Aerotec’s tear down area involves many steps. Once the APU arrives at our door, the customer’s paperwork is reviewed. The unit is then boroscoped and pre-tested if necessary.
Accessories are then routed for pre-test and are disassembled to the necessary level so that an evaluation can be made.
Each of our shop managers personally reviews each aspect of the APU repair process. The evaluation that is made will allow us to pass the cost savings to our customers while maintaining a high quality product. The evaluation is then sent to the customer for review and approval.
Aerotec’s Inspection department is responsible for maintaining the highest level of quality control. One of the procedures we have implemented, that we believe is unique to our company, is the participation of our disassembly mechanics in the inspection process. The Director of Maintenance, Quality Manager, and the Overhaul and Rework Shop Managers will also review the disassembly/inspection findings.
Our inspection department has all the precision equipment necessary to achieve air worthiness
The Coordinate measuring machine is a state of the art piece of equipment which enables the operator to measure angles, contours, curves, inside and outside diameters, and multiple dimensions on simple and complex parts of various sizes with a high amount of accuracy. This machine, connected to a personal computer, ensures proper documentation of all measurements and inspection results.
The Optical comparators provide magnified views of 10 power and more of profiles and surfaces allowing high accuracy measurement of various sized parts using a non-contact method.
The In-house Non-destructive test uses liquid penetrants, type 1, methods A, C and D, to inspect on cast, wrought and welded assemblies for the detection of discontinuities open to the surface.
Magnetic particle inspection is a non-destructive testing method using AC and DC currents to detect surface and near surface discontinuities in ferrous metal materials.
Our quality department is responsible for the assurance and control of all technical publications. The quality department also maintains all information pertaining to customer maintenance programs, customer build standards, FAA requirements and regulations, EASA approval, internal audits, and subcontractor approval and surveillance.
Internal audits are periodically performed to assure compliance with the inspection procedures contained in Aerotec’s Inspection manual. Unscheduled audits of any function may be initiated by the Quality Assurance Manager based upon the recognition of conditions that deviate from specifications.
Aerotec’s Machine shop has the capabilities to perform the majority of our repairs in-house. Aerotec has a fully equipped Machine shop designed with extensive machinery and equipment to accomplish the repair of Gas Turbine Engines and components.
The CNC Curvic Grinder is used to grind the curvic coupling on rotating components, such as compressor wheels and turbine disks.
In addition, we also have 4 manual Gleason Curvic Grinders used to re-establish curvic coupling teeth for APU rotating components. Having 5 curvic grinders in shop allows Aerotec to produce a large volume of curvic grind work with minimal set up time and an expeditious turn time.
The 5 Axis Milling Center is used to re-establish the airfoil profiles on compressor and turbine wheels. This saves many man hours in hand finishing with a much lower percentage of error. The manual operation to hand finish averages 40 hours per part with approximately 30 to 35% error, in comparison the 5 Axis milling center has reduced this average to 3 hours with approximately 0 to 2% error.
The Vertical and Horizontal CNC Lathes are used for more repeatability with less error than manual lathes. These lathes are used to profile impellers and rotating components and contour their respective mating housings. These CNC lathes repeatedly produce a more accurate tolerance.
Our Pratt Whitney Jigbores are used to machine gearbox liners to size and location, hold tolerance of one thousandths concentricity over a 4-inch span.
The Argon Chamber Welder creates an inert atmosphere, free of oxygen and any impurities. Argon chambers are used on titanium compressor wheels and impellers to restore leading edge, contours or trailing edge damage caused by rub, FOD, or bearing failures.
Aerotec uses our Metal Spray capabilities for wire or powder coating. 70 to 80% of repairs done here at Aerotec are performed with this metal spray process.
The Electron Beam Welder is used for welding turbine engine components. This welding method applies 100% penetration weld with little distortion. This process is performed within a vacuum on various high temperature metals including dissimilar metals.
Spin testing is performed after repairs of rotating components. Aerotec performs this over speed test to verify the integrity of the repair.
Aerotec performs many machining operations with our various conventional Lathes, Mills & Grinders. Each customer requirement and individual part can be unique in its required repair scope. To maximize repair benefit, conventional machines ensure parts are repaired to the appropriate customized repair with the least amount of material removal.
Aerotec balances each dynamic component as an individual part using one of our Various Balance Machines. After assembly of components into a group, the assembly is then precision trim balanced. Our balance machines are digitalized for precise balance of these assemblies and individual components. The machine produces a print out, documenting final balance results.
The E.D.M. or Electronic Discharge Machine is a fully programmable CNC controlled machine used to remove large amounts of exotic material without causing any compromise to material integrity.
Aerotec’s Accessory department encompasses a variety of tasks. Our technicians are responsible for the pre-test, disassembly, inspection, reassembly and functional test of each APU accessory.
Aerotec’s APU Assembly department includes the skilled and experienced personnel required to assemble various compressor / turbine assemblies and gearboxes in strict compliance with FAA and customer build standard requirements. In addition to having the qualified personnel and tooling, we also have in house test capabilities on APUs, generators, air cycle machines, air turbine starters and a variety of pneumatic valves. Our assembly department is equipped with the proper tooling required to build narrow and wide body APUs manufactured by Hamilton Sundstrand. Detailed work instructions are followed to insure proper build procedures, and specific customer requirements are accomplished. Inspection stops are installed for verification by the in-process inspector at each critical step of assembly. We are equipped with all required tooling to build and test:
- GTCP 36 Series
- GTCP 85 Ground Power
- GTCP 85 Series
- GTCP 660 Series
- TSCP 700 Series
- GTCP 331-200ER/250H
- GTCP 331-500
- 131-9 Series
Our test cell includes a manual test system capability as well as the investment in a state of the art computer controlled data acquisition system necessitated by new generation APU types.
Aerotec’s Engineering department has the expertise to develop the most difficult repairs that often cannot be accomplished by others. Our DER approved repairs using state of the art computer engineering analysis programs, along with our in-house DER capability, has proven to be one of our most effective cost-saving measures. Our objective is to minimize the use of new replacement parts by using high quality repaired parts. The results are substantial monetary savings, which are passed on to our customers. In many ways, we are able to improve the reliability of the part.
Aerotec’s Planning department uses computer-generated planning to maintain each customers’ build standard requirements, along with the OEM’s required repair steps. This allows the planner to maintain the highest level of integrity in each repair performed. A record of each operation is documented on our planning paperwork. This form allows both the production mechanic and inspector to sign off on each procedure performed. The planning form accompanies the respective part through the entire repair system. This ensures the final product has met all the customer and manual requirements, resulting in a well documented, successfully repaired part.
Aerotec’s customer service features a single point of contact, allowing for a same day or next day response to our customers. Customer service follows and controls parts flow throughout the complete repair process, from receipt to shipment. Our customer’s special needs, requirements and specific work instructions are initiated up front on the job order release.
Aerotec’s Field Service and training programs can be tailored to fit your specific needs or requirements. We offer in house or in the field training and troubleshooting, as well as campaign training for outstation customer needs. Our Field Service department can review your specific requirements and propose maintenance and preventive maintenance programs to fit any customer’s needs.