Making aircraft innovations fly. With high-end surface solutions, advanced materials, turbine components and services for aerospace applications

Transcription

1 Making aircraft innovations fly With high-end surface solutions, advanced materials, turbine components and services for aerospace applications Aerospace

2 High-end solutions provide reliability and extended component life for the aerospace industry To maximize operational efficiency and safety in the aerospace industry, high-end surface soutions, advanced materials and spezialized components play an essential role as they vitally increase aircraft performance and reliability. Oerlikon Balzers and Oerlikon Metco offer a uniquely broad range of coating solutions, application equipment, materials, services and manufactured engine components which facilitate longer service life and help prolong maintenance intervals. Moreover, they allow cost savings to be realized through reduced energy and fuel consumption of flight control systems and power plants, resulting in increased safety and lower cost of ownership. Likewise, they are helpful in meeting environmental challenges thanks to reduced emissions and the replacement of traditional processes. coated precision tools Improve milling and drilling for a wide spectrum of difficult-to-cut materials Maintain the hardness of the tool at high temperatures Reduce cutting stresses as a result of low frictional coefficient Enhance the performance and reliability of precision tools Interior decoration Attractive wear protection colour coatings with long life and high performance for interior appliances. Landing gear Hardface coatings deliver durable resistance against fretting, sliding, general surface wear, abrasion and corrosion. They provide an excellent alternative to hard chromium plating. Hydraulic systems Fuel pumps Air management systems Component service life is increased by using our coatings that reduce friction and protect against wear. Coatings enable the use of lightweight alloys in critical components (i.e. Titanium, Aluminium), to replace heavier alloys.

3 Actuation systems Reduced danger of seizure of flight control systems thus increasing operational safety significantly. Engine pylons Anti-fretting thin-film solutions stop cold welding of connection pins to critical components, reducing the risk of damage to critical parts during maintenance, repair and overhaul. Combustors and Turbines Hot section components are protected from high temperatures and fuel efficiency is increased with thermal-barrier coatings Air seal components maximize turbine efficiency Materials for additive manufacturing opens up new horizons for hot section components Compressors Boost engine efficiency and safety margins with gas-path abradable coatings that control clearances Improve and prolong engine efficiency with thin-film solutions that provide erosion and corrosion protection for compressor blades and vanes Maximize compressor efficiency with custom manufactured components

4 Oerlikon Balzers is one of the world s leading suppliers of thin-film coating technologies that significantly improve the performance and durability of precision components as well as tools. Protected with our coatings, the light-weight components used in the aerospace industry permit greater loads, meet closer tolerances, and lower the cost of maintenance. and BALIQ coated cutting tools meet the highest expectations in machining high-end Aerospace materials. Thanks to our network of Nadcap-certified Customer Centers in all relevant industry locations around the globe, our aerospace customers benefit from high-end job coating services wherever they are. High-end coating solutions and outstanding services provide reliability and long life for the aerospace industry Tribological wear, friction and mechanical impacts take their toll. During service, components must withstand wear, corrosion and great loads while maintaining their light-weight and low-friction properties. Plus: Mechanical aerospace components have to meet very strict regulations regarding environmental and safety requirements. With coatings, surface properties are optimized to realize important advantages for aerospace components: Besides, the production of innovative and economical aerospace components faces a huge challenge: Cutting tools have to resist wear under serious conditions, from high cutting temperatures to heavy loads causing friction and difficulties in removing chips. Oerlikon Balzers supplies state-of-the-art coatings which fulfil those requirements and are based on the environmentally friendly and future-oriented PVD and PACVD coating technologies. Longer service life Greater load tolerance Reduced energy consumption Dry-running operation Close tolerances Easy, low-cost of maintenance Resistance against fretting

5 Oerlikon Balzers coating solutions for aerospace components COMPONENTS A ALCRONA PRO C DLC Star TURBINE PRO Coating material TiN AlCrN-based a-c:h:me (WC/C) CrN + a-c:h TiAlN-based Coating structure mono layer mono layer nano layers multi layer mono layer Coating colour gold-yellow bright grey anthracite black violet-grey Coating hardness H IT [GPa] 30 +/ / ~ /- 2 Coefficient of friction (dry) vs. Steel ~0.6 ~0, ~ 0.5 Intrinsic stress [GPa] -2 +/-1-3 +/-1-0,5 +/- 0,5-1 +/- 0,5-1,5 +/- 1 Max. service temp. [ C] Coating temperature [ C] < 500 < 500 < 250 < 250 < 500 Typical coating thickness [µm] Applications Fasteners, bushes, bearings and attachment systems Used for high temperature protection and high abrasive wear resistance Bearings, gears, fasteners, flight control systems and air conditioning Hydraulic systems, fuel systems Compressor blades, blisks and compressor vanes All given data are approximate values, they depend on application, environment and test conditions. Oerlikon Balzers coatings for precision tools machining aerospace materials TOOLS ALNOVA DIAMOND MICRO DIAMOND NANO HARD CARBON PERTURA Coating material AlCrN-based C (sp3) micro-crystalline C (sp3) nano-crystalline ta-c AlTiN-based Coating structure multi layer mono layer mono layer mono layer nano layers Coating colour light-grey grey grey black-rainbow aubergine-grey Coating hardness H IT [GPa] 38 +/ /- 3 Max. service temp. [ C] > 1, ,000 Coating temperature [ C] < 150 Typical coating thickness [µm] 1 4 6, 8 6, 8, Applications Milling of Ti and Al alloys Drilling and milling of graphite Drilling and milling of CFRP and Sandwich materials Drilling and milling of Al < 12 Si content and non-ferrous metals Drilling of challenging material All given data are approximate values, they depend on application, environment and test conditions.

6 Oerlikon Metco has over 80 years of market experience and more than 50 years of partnership with the Aerospace industry. Oerlikon Metco s materials, coating equipment and services, spezialized machining services and components for aircraft engines significantly increase efficiency and fuel economy and reduce emissions in engine operation. Specifically designed materials and coatings protect the base material of critical turbine parts from oxidation, hot gas corrosion, erosion, wear and excessive heat. Today, almost all turbine-powered aircrafts have Metco solutions on board, and Metco has more OEM approvals than any other coating material supplier. Metco s next-generation solutions, designed for coating, brazing and additive manufacturing processes, are opening up new horizons for high-performance engine components. Tailored aerospace solutions that increase the efficiency and longevity of critical components Coating systems and materials for advanced thermal barrier coatings protect hot section components and increase power plant thermal efficiency. Environmental barrier coating technology protects advanced Ceramic Matrix Composite structures. Ceramic-based abradable materials allow hot section turbine components to operate more efficiently than ever. MetcoAdd materials for powder-bed additive manufacturing produce new, complex components with excellent mechanical properties. MetcoClad laser cladding materials dimensionally restore and enhance the surfaces of critical components. Build-to-print manufacturing and specialized machining services for critical power plant components ensure top-notch performance. Advanced high-velocity oxy-fuel solutions replace hard chromium plating and allow landing gears to return to service faster than ever. Wear-resistant coatings allow flap tracks to consistently actuate smoothly. Braze materials provide high-temperature, oxidationresistant joins and repairs on critical turbine engine components. Thermal spray coating services and laser cladding services enhance performance and reduce component manufacturing and maintenance costs.

7 Every successful solution begins with the right material choice MATERIALS FUNCTIONS ENGINE Fan LPC IPC HPC Comb HPT LPT AIR FRAME MCrAIYs, standard & advanced zirconias Thermal barrier X X X Thermal sprayed abradables, honeycomb seals Clearance control and seals X X X X X X Carbides Wear protection X X X X X X X X MCrAIYs, superalloys, pack diffusion alloys Oxidation protection X X X X MCrAIYs, superalloys, pack diffusion alloys Hot corrosion X X X X Silicon, Mullite EBCs for CMCs* X X X Ni- an Co-based braze Joining X X X X X X X Steels, standard alloys, superalloys, activated diffusion alloys Steels, standard alloys and superalloys Surface restoration Additive Manufacturing X X X X X X X X X X X X X X * EBCs = Environmental Barrier Coatings CMCs = Ceramic Matrix Composites Coating Systems Customer Services Thermal Spray Single- and multi-process systems with standard and customized handling designed for every budget and need. Atmospheric Plasma Spray: APS Controlled Atmosphere Plasma Spray: VPS, LPPS, LVPS, LPPS-Hybrid High-Velocity Oxygen Fuel Spray: HVOF-GF, HVOF-LF Electric Arc Wire Spray Combustion Wire and Powder Spray Laser Cladding LC Systems with customized robotic handling for process head and work piece movement. Coating Systems Thermal spray and laser cladding coating services Coating Solutions Centers for Coating Development AM printing for materials testing and test article production Technical and Field Services Customer training Spare parts Build-to-print services 1-stop-shop for your hot and cold section turbine engine components Production cell concepts delivering a high level of delivery performance Automation in place to maximize efficiency Cross-functional work approach with customers for new parts introduction

8 Competence in the heart of the EU and US aerospace industry All locations of Oerlikon Balzers and Oerlikon Metco Nadcap-certified Ferrières-en-Brie / France (Balzers) Milton Keynes / UK (Balzers) Niedercorn / Luxembourg (Balzers) Balzers / Liechtenstein (Balzers) Lomm / Netherlands (Metco) Debrecen / Hungary (Metco) Nadcap accredited in accordance to AS7003 Troy, MI / USA (Metco) Westbury, NY / USA (Metco) Salzgitter / Germany (Metco) Ft. Saskatchewan / Canada (Metco) Guelph / Canada (Balzers & Metco) Accredited in accordance to ISO Barchfeld / Germany (Metco) EN/AS/JISQ 9100 certified quality management Wohlen / Switzerland (Metco) Ferrières-en-Brie / France (Balzers) Milton Keynes / UK (Balzers), planned Stockport / UK (Metco, Neomet) Debrecen / Hungary (Metco, Eldim) Lomm / Netherlands (Metco, Eldim) Ft. Sasketchewan / Canada (Metco) Westbury / USA (Metco) Troy / USA (Metco) Salzgitter / Germany (Metco) Barchfeld / Germany (Metco) Contact us today and tap into our productivity-boosting expertise in surface solutions, materials and turbine components tailored explicitly to aerospace industry applications! Headquarters Oerlikon Balzers Iramali 18 LI-9496 Balzers Liechtenstein T Oerlikon Metco Churerstrasse 120 CH-8808 Pfäffikon Switzerland T You can find a full listing of our locations at: OSS003EN (1705)