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.