Modern aerospace engineering demands components that perform reliably under extreme temperatures, pressure, and environmental stress. Identifying high-quality aerospace materials that can withstand these intense conditions is essential to ensuring safety, reducing failure risk, and extending component life.
Utilizing effective heat-resistant materials and fire-repellent materials is critical in high-temperature applications. Keep reading for more information about the different types of high-temperature materials, common aerospace applications for them, and the importance of choosing reliable aerospace components manufacturers.
Understanding High-Temperature Materials in Aerospace
The extreme thermal conditions faced by aerospace systems – from landing systems to jet engines – demand advanced aerospace materials that won’t degrade under intense heat. The use of fire-resistant, fire-repellent, and other high-temperature materials is critical to upholding high standards of safety in the aerospace industry and optimal component performance.
The right materials ensure that critical aerospace systems maintain their integrity and operate safely, minimizing risks associated with high-temperature environments. These high-performance materials are chosen by aerospace engineering companies for their balance of heat-resistant properties, durability, and efficiency. Integrating these high-temperature aerospace materials not only enhances performance but also extends the lifespan of components, reducing maintenance costs over time.
Types of High-Temperature Materials
Ready to learn about high-temperature materials used for aerospace components? Or wondering what materials are fireproof? First, let’s break down some definitions.
While all are related in terms of fire-resistant properties, fireproof materials do not burn or deteriorate when exposed to fire. There are also fire-resistant materials that withstand very high temperatures without melting or igniting, but may eventually be damaged by prolonged exposure. These are not to be confused with fire retardant materials, which slow or prevent the spread of fire. Aerospace engineering companies also look tofire-repellent materials that prevent ignition from occurring in the first place and other heat-resistant materials that endure high temperatures without significant degradation.
Learn more about the high-temperature materials commonly used:
Refractory Metals
Refractory metals — including tungsten, molybdenum, tantalum, and niobium — are known for their exceptional melting points, often exceeding 2,000°C. These metals are heat-resistant and maintain stability, making them ideal for aerospace environments where components must withstand long-term exposure to extreme temperatures. Their heat tolerance and strength under thermal stress make them valuable materials for aircraft machining and component manufacturing.
Ceramics
Ceramics are lightweight, non-metallic, and can endure extreme temperatures without melting or warping, categorizing them as heat-resistant materials. With resistance to heat, wear, and corrosion, ceramic materials are commonly used by aerospace engineering companies. Ceramic materials can be further enhanced as composite aerospace solutions, like ceramic matrix composites (CMCs), which improve component strength and fracture resistance.
Superalloys
Commonly made from nickel, cobalt, and iron, superalloys are engineered to withstand high temperatures while maintaining strength and oxidation resistance. Superalloys are commonly used in turbine blades and other critical engine parts, where they contribute to both safety and operational efficiency. Though not a fireproof material, they are considered fire retardant due to their ability to resist heat and prevent the spread of flames in high-heat environments.
Carbon-Based Materials
Carbon-based materials, including graphite and carbon composites, offer both lightweight properties and high heat tolerance, which are ideal for a wide range of aerospace applications. They effectively dissipate heat and resist thermal shock, allowing them to endure sudden temperature changes without cracking or deforming. For example, carbon-based composites are frequently used in aircraft landing systems like brakes, providing robust fireproof material solutions that withstand extreme conditions without igniting.
Applications in Modern Aerospace
The use of high-temperature aerospace materials is essential across multiple critical systems. Here are a few of the main areas where these materials play a pivotal role:
Jet Engine Components
Aerospace components manufacturers rely on high-strength stainless steels and nickel-based superalloys for jet engine components, like fuel control values and hydraulic actuator valves. Superalloys and ceramic matrix composites are also commonly used for turbine blades and combustion chambers. These materials provide the durability required to perform reliably under the extreme conditions inside jet engines, where temperatures and pressures are consistently high.
Braking Systems
Aircraft braking systems require materials that can resist intense heat and friction. Fireproof materials like carbon-based composites provide high thermal stability and wear resistance, making them ideal for aerospace brakes, where consistent performance under high stress is essential.
Insulation Barriers
Insulation barriers are designed to protect sensitive equipment from excessive heat, particularly in aerospace applications. Made from advanced materials like ceramics and carbon-based fire retardants, these barriers offer exceptional thermal resistance and fire-retardant properties.
Precision Machined Components
Precision-machined components are essential in aerospace for parts that must resist extreme heat. Using heat-resistant and fire-retardant materials such as advanced alloys and fire-resistant metals, these components – including landing gear, aircraft evacuation and actuation components – are precision machined to maintain integrity under high temperatures. Precision machining also ensures dimensional accuracy and adherence to stringent industry standards.
Partner with NMG for High-Quality Aerospace Solutions
Working with a reliable aerospace components manufacturer is crucial to maintaining safety, efficiency, and durability in aerospace applications. With extensive experience in aerospace materials, precision machining, and aircraft component manufacturing, NMG Aerospace provides high-performance solutions that exceed the demanding requirements of aerospace engineering companies.
Contact us today to learn how NMG Aerospace can elevate your projects with high-quality aerospace materials and solutions.
Maintaining safety standards and ensuring high-quality components are paramount in the aerospace industry. EASA Part 145 certification plays a crucial role in achieving this goal by setting rigorous standards for the approval and oversight of aircraft maintenance organizations. This comprehensive set of regulations developed by the European Union Safety Agency, along with its U.S. counterpart 14 CFR 145, ensures that organizations adhere to stringent aviation safety regulations and can perform maintenance safely and effectively.
EASA Part 145 refers specifically to the section of regulations under 14 CFR Part 145 that governs the requirements for repair stations in the United States. This section outlines specific rules for the operation and maintenance of aircraft and aircraft components in accordance with Federal Aviation Administration (FAA) regulations.
Why Manufacturers Become EASA Part 145 Certified
EASA Part 145 (14 CFR 145) regulations set strict standards to ensure that maintenance work on aircraft and components adheres to rigorous safety and quality requirements. EASA Part 145 approval allows aerospace manufacturers to operate as a repair station under FAA regulations and perform maintenance, repair, and overhaul work. Certification also ensures alignment with globally-recognized regulations, opening the door to international markets and partnerships for aerospace manufacturing and design companies.
For an aerospace components manufacturer, EASA Part 145 certification demonstrates a commitment to maintaining the highest safety standards and maintenance processes, which leads to improved product quality, reduced errors, and increased customer satisfaction. EASA Part 145 helps mitigate risks by identifying and addressing potential safety concerns, ensuring safer components and reducing liability. Additionally, the stringent processes required for certification often lead to improved operational efficiency, reduced waste, and optimized workflows for aerospace components manufacturers.
How to Get EASA Part 145 Approval
Achieving EASA Part 145 certification involves a multi-step evaluation of an organization’s capabilities, facilities, and procedures to ensure compliance with aviation safety regulations. For aerospace components manufacturers and repair stations outside the European Union, the process typically includes these steps:
Determine Eligibility: Confirm that the organization meets the basic requirements for EASA Part 145 certification, including appropriate facilities, equipment, and trained personnel, as well as the ability to comply with EASA regulations. For U.S.-based organizations, ensure alignment with both FAA 14 CFR Part 145 and EASA Part 145 standards.
Prepare Documentation: The organization develops a comprehensive Maintenance Organization Exposition (MOE) that outlines procedures, quality management systems, and compliance with EASA Part 145 requirements.
Submit Application: The applicant must complete EASA Form 2 and submit it directly to EASA along with the MOE and other supporting documents. U.S. repair stations should coordinate with both the FAA and EASA during this process to ensure compliance with bilateral agreements.
Initial Review: EASA conducts a thorough examination of submitted materials to ensure compliance with Part 145 requirements. For U.S. applicants, this review may involve coordination between FAA and EASA authorities.
On-Site Audit: EASA performs an on-site inspection of the aerospace machine shop or repair facility to verify that all aspects meet the required standards.
Address Findings: If EASA identifies any deficiencies during their audit, the organization will be required to correct them before proceeding. This may involve revising manuals, upgrading equipment, or providing further training for employees.
Certification and Approval: Once EASA confirms full compliance with Part 145 standards, they will grant EASA Part 145 certification.
EASA Part 145 certification not only ensures that your precision aerospace components are serviced to meet or exceed safety and quality expectations, but that manufacturers implement best practices throughout their operations. These regulations, including sections like Part 145 that govern requirements for U.S. repair stations, ensure manufacturers operate with the highest standards, covering personnel qualifications, facilities, equipment, and quality control measures.
This commitment to excellence reduces errors and enhances overall component quality, contributing to the longevity and operational life of your aircraft systems while minimizing associated risks. Furthermore, working with a Part 145 certified manufacturer can streamline regulatory approvals and reduce the time needed for audits, driving efficiencies in your operations.
At NMG Aerospace, we proudly hold EASA Part 145 certification, ensuring that our maintenance and repair processes meet the highest safety and quality standards. Our Stow, Ohio FAA repair station is compliant with EASA Part 145 and rated for Accessory (Class 1) and Limited Accessory. Our certifications are augmented by over 50 years of experience in aerospace manufacturing and design, enabling us to build a reputation for delivering precision aerospace components and high-quality repair station services.
Talk to a member of our team to learn more about how our EASA Part 145 certification and extensive expertise can enhance the reliability and performance of your aerospace systems.
Root cause analysis (RCA) is used to identify the root cause of issues within processes, systems, or equipment. In the aerospace industry, root cause analysis training is essential for maintaining high standards in aerospace manufacturing and ensuring product quality. This analysis aims to understand underlying causes rather than just symptoms, providing long-term solutions to prevent the recurrence of issues.
The Importance of Root Cause Analysis in Aerospace
Root cause analysis is essential for advancing safety, compliance, and product quality in aerospace applications. By systematically conducting root cause problem-solving to identify and address underlying causes of issues, this analysis enhances quality management and ensures the reliability of products and systems. The method supports continuous improvement initiatives, enabling aerospace manufacturers and organizations to identify and implement best practices while minimizing variations in production and operations. Additionally, root cause analysis is crucial for meeting stringent regulatory requirements, adhering to safety standards, and maintaining compliance in the aerospace industry.
Manufacturers vs. Commercial Airlines
While both manufacturers and commercial airlines aim to ensure passenger safety, their approach to root cause analysis varies based on their respective roles. For aerospace manufacturing, the primary concern is ensuring that the aerospace parts produced meet stringent safety standards. Manufacturers must continuously analyze any defects or failures in components before they are integrated into aircraft systems. On the other hand, commercial airlines focus on maintaining safety protocols through root cause and corrective action training to ensure any in-flight incidents or maintenance issues are addressed promptly and effectively.
How to Conduct Root Cause Analysis for Safety & Reliability Incidents
To conduct effective root cause analysis for aerospace safety and reliability incidents, assembling a well-rounded team is essential. This team should consist of key stakeholders, including suppliers and customers, as well as relevant job functions that influence the corrective action process. Their collaboration ensures a thorough examination of the issue. Effective root cause analysis training prepares each team member by clarifying their roles and responsibilities.
The process of root cause problem-solving typically involves a series of structured steps, as outlined below:
Define the Problem
After the RCA team is selected, the next step is defining the problem. This involves understanding the problem’s significance, impact, and size and identifying which product, process, or defect is at fault in the safety or reliability incident. It’s important to differentiate between the effect (outcome of a problem) and the cause (the origin of a problem). A clear and agreed-upon definition ensures everyone is aligned from the start.
Causal Factor Identification
Once the problem is defined, the next step is identifying the causal factors that contribute to the issue. Understanding all factors that contributed to the undesirable condition, situation, nonconformity, or failure enables a comprehensive review of the circumstances that led to the problem. These causal factors could include design flaws, procedural errors, human factors, or even environmental influences.
Root Cause Identification
In this step of root cause problem-solving, root cause identification tools are employed. The goal is to identify both common and special cause variations. 7 different root cause analysis techniques include:
Process Mapping
Fishbone Analysis (Ishikawa)
Cause and effect
FMEA (Failure Mode and Effect Analysis)
5 Whys
Failure Tree Analysis (FTA)
Root Cause Chain
By analyzing each variation, teams can stabilize processes to eliminate special causes and enforce control measures to reduce common cause variations. This ensures that all critical factors contributing to the problem are addressed.
Define Corrective Actions
After root causes are identified, the RCA team is responsible for defining corrective actions that will address the root causes and permanently prevent the undesirable condition, situation, nonconformity or failure from recurring. Root cause and corrective action training gives teams the tools to prioritize solutions that stabilize and improve processes.
Implementing Root Cause Analysis at NMG Aerospace
At NMG Aerospace, we employ a structured approach to root cause analysis that drives continuous improvements in our quality management and aerospace manufacturing processes. Our team receives regular root cause analysis training to ensure they are well-prepared to implement permanent corrective measures and assess their impact. Once all corrective actions are taken, their effectiveness is evaluated, and the knowledge gained is shared across our teams. This continuous learning process highlights the contributions of all NMG team members and ensures that all action items are thoroughly addressed.
Partner With NMG Aerospace
Ready to leverage our expertise? Our advanced root cause analysis and quality management processes ensure the highest standards in aerospace manufacturing. Contact us today to begin your partnership with NMG.
Linear actuators, motor actuators, and other specialized aircraft actuators perform essential functions across key aircraft systems, from engaging and retracting landing gear to managing flight control surfaces and regulating engine systems and valves. NMG has leveraged our years of aircraft manufacturing experience to become a leading supplier of aircraft actuator components, including hydraulic valves and air pressure regulator valves, that control essential functions from nose to tail. Our robust manufacturing, assembly, and testing capabilities support pressure applications up to 10,000 psi, allowing us to manage a wide range of aircraft actuator projects with precision and reliability.
Types of Actuators
Linear Actuators
The most common type of aircraft actuator, linear actuators are deployed across various aircraft systems to convert energy into motion. These actuators control key components and functions that vary in complexity, providing reliable performance in applications ranging from landing gear to flight control surfaces.
Hydraulic Actuators
Hydraulic actuators are powerful and durable, making them an excellent option for high-force applications. Hydraulic actuators use fluids, such as Skydrol and Red oil, to generate the necessary force and torque in high-pressure scenarios. Hydraulic valves maintain fluid control and system efficiency within a hydraulic actuator.
Solenoid Actuators
Solenoid actuators convert electrical energy into mechanical force, often to control the movement of doors, latches, switches, solenoid operated valves, and other aircraft mechanisms. Solenoid valve actuators provide reliability and efficiency even when operating in harsh conditions, making them a common choice for aerospace applications.
Common Applications of Aircraft Actuators
Aircraft actuators enable precise movement and adjustments of aircraft flight controls, landing gear, and other critical systems. This precision is crucial for maintaining stability, maneuverability, and safe operation of the aircraft. Additionally, air pressure regulator valves are often integrated within aircraft actuator systems to ensure optimal performance and pressure control, contributing to overall system reliability.
Flight Control Systems
Flight control surfaces depend on aircraft actuators to manage adjustments in the wings, rudders, and flaps. These systems require precise control to ensure smooth handling during various flight maneuvers. Linear actuators and motor actuators are essential components for maintaining stability and performance throughout flight.
Landing Gear Systems
Landing gear systems rely on robust hydraulic actuators to retract and deploy the gear during takeoff and landing. The high-force requirements of these operations demand the reliability and power of hydraulic valves and solenoid valve actuators, ensuring dependable performance under stress.
Engine Control Systems
Engine control systems utilize solenoid valve actuators and air pressure regulator valves to manage fuel and air intake with precision, optimizing engine performance. These aircraft actuators are essential for maintaining operational efficiency and preventing malfunctions by accurately regulating critical engine functions.
The NMG Quality Difference
NMG has over a decade of experience manufacturing top-quality aircraft actuators that perform reliably regardless of service conditions. We prioritize strategic quality control checks every time we design a new manufacturing process for an aerospace actuator, so we can get it right the first time, every time.
Aerospace solenoid valves are crucial components for precision and reliability. But how does a solenoid valve work to maintain reliable aircraft performance? The purpose of solenoid-operated valves is to precisely regulate fluid and gas flow across various critical aerospace systems, from braking mechanisms to deicing equipment. Aerospace systems commonly use hydraulic solenoid valves, pneumatic solenoid valves, electric solenoid valves, gas solenoid valves, and other types to serve essential functions within an aircraft.
What Is a Hydraulic Solenoid Valve?
A hydraulic solenoid valve controls hydraulic fluid flow in high-pressure applications. These valves manage hydraulic power in aerospace systems like landing systems, brakes, and flight controls. These valves use an electric current to actuate the valve, ensuring precise control of hydraulic fluid flow. This precision is vital for optimal performance and safety of aerospace systems. For example, in landing systems, hydraulic solenoid valves ensure smooth and reliable deployment and retraction of gear during extreme environmental conditions.
Components of Aerospace Solenoid Valves
In aerospace systems, solenoid-operated valves consist of three critical components: the coil, plunger, and body. These parts work together to ensure precise fluid and gas control and system reliability.
The Coil
The wire coil is the core of the solenoid valve. When electrical current flows through it, the coil generates a magnetic field that moves the plunger within the valve. The responsiveness and efficiency of a solenoid valve are determined by the coil’s material, voltage rating, and power consumption.
The Plunger
The plunger is a movable metal component within the solenoid valve. When the coil is energized, the magnetic field pulls the plunger, causing it to open or close the valve to control fluid or gas flow. High-quality materials and exact dimensions are crucial for accurate and reliable valve operation, particularly in high-stress aerospace environments.
The Body
The body of a solenoid valve houses all of the internal components. It also features inlet and outlet ports through which fluids or gases flow. The body is designed to withstand high pressures and harsh environmental conditions. This durability and structural integrity are vital for ensuring long-term reliability and performance of the solenoid valve.
Types & Applications of Solenoid Valves Used in Aerospace
Different types of solenoid valves are used in aerospace, each suited to specific applications:
Pilot-Operated Valve
Pilot-operated solenoid valves use a small pilot valve to control a larger valve. This type is ideal for high-pressure applications where direct control would require excessive force. By employing a pilot valve, these solenoids can manage large flows efficiently and with lower power consumption. They are commonly used in fuel and hydraulic systems in aircraft where precise control is critical.
Direct-Acting Valve
Direct-acting solenoid valves operate without a pilot valve. Instead, the electromagnetic force directly moves the plunger to open or close the valve. This makes direct-acting valves simpler and faster in operation and well-suited for high-stress aerospace environments. These valves are ideal for critical safety systems, such as emergency shut-off valves in fuel and hydraulic systems.
2-Way, 3-Way, and 4-Way Valves
2-way valves have two ports and are used to allow block fluid flow. They are commonly found in simple on/off applications. With three ports, 3-way valves can direct fluid between two different paths. This makes them suitable for more complex control scenarios, such as switching between landing systems. Lastly, 4-way valves have four ports that control double-acting actuators. They are essential in systems that require reversing the direction of fluid flow, such as flight control surfaces.
Choose NMG Aerospace for Superior Aerospace Solenoid Valve Solutions
NMG Aerospace stands out as a leader in the design and manufacturing of high-quality hydraulic valves that integrate seamlessly into various systems to ensure exceptional aircraft performance and safety. Our solenoid division, Electromotive Inc., brings decades of specialized experience in custom solenoids, solenoid valves, and actuators to support your project from the ideation stage through quality testing. To discuss your next project, talk to a member of our team today.
Aviation safety standards are universal requirements that create a shared benchmark used by aircraft manufacturers and airlines to ensure the safety of everyone in and around an aircraft. These standards govern everything from the durability of military aircraft wheels to pilot activity in business aviation.
All categories of aircraft must comply with aviation safety standards, though the specifics may differ between commercial, military, private, and business aviation. Aviation safety standards are developed based on the risks associated with each type of aviation or aircraft, with the goal of optimizing safety from as many angles as possible.
Regulatory Bodies
Aviation safety is governed by multiple regulatory bodies, from governmental bodies to global entities.
Federal Aviation Administration
The Federal Aviation Administration, or FAA, is part of the United States Department of Transportation. The FAA manages a vast body of regulations, statutes, and rules, all of which are developed with the goal of protecting pilots, flight attendants, passengers, and the general public. FAA standards touch virtually every aspect of aviation, including:
Aircraft design, manufacturing, and maintenance
Pilot training
Flight
Ground activity
Some FAA standards apply to all types of flight, while others are specific to certain categories, such as military or business aviation.
International Civil Aviation Organization
The International Civil Aviation Organization, or ICAO, is an agency of the United Nations. The ICAO plays a critical role in overseeing and supporting the growth of the aviation industry on a global scale, with the goal of ensuring safety. The ICAO keeps updated information on member countries’ aviation standards and practices and manages its own library of standards on passports and infrastructure management.
How Safety Standards Drive the Manufacturing Process
Aviation safety standards and regulations apply to aerospace manufacturing as well as aircraft operations. Excellence in manufacturing is critical to ensuring safety in flight.
Material Selection
Many aircraft components are subjected to intense conditions during takeoff and landing and throughout the flight. Ensuring the reliable performance of these components begins with choosing a manufacturing material that can withstand the rigors of the aerospace environment and meet the safety standards put forth by the relevant governing bodies.
Quality Assurance and Control
Some aviation safety standards require specific quality control practices during the aerospace manufacturing process to ensure well-made components that will perform as designed. Conducting multiple quality checks increases the likelihood of detecting potential issues early, so they can be addressed, and improves consistency on the manufacturing floor.
The Impact of Safety Standards on Business Aviation
Aviation safety standards compel manufacturers to innovate reliable products and improve their own practices to support safe flight. In the world of business aviation, this has a few key impacts:
Enhance Passenger Safety
Aviation safety standards are developed with the goal of protecting all passengers. In the world of business aviation, this may include key leaders, valued employees, important clients, and other special guests aboard the aircraft.
Build Trust in the Industry
A strong track record of safe flights is critical for the success of business aviation. Business aviation safety standards ensure the highest likelihood of a safe journey from one destination to another.
Innovation and Continuous Improvement
The inherent constraints of aviation safety standards have inspired tremendous innovation over the years as aerospace manufacturers strive to develop better components that still meet requirements. Aviation safety standards drive continuous improvement in business aviation by compelling manufacturers to think creatively about innovation and safety together.
NMG’s Commitment to Quality and Safety
NMG Aerospace is proud to make top-quality business aviation components that adhere to the most stringent aviation safety standards. With rigorous quality control practices and our innovative methods of design, we take a multi-faceted approach to safety and quality in business aviation. From clean-sheet design to existing component updates and beyond, you can count on NMG for reliable manufacturing, exceptional quality, and excellent service.
Just as cars need routine maintenance and new parts from time to time, aircraft components need to be serviced and replaced on a regular basis. Aerospace parts often operate in intense conditions, and even those engineered for longevity don’t last forever. Maintaining and upgrading aircraft components on a consistent schedule is not only critical for safety and performance, it can also yield cost savings and extend the lifespan of aircraft systems.
Ensure Safety
Worn-out parts, such as engine components, filters, electronics, and brake parts, can cause serious problems if they fail to meet expectations while the aircraft is in use. Upgrading and replacing components on the recommended schedule, or when signs of wear begin to appear, is key to ensuring safe operation of the aircraft.
Maximize Aircraft Performance
Some aircraft components can continue to function past their recommended service life, but they are unlikely to perform as well as a new part. The fading efficacy of a worn-out part can have a ripple effect throughout the aircraft. Upgrading aircraft components regularly contributes to the superior performance of the aircraft as a whole.
Extend Component Lifespan
Upgrading smaller components within a larger system can meaningfully extend the life of the larger system. Replacing belts and valves on a regular basis, for example, is vital for maximizing the lifespan of the engine.
Comply with Regulatory Standards
While upgrading some aerospace components is a judgment call, other aircraft upgrades are mandated by regulatory bodies. Keeping up with the required schedule is critical to maintaining compliance.
Save on Maintenance Expenses
Regularly upgrading aircraft parts can help prevent more significant expenses down the road. Keeping up with routine maintenance minimizes the risk of larger malfunctions or expensive repairs, which are often far more costly and time-consuming to resolve.
Commonly Replaced Aircraft Components
Some aircraft components can last for years or even decades, while others must be replaced or upgraded on a schedule. This largely depends on the function of the component and its rate of wear while in service. Commonly replaced aircraft components include:
Wheels and Brakes
Aircraft wheels and brakes are designed to perform under incredible duress, absorbing the full weight and momentum of the aircraft while performing critical functions. Even those designed for maximum longevity must be upgraded or replaced on a regular basis to ensure optimum function. Routine maintenance for aircraft wheels and brakes should include close inspection and regular replacement of wheels, brake pads, and other components as needed.
Avionics Systems
Many aircraft are engineered and built to last for decades, but the lifecycle of avionics is much shorter. This is partially due to the speed of advancements in electronics, as well as the shorter lifespan of delicate avionics components. In order to avoid obsolescence, avionics systems should be upgraded according to a regular schedule.
Engine Components
Aircraft engines are high-performance machines that convert tremendous amounts of power into motion, often in intense conditions. Replacing and upgrading aircraft engine components, such as belts, filters, and fan blades, is critical to extending the life and improving the performance of the engine.
NMG’s Commitment to Quality and Safety
NMG Aerospace understands the vital importance of quality when it comes to aerospace components and how quality contributes to safety in the skies. We take a multi-pronged approach to quality assurance in our aerospace component manufacturing practices, from coveted accreditations from federal and industry bodies to extensive qualification testing of finish components. And with our company-wide commitment to continuous improvement, we’re always looking for ways to do even better. Our customers return to us over and over because they know they can count on NMG for quality and consistency, every time.
Upgrade Your Aircraft With NMG Aerospace
From MRO services to aerospace component manufacturing, NMG Aerospace offers the services and expertise to support aircraft upgrade projects of every kind. Our team can help you determine whether you need to simply replace worn parts or upgrade an entire system based on your needs and goals. To learn more about aircraft upgrades with NMG Aerospace, get in touch.
NMG Aerospace is proud to offer a robust portfolio of aerospace manufacturing and design services for a wide range of aerospace components and assemblies. Our aerospace manufacturing experience dates back to 1967, when we began providing machining services for the aerospace industry. Since then, we have strategically expanded the capabilities and expertise of our aerospace manufacturing company to support the evolving needs of the aerospace industry through continuous innovation, rigorous quality standards, and a commitment to on-time delivery. As an elite Tier 2 manufacturer, NMG leverages advanced capabilities including fabrication, precision machining, NADCAP welding, and more to support you at every stage of the aerospace manufacturing process. We consistently deliver aerospace components and assemblies of the highest quality that meet the most stringent industry standards.
Core Capabilities
We have earned NADCAP certifications for welding and chemical processing, refined our fabrication and design skills through decades of experience, expanded our precision machining and MRO footprints, and conducted countless quality validation tests for aerospace components, systems, and assemblies. Our comprehensive core capabilities allow us to address the diverse demands of the industry, ensuring that each aerospace component meets rigorous performance and excels in the most challenging service environments.
With many years of experience in aerospace manufacturing and building assemblies from the ground up, NMG brings tremendous knowledge and perspective to the fabrication and assembly process. From sheet metal fabrication and NADCAP certified welding to streamlined assembly, we excel at both modifying existing designs and developing innovative aerospace components from scratch. Our experts provide comprehensive support from your first conversation through testing and validation, solidifying our reputation as an aerospace manufacturing company you can rely on.
NMG Aerospace has over 40,000 square feet of dedicated precision machining space, staffed by highly experienced machinists who specialize in aerospace manufacturing. We address the intricate requirements of aerospace components using cutting-edge machinery and advanced processes, ensuring each component adheres to exacting tolerances and withstands the rigorous demands of aerospace applications. From landing gear and braking assemblies to steering, evacuation, and actuation components, NMG is a trusted name for aerospace manufacturing and precision machining that exceeds industry standards.
With our extensive experience in aerospace manufacturing, NMG Aerospace offers peerless insight into the design process for aerospace components and assemblies. We leverage our knowledge as a top aerospace manufacturing company to help you address tough design challenges and expedite time-to-market. From simple aerospace components to complex, specialized assemblies, our innovative technologies help our customers meet evolving industry demands. In addition to component and assembly design, we can also create custom fixtures to support new aerospace manufacturing processes.
NMG is proud to hold NADCAP certification for our aerospace welding services. Our highly skilled NADCAP team has extensive experience in welding critical aerospace components such as pressurized vessels, rigid tubes, stainless steel tanks, and custom welded components that adhere to NADCAP standards. We’ve developed advanced processes to ensure precise control of shrinkage, tight tolerances, and minimal warping throughout the lifecycle of NADCAP welded components and products.
As part of our dedication to supporting the entire aerospace manufacturing process, NMG Aerospace offers comprehensive qualification testing for aerospace components. Our on-site testing capabilities adhere to the requirements of RTCA DO-160 and other aerospace manufacturing quality standards. With our many years of experience in aerospace manufacturing, design, and testing, we can develop custom testing protocols that simulate real-world conditions and ensure the highest standards of safety and performance for our customers’ aerospace components. These qualification testing capabilities provide critical data for research and development purposes and for validating component reliability in unusual situations or service environments.
NMG’s broad aerospace manufacturing and design services are augmented by our extensive maintenance, repair, and overhaul (MRO) capabilities for aerospace components and systems. Our MRO experts have specialized knowledge in deicing, electromechanical, and hydraulic systems, as well as packboards and accessories. To ensure thorough and reliable MRO support, NMG also operates two FAA repair stations in the United States: one in Stow, Ohio, and one in Tempe, Arizona. Our Ohio FAA repair station is also compliant with EASA Part-145. NMG’s comprehensive MRO capabilities ensure operational readiness and extend the lifecycle of critical aerospace components.
As a leading aerospace manufacturing company, we are proud to stand behind extensive chemical processing capabilities ranging from anodizing to powder coating that reinforce our commitment to superior-quality aerospace components. In addition to our NADCAP welding services, NMG has earned other coveted NADCAP certifications for a range of chemical processing services. Our NADCAP certified chemical processing capabilities include shot peening, painting, pickling/passivation, brazing, and anodizing. With advanced machinery designed for sizable aerospace components, our chemical processing services ensure strict adherence to rigorous industry standards and consistent performance in demanding environments.
What Sets NMG Aerospace Apart
At NMG Aerospace, our dedication to actively listening to our customers distinguishes us from other aerospace manufacturing and aerospace machining companies. We show our commitment to quality and exceptional service through tailored solutions that align with your strategic goals. Our customer-focused approach drives us to continually innovate and improve our aerospace manufacturing capabilities, ensuring you stay competitive in the rapidly evolving aerospace industry.
With over 50 years of industry experience, we are an elite Tier 2 manufacturer offering comprehensive services to address specific challenges in aerospace manufacturing and precision machining. Our adherence to LEAN manufacturing ensures efficient production, while our advanced precision machining and NADCAP certified services guarantee top-tier quality in aerospace components and assemblies. We also prioritize on-time delivery and leverage our global supply chain to keep your projects on track and efficiently managed.
Partner With NMG Aerospace
From the first conversation between your team and ours to the final delivery, NMG earns your trust by prioritizing quality and service.
To learn more about our aerospace manufacturing, MRO, chemical processing, and testing services, talk to a member of our team.
Safety is important in many industries, but in the realm of aerospace manufacturing, there is a tremendous price to pay when safety is not prioritized. And safety goes far beyond evacuation slides, life rafts, and emergency brakes. Every single component of an aircraft, from a single screw to a massive fuselage, contributes to its safe operation, both in the air and on the ground. When safety is a priority, everyone—from the people aboard the plane to the bystanders on the ground—benefits.
A robust safety strategy is the product of many different factors, but at its core, safety starts with quality.
NMG’s Commitment to Quality
NMG Aerospace understands that safety, quality, and consistency are inextricably linked. Quality aerospace components lay the foundation for safe aircraft operations, and for high-volume production runs, consistency is key to ensuring that every single component meets the exacting standards of our customers.
Quality is built into the fabric of NMG, from new hire training to production. There are multiple quality checks built into our aerospace manufacturing processes, above and beyond what is required by regulatory bodies. Every single member of our aircraft design and manufacturing team undergoes intensive continuous improvement training, so we can work together to deliver our best, every time.
Our safety and quality measures also include multiple certifications and accreditations and rigorous on-site testing to validate aerospace component performance.
Quality Assurance & Certifications
NMG has earned a number of coveted accreditations at our aerospace manufacturing and repair facilities. These accreditations are only granted to companies that meet incredibly high standards for quality and integrity, and are willing to undergo a rigorous certification process.
Standards
NMG Aerospace is ISO 9001 accredited and AS 9100 certified at our facilities in both Ohio and Arizona.
Processing
NMG is proud to be NADCAP certified for aerospace welding and chemical processing.
Air Agency
NMG’s repair stations in Stow, Ohio and Tempe, Arizona are FAA certified and compliant with federal quality and safety standards. The Stow facility is also EASA certified.
Qualification Testing Capabilities
NMG has invested in extensive in-house aviation qualification testing capabilities so we can validate the performance of components and assemblies and ensure a superior final product. We can recreate a wide range of intense environmental conditions in a controlled environment, so we can observe how components will perform when they encounter those conditions in the field. Understanding the relationship between a component and an uncontrollable variable, such as temperature, humidity, or altitude, is key to developing aerospace components that can perform as intended while in service in adverse conditions. This insight into product performance gained through aviation qualification testing is another predictor of quality and, ultimately, safety.
Partner With NMG Aerospace
Countless major aircraft and aerospace manufacturers trust NMG to provide high-quality components that meet their rigorous standards and enhance safety. With our accreditations, robust quality checks, and stringent testing, we’ve built our entire operation around delivering quality and consistency, every time.
Collaborative Solutions
NMG is more than just an aerospace component manufacturer. We strive to be a true partner to other aerospace companies. We take a highly collaborative approach to every customer interaction, so we can understand your needs and create a solution that matches your specs, meets your deadlines, and keeps your aerospace company moving forward in a competitive marketplace. And because NMG is a private aerospace company, we can be nimble and adapt our approach quickly if your circumstances or needs change.
To learn more about our approach to collaboration, our quality standards, and how we can support you, talk to a member of our team.
Different types of aircraft rely on a variety of braking systems for safe operation. From aircraft brake calipers and brake discs to rotor brakes on helicopters, braking systems are critical for safety and performance.
Each type of aircraft braking system has unique features and functions based on its position and purpose.
Aircraft Wheel Brakes
Aircraft wheel brakes are incorporated into the aircraft’s landing gear. Aircraft wheel brakes must apply tremendous force to fast-moving wheels to slow or halt their rotation and bring the aircraft to a stop on the tarmac or runway. All components of an aircraft’s braking system must withstand the friction and heat generated by the braking process.
Different types of aircraft must perform braking maneuvers in different environments. Commercial aircraft wheel brakes are operated almost exclusively on well-maintained airport runways. These runways tend to be long, allowing ample time for braking. Military aircraft, on the other hand, often must land on fields, rough surfaces, or aircraft carriers with extremely short runways. These strenuous and often unpredictable situations put considerable stress on the aircraft’s braking system, which must be taken into account during the design process.
The tremendous forces of aircraft wheel braking systems are operated entirely via a foot pedal, controlled by a human pilot.
Helicopter Rotor Brakes
The purpose of helicopter rotor brakes is to stop the rotation of the helicopter’s blades. Helicopter pilots do not deploy the rotor brakes until after the helicopter has landed and the engine has been shut down. Only after the spinning rotors have come to a complete stop is it safe for the pilot and passengers to exit the helicopter.
Helicopter rotor brakes are very different from aircraft wheel brakes. While wheel brakes, which are integrated into the aircraft’s landing gear, have virtually no impact in the air, it is incredibly dangerous to activate helicopter rotor brakes while in flight, even for a moment. For this reason, helicopter rotor brakes are activated with a manual lever, instead of a foot pedal that could be tapped by accident.
Brakes for Homebuilt Aircraft
Many homebuilt aircraft are entered into short takeoff and landing (STOL) competitions. Pilots of homebuilt aircraft strive to execute a complete stop as quickly as possible after landing, often less than fifteen feet from the touchdown site.
Needless to say, fast-acting brakes must be able to apply and withstand tremendous pressure. And because these aircraft are homebuilt, the landing gear and braking system installation process must be simple enough for the average STOL competitor to do it safely. Performance and ease of use must both be considered during the design process.
Aircraft Braking System Materials
Material choice for aircraft braking systems can be a balancing act. Aircraft brake materials must be durable enough to withstand heat, pressure, vibration, and other forces. However, aerospace manufacturers must also be mindful of weight, since heavy materials affect the fuel economy and aerodynamics of the aircraft.
Some common materials used for aircraft brakes and landing gear include:
Metals
Disc brake rotors are often made from iron or steel. Brake linings also frequently contain metals and may be semi-metallic or sintered.
Rubber
Braking system hydraulics are operated with rubber components.
Carbon Fiber
Some aerospace manufacturers have started using carbon fiber as an alternative to traditional metals in aircraft braking systems. Carbon fiber is light, strong, durable, heat resistant, and can last a long time. As carbon fiber becomes less expensive, its popularity is expected to grow.
The Right Braking System for Your Aircraft
Designing and building the right aircraft braking system and landing gear for a given platform requires understanding both the aircraft and its anticipated service environment. The experts at NMG have years of experience in aircraft brake manufacturing and deep knowledge of the many variables to consider during the design process. From the early stages of ideation and design to material selection, manufacturing, and quality testing, NMG can support every step of the aircraft brake production process.
NMG is proud to offer a robust portfolio of aerospace testing capabilities to validate the environmental, structural, and functional performance of aircraft parts, products, and components. We’ve aligned our capabilities at our state-of-the-art aircraft testing and qualification facilities with RTCA DO-160 and other critical aerospace testing standards to ensure that we can help our customers remain competitive and current in the aerospace industry. In addition to standard tests, we can also design custom aerospace testing protocols for R&D and predicting outcomes of unique situations and environments. Whether we’re running an industry-standard test, such as RTCA DO-160, or designing a custom aircraft testing protocol, we emphasize accuracy, reliability, and repeatability to ensure quality data.
NMG’s Qualification Testing Capabilities
Temperature Testing
From the heat of launch to the extreme chill of altitude, aerospace components are often exposed to a wide range of extreme temperatures while in service. The purpose of temperature testing is to predict how a given material or component will perform under these circumstances. NMG’s thermal shock and environmental test chambers can recreate these dramatic temperature swings or prolonged periods of extreme exposure in a controlled aerospace testing laboratory environment.
Altitude Testing
Changes in altitude are often accompanied by drastic changes in both temperature and pressure. Aircraft parts and materials must be able to withstand these changes while continuing to fulfill their intended purpose. Laboratory altitude testing allows manufacturers to demonstrate how an aircraft component will handle altitude changes without ever leaving the ground.
Humidity Testing
Many aircraft components are exposed to humid environments while in service. While excess humidity can cause a number of issues, the greatest is corrosion, which can lead to mechanical failure and electrical shortages. Understanding the effects of humidity is vital to designing a system that can maintain performance when exposed to humid conditions. NMG leverages RTCA DO-160 humidity testing methods to allow manufacturers to qualify the effects of humidity on aerospace components in a controlled environment so they can validate performance.
Shock and Crash Safety Testing
Even in normal operations, an aircraft—and its many components and assemblies—can experience a variety of shocks. Landing, taxiing, strong winds during flight, and other standard events can transmit shock throughout the aircraft. RTCA DO-160 operation shock and crash safety testing is designed to demonstrate how aircraft parts respond to these forces by recreating shocks in an aircraft testing laboratory setting.
Vibration Testing
Propellers, fans, turbojets, and other aerospace mechanisms generate a lot of vibration while in service. The intensity and duration of vibration can vary depending on the aircraft and the flight. Aircraft components can be subjected to standardized vibration profiles in an aerospace testing lab based on what they may encounter in service to ensure compliance with performance standards. NMG has deep knowledge of the vibration testing methods for each aircraft outlined in RTCA DO-160.
Waterproofness or Fluid Susceptibility Testing
From puddles on the runway to precipitation in the skies, aircraft are exposed to moisture. Fluid susceptibility testing assesses a component’s vulnerability to fluid ingress and fluid contamination. NMG can recreate a wide range of fluid exposure scenarios in a controlled laboratory setting based on the unique environment of each component. RTCA DO-160 test methods range from full immersion or soak testing to minimal contact or dripping.
Icing Testing
Changes in altitude, humidity, and temperature can lead to ice buildup on aircraft. Icing test protocols can recreate several icing scenarios, based on the location of a component within an aircraft, and determine whether performance is compromised by icing. This type of aerospace testing is conducted in a specialized environmental test chamber.
Other Tests: RTCA DO-160 and Custom Protocols
NMG’s aerospace and aircraft testing facilities are equipped for a wide range of additional validation, performance, and conditioning tests. In addition to RTCA DO-160 testing, we can design custom protocols and combine multiple variables to recreate unique service environments based on our customers’ needs.
What Is RTCA DO-160 Testing?
RTCA stands for Radio Technical Commission for Aeronautics. RTCA DO-160 is an aerospace testing standard that describes laboratory testing methods for assessing the performance of aircraft parts in different environmental conditions. RTCA DO-160 includes 23 different aerospace testing procedures, such as temperature, humidity, and vibration testing. Each RTCA DO-160 test procedure includes options for tailoring the method based on the type of aircraft or component undergoing testing.
The RTCA is not a government entity, but many RTCA DO-160 test procedures have been adopted by federal agencies, such as the United States Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA).
Continuous Improvement
NMG’s robust in-house aerospace testing capabilities are an important pillar of our commitment to continuous improvement. While aircraft testing is vital to demonstrating compliance, it also reveals data and insight that can pave the way for the next generation of exceptional aerospace components and platforms. Our team members are always looking to make our aircraft testing processes better so we can help you make your products better and remain competitive in the ever-changing aerospace market.
How Can We Support You?
Tell us about the components you need – we’re here to help you overcome your challenges with service and science that take you to new heights.
Aircraft wheels and brakes must perform critical functions under extreme duress. The aircraft braking process generates tremendous pressure and heat, which puts considerable strain on landing gear components.
Understanding these stressors during the landing gear design process is key to manufacturing airplane wheels and brakes that function as intended.
The Landing Gear Design Process
Effective landing gear design starts with a comprehensive understanding of the landing gear’s performance requirements and service environment. Manufacturers may ask a few questions to guide the landing gear design process, including:
How large and heavy is the aircraft?
Will the aircraft perform take-offs and landings primarily on well-maintained runways or unpredictable field sites?
How much heat will be generated by braking forces?
In some cases, a totally new landing gear assembly or component concept will call for a clean-sheet approach to the design process. However many manufacturers can use an existing landing gear design as a jumping-off point.
After the design stage, manufacturing will look slightly different for each component of the landing gear assembly.
Aircraft Wheels: The Manufacturing Process
Most aircraft wheels are two-part assemblies, called a split-wheel construction. The inboard and outboard wheel halves are designed differently, since the inboard wheel half drives the brake rotor. The two halves are bolted together, with a high-performance O-ring creating a tight seal.
Airplane wheels must be manufactured to withstand tremendous pressure and high heat from heavy braking. For this reason, the most common manufacturing methods for airplane wheels are casting and forging, since both result in incredibly strong wheels. Many aircraft wheels are made from aluminum alloy, but magnesium alloy is also a fairly common material choice. Once the wheel halves have been cast or forged, additional steps may be taken, such as:
Machining grooves or holes into the assembly
Heat treating
Finishing treatments, such as shot peening or anodizing
Brake Rotor: The Manufacturing Process
Manufacturing brake rotors for aircraft landing gear starts with designing and creating a mold, usually with a CNC mill or other machine. The aircraft brake rotor mold is filled with hot liquid iron and compacted to ensure durability. Once the rotor has been cast, a machinist may use precision milling techniques to create level surfaces and meet tight tolerances, and CNC drilling to make precise holes for heat to escape. The final steps of the aircraft brake rotor manufacturing process are polishing and finishing.
Brake Discs: The Manufacturing Process
Aircraft brake disc manufacturing begins with a steel, iron, or composite material plate. The basic shape of the brake disc, called a blank, is punched from the sheet. At this stage, two types of holes may be punched from the aircraft brake disc blank:
Process holes, for mounting the disc
Heat dissipation holes
The size and placement of these holes will differ depending on the design.
Further shaping of the blank may be achieved through heating, flattening, and extrusion. Edges and holes may also be chamfered.
Design and Manufacture with NMG Aerospace
NMG Aerospace has decades of aircraft wheel and brake manufacturing experience. We are proud to support aircraft manufacturers from the early stages of design and development to production design, manufacturing, and quality testing. With our deep knowledge of aircraft braking systems, airplane wheels, and landing gear assemblies, we can advise on nuanced design and production challenges.
With a broad range of manufacturing capabilities and over 40,000 square feet of machining space, NMG Aerospace is equipped to meet all of your aerospace manufacturing needs. Whether you are designing something new, updating an existing design, or seeking to solve a problem, you can count on NMG Aerospace for guidance.
To learn more about our aircraft brake and plane wheel manufacturing services and discuss a project, talk to a member of our team.
