Can Be Retrofitted To Lycoming Motors

Representatives with Superior Air Parts told Aero-News Monday the Coppell, TX-based company has received FAA approval to begin production of the its new ESR crankshafts, which utilize a new forging process known as Electro Slag Remelt.

According to the company, the ESR process removes many more impurities than the more common Vacuum Arc Remelt (VAR) process. Such impurities can lead to production and service problems.

“This process gives us the ability to add chemicals to the slag that will absorb and remove greater amounts of impurities from the metals to create much cleaner steel,” said Keith Blockus, Superior's Senior Director of Product Development and Engineering. “Beyond that, electro slag is a much more modern and controllable process. Because of the better material properties achieved with ESR a lot of critical applications in other industries have switched to this process.”

“Superior is the first company to use the ESR process in the production of general aviation engine parts,” added Blockus.

The new crankshafts will be offered in the company's XP-360 Sport Av engine, according to Blockus, as well as its recently FAA-certified Vantage engine (above and below). The parts will also be available in the aftermarket as direct replacements for applicable Lycoming four-cylinder engines.

“With the recent high profile problems centered on current-generation crankshafts, we have been looking for a better, more reliable way to produce critical parts,” explained Superior’s President and CEO Tim Archer. “The bottom line is this; our new proprietary material and ESR technology is another step towards our goal of ensuring superior performance, quality and reliability.”

Superior's ESR crankshafts also utilize a special proprietary steel, according to company officials, which contains more chrome and nickel content than conventional 4340 aviation steel. The properties of this special steel allow a shorter nitriding process, accomplished at lower temperatures than 4340 requires.

“This helps to better retain the base metal properties,” said Backus. “Using this new steel provides better process margins for safety and better fatigue properties overall. It eliminates many of the problems found in prior generation manufacturing processes.”

The FAA was actively involved in the development and approval process. “This has been a very high profile project with the FAA,” Blockus said.

FMI: www.superiorairparts.com