An aircraft engine crankcase is a structurally and metallurgically complex piece of material. Cracks may develop because of either damage or casting defects; a thrust surface may be worn or a bearing spun. The case must be either replaced or repaired.
Engine Components' proprietary repair process, Electro-Fusion® can restore the strength and integrity of a crankcase and do it at a fraction of the cost of replacement.
When a crankcase is received at Engine Components, it is carefully inspected visually, then submitted to a full submersion dye check to determine crack locations. Then it is Brinnel-checked to determine hardness
Material around cracks and damaged areas is ground away to provide a clean metal base for welding
The crankcase is placed in an oven and the temperature is slowly increased to the optimum temperature for welding.
The area around cracks is repaired with the Electro-Fusion® heli-arc welding process vibratory peening to increase density. The case is then allowed to cool in ambient air
The crankcase is completely inspected again, Brinnel-checked and prepared for machining.
Camshaft and crankshaft bearing surfaces are line-bored to guarantee engine smoothness and minimal wear.
The final inspection assures that precise measurements of all critical elements have been met.
The final step is to attach the EC Limited Warranty - 180 days/240 hours pro-rated to TBO