydraulic machines and forming tools. We can use orbital and computer welding if necessary or if the case and process requires, hand weld with TIG or braze. Any process no matter how hi-tech is correct for all situations. Aircraft maintenance is not on size fits all. Repair Stations need to be flexible.

5 One of Moss Vale s customers is Cirrus Design, a single engine aircraft manufacturer based in Duluth, MN. Cirrus manufactures a state of the art composite aircraft that carries up to four passengers at speeds of over 200 miles per hour. Moss Vale started manufacturing for Cirrus (CDC) in 2001 on the SR20 and later the SR22 class aircraft. Products manufactured for CDC include hydraulic brake lines, pitot static lines, fuel lines, welded rudder pedal components, induction system components and conduits for electrical harnesses. In January 2003 Moss Vale was named Supplier of the Year for Cirrus Design. Cirrus Aircraft was the first to incorporate many new technology features. Some of these features include a safety parachute (Ballistic Recovery System BRS), computer controlled navigation, engine display systems, anticollision system, global positioning systems and anti-ice (TKS) systems. All pictures courtesy of Cirrus Design

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7 DC-8 Re-pylon Program The DC-8 Re-pylon Program was a program for a large aircraft modification shop to installed new engines on a 345,00 pound four-engine airliner. The program required over one hundred new part fabrications and over 500 tubes for the first run aircraft. Several types of tubes were required. Large hydraulic supply lines made of strong and light weight materials, small diameter pneumatic lines were required, small soft light weight fuel vent lines and welded branch fire extinguisher lines were among the over 500 parts fabricated by Moss Vale, Inc. Each part required testing per a customer supplied specification, Douglas Process Specifications. All aircraft grade certified materials were needed from MIL-T8504 Stainless Steel tubing, to MIL-T-8808, WW-T-700/6 6061T6 Aluminum. All material markings were required with Douglas Aircraft Process Specification Materials. Strict testing requirements per the process specifications were required on all tubes manufactured with some independent sampling on new lots. The largest problem was that the customer had little data available. Materials for each part and part markings were given to Moss Vale. Many of the parts had to be fabricated off of old line used as a pattern for the new manufactured parts.

8 Many lines had to be custom fit on the aircraft. Soft aluminum was bent to fit the aircraft installation and used as a pattern for a shop template. A jig template fixture was fabricated in the Moss Vale shop and sent to the aircraft for a fit check. When the proof part was verified to fit the aircraft properly, a production part was made, pressure tested, inspected by our inspection department and re-inspected by a Federal Aviation Administration (FAA) Designated Airworthiness Representative. Every one of the over 500 Moss Vale, Inc. parts which were installed on the DC-8 aircraft was inspected to those requirements. Near the completion of the first aircraft the modification center found it necessary to make engineering changes to facilitate engine installation. The customer requested redesign of a handful of parts. Because of schedule constraints of installing engines, structural parts and tubes many parts were needed quickly. The DC8- Re-pylon aircraft rolled out the third week of April It was flight tested through May 1993 and received Federal Aviation Administration approval to enter revenue service in June 1993.

9 Noise Modification for DC-9 Aircraft In 1989 a manufacturer of a kit to make older aircraft meet new federal noise rules contacted Moss Vale, Inc. about fabricating parts to relocate the Engine Pressure Ratio Indication System and Constant Drive Electrical system fluid coolant system. Above: Moss Vale participated in the DC-9 Hushkit Certification. The customer supplied the material requirements and Moss Vale, Inc. fabricated the parts to an engine mockup. The parts were manufactured, and a FAA Conformity inspection was performed. The first aircraft was FAA certified in June 1991 and entered service shortly there after. Currently hundreds of DC-9s serving domestic and international airlines fly with the DC-9 noise modifications and Moss Vale, Inc. tubes. Below: A 737 Engine certification test which has Moss Vale tubes installed

10 Our Equipment Moss Vale, Inc. has many benders capable of bending sizes from ¼ inch to 2 ½ inch material. The largest of the manual machines is the Wallace #4 Bender which is capable of production run parts up to 2 ½ inch tubing. Moss Vale, Inc. owns two tons of tooling for this machine in various radii and diameter sizes. The Schwarze Wirtz CNC bender and two Eaton Leonard CNC benders perform a majority of the critical bending applications. They use state of the art computer controlled servos to maintain speed, accuracy and repeatability. Moss Vale, Inc. has a number of short run benders; two Pines 1200s, a Douglas Leonard, a Conrac and a Parker-Hannifin 412 with plane of bend precision ability. These machines have ¼ inch to ¾ inch capability. These machines have short set up times with precision for bend and rotation. About 75% of our in-house tooling may be used on more than one machine. This gives Moss Vale, Inc. flexibility to run each job efficiently.

11 Our Equipment Cold lubricated cutoff and deburr machines insure that our tubes are burr free and square. Tooling in ¼ inch to 1 ¾ inch is available for this equipment. A Bridgeport, lathe and Jancy machine allow Moss Vale to produce precision products involving holes, machined surfaces and coped joints. They also enable development of precision jigs and fixtures. Four methods of end fitting installation are swage, impact flaring, Hydraulic flaring and rotary flaring. Beads are installed in both Wiggins Coupling style and Military Specification Beads. Some special sizes and styles may involve tooling lead times.

12 Welding Moss Vale s welding capabilities range from repairing a single 1/4 stainless steel line to producing 50+ thin-wall aluminum tubes per month Our weld operators are certified under Aerospace Standards including AMS-STD2219. Our weld operators are qualified to weld Aluminum (2024, 3003, 5052, 6061, Group II) from to and Stainless Steel (304, 321, Group IV) from to This welder is welding 4130 Chrome-moly steel The welding department maintains three TIG welders; a Dynasty 300, a SynchroWave 250, and a MaxStar 175, and a Lincoln Electric 125 MIG welder. Two glass bead blasters, a belt sander and an OxyAcetylene torch are also on hand for weld preparation and finishing.

13 Inspection Department Our inspection equipment starts with a SAE, MIL and National Pipe and Tube Specifications library. National Standards and Military Specs are on Microfiche for materials and processes. Moss Vale, Inc. can manufacture and inspect to customer supplied specifications, Boeing Process Standards, Douglas Process Specification, SAE and MIL Specs. Moss Vale, Inc. calibrates its Hydraulic Test Gages to National Bureau Standards and carries full traceability. Other required measuring equipment carries the same traceability. Moss Vale, Inc. has two pressure test benches with fluid test capabilities to 10,000 psi in MIL-H 5606 MIL Spec hydraulic fluids and Exxon 2380 oils. Testing with 500b Skydrol and calibrated test oils are facilitated with notice. Inert Gas Pressure Testing can be performed in house to 3000 psi. Air pressure testing is available with normal safety constraints to 160 psi (Higher pneumatic test pressures can be accommodated with advance notice).

14 Inspection Department Moss Vale utilizes TubeCAD Design Software and a Laser inspection system, along with traditional height gauges, calipers, inclinometers and other inspection tools to provide accurate inspection results. TubeCAD is a design package that interfaces with standard Computer Design Software. Tubes are dimensioned using XYZ coordinates or standard length rotation and bend angles. Data may be coordinated directly between both systems and may be easily converted to other CAD systems for 1:1 prints. Moss Vales QC department utilizes an Eaton Leonard Vector One Tube Inspection Center. The computer can scan a bent tube and generate measured XYZ dimensions, compare measured parts to a master tube, or figure an average or a run of multiple tubes. TubeCAD is a registered Trademark of Advanced Tubular Technologies

15 Tubecad Moss Vale Engineering maintains a Computer Aided Design System as well as tube specific Cad called TubeCAD. TubeCAD allows the engineer to design and draw tubes using coordinate data such as derived from XYZ datums and aircraft station data. TubeCAD maps the tube, draws the tube, calculates bend data and computer simulates the bending process to determine produceability of the part. It provides an excellent inspection tool and superior drawing interface. Drawings are programmed in TubeCAD and imported into AutoCAD. AutoCAD receives the three dimensional data and places tubes into an installation drawing or merely a detail parts drawing. Standard operations for three views provide all the needed drawing requirements. Moss Vale, Inc. is a full service Tube Shop from design prototype to production. Call us for your development engineering needs. TubeCAD is a registered Trademark of Advanced Tubular Technologies AutoCAD is a registered Trademark of AutoDesk

16 Custom Applications Design Drawing Prototype Production Bending Capabilities Steel and Aluminum Pipes One Quarter inch up to 3 Thin Wall Tubes 3/8 to 1 ¼ Thick Wall Tubes ¼ to 1 Solid Rod to 7/8 in mild steel Solid Rod to ¾ in other grades Several radii are available and may be fabricated with short lead times. If you have a specific need let us know. If we have your specific radius and tooling we can make your part immediately. Tube Forming Methods 37 deg. Flare Bite Type Fittings 37 deg. Double Flare AN Aircraft Fittings 45 deg. Flare upon request MS Military Spec Bite Type Fittings Expanding Boeing BAC Bite Type Fittings Reducing Deutsch Permaswage Fittings Wiggins Couplings Fabrication Sizing Beading Custom End forming Orbital Tube Welding *Some requirements may require tooling lead-time

17 Meeting Other Needs If your contractual needs include hydrostatic test Moss Vale, Inc. will test your tube assemblies in either water or hydraulic fluid or inert gas mediums. Pressure test may be accomplished up to 10,000 psi in our shop test equipment. Moss Vale, Inc. maintains a current specification library of MILSpec, Navy, Air Force, and SAE Standards. Fabrication in accordance with your special specification is available. Time is of the essence No longer is there a need to wait. For a quote on your prototype, short or medium size production run (5,000 parts/wk or under) give Moss Vale, Inc. a call. You ll be glad you did! Moss Vale, Inc. (513)