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PRESSURE DUCT SYSTEMS & FLEXIBLE JOINTS FOR THE AEROSPACE INDUSTRY PRESSURE DUCT
FOR THE AEROSPACE INDUSTRY
Bird
Bel
low
s
CONTENTS Global aerospace engineering 3
Dedicated services and facilities 4
Flexible solutions for pressure ducting joint applications 6
A comprehensive product solution 8
A worldwide reputation for quality 10
© AIRBUS S.A.S. 2006 - Photo by ExM Company/H.Goussé
Senior is an international manufacturing group
with over 6000 employees and operations in
12 countries. Structured in two divisions;
Senior Flexonics and Senior Aerospace
(Structures and Fluid Systems) Senior designs,
manufactures and markets high technology
components and systems for the principal
original equipment producers in the worldwide
aerospace, diesel engine, exhaust system and
energy markets.
> Modal testing
> Insulation and heat transfer analysis
> Fatigue analysis
> CAD/CAM
> CATIA Version 5
> 3-D modelling
> EDI capability
> Inventor
Bird Bellows technical staff utilise the mostcontemporary computer aided designprogrammes in the industry. We work withsystems compatible with those of ourcustomers to ensure efficient and accurateexchange of information between our facilitiesand off-site locations. We believe that technological information is oneof the most critical measures of excellence.
GLOBAL AEROSPACEENGINEERING
> Specialisation in pressurised duct systems and flexible duct joints
> Design facility including systems engineering and stress analysis
> Comprehensive manufacturing and non-destructive testing processes
> Fully certified QA systems to EASA Part 21 and AS9100 Rev.C
> Extensive product development facilities for future growth
> Full materials capability
> The total resources of Senior Aerospace in Europe, North America and SE Asia
RESOURCES
Senior Aerospace Bird Bellows is a worldleader in the design and manufacture of metal bellows, bellows assemblies andaerospace products. As one of the most respected names in the industry,Bird Bellows is uniquely positioned tomeet the demands of our customers forprecision engineered and manufacturedproducts.
Our development and product testingfacilities are among the best available.Sophisticated analysis and designpractices include:
> Finite-element analysis (Ansys)
> Stress analysis
> Motion and load analysis
> Flow and pressure drop analysis
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Senior Aerospace Bird Bellows specialises
in the design of bellows, bellows assemblies,
gimbal bellows, flexible joints and aerospace
bleed air ducting systems. Drawing on years of
design experience, the latest in computer-aided
design programmes, and finite-element analysis,
our engineering team has the flexibility and
speed required to respond to the needs of our
customers.
DESIGNBird Bellows utilises AutoCAD 2000/3DModelling, FEA Ansys and CATIA Version5, allowing 2D and 3D realisation ofproducts, and the preparation ofdetailed drawings and technicalspecifications. These design tools give us the ability to work in thecomputer environment best suited toour customers and to directly exchangeelectronic data with customers andsuppliers worldwide. A key element inthe design process is our ability todevelop innovative and cost effectivesolutions to customer challenges.
Design propositions will satisfy allinternational codes of practice.
ENVIRONMENTAL TESTINGEnvironmental testing is carried out toensure that components will performsatisfactorily in service, the degree oftesting being determined by the classof equipment and the performancetesting required.
A typical test regime for duct equipmentand bellows-sealed components may include:
> Cyclic fatigue testing at cryogenic, ambientor elevated temperature
> Pressure pulse testing at ambient orelevated temperature
> Operational shock and vibration testing
> Susceptibility to fluids including salt spray
> Fire testing
> Ultimate proof pressure test
TYPICAL PRODUCT APPLICATIONS> Environmental control systems (ECS)
> APU ducting and components
> Anti-ice ducting
> Cabin air system ducting
> Silencer assemblies
> Engine bleed air ducting
> Engine drain systems
> Flexible joints and couplings
> Air start ducting systems
> Ground start ducting systems
DEDICATED SERVICES AND FACILITIES
INSULATIONInsulation is a key component in the designof a ducting system and a significantfactor in weight calculations. The ductinsulation may be either detachable orpermanently fixed, and metal cladding canbe supplied in stainless steel, titanium oraluminium.
PRODUCTIONBird Bellows has a reputation for highquality craftsmanship, which is maintainedthrough continuous training anddevelopment in a lean manufacturingenvironment. The Company has respondedto the challenges of weight reduction by adopting the use of high strengthtitanium alloys, such as 6Al4V, for criticalcomponents. Hot forming and hybrid SPFof these alloys is an established productionprocess. Quality assurance and control isintegral to the manufacturing process,which is also subject to continuousimprovement from the implementation ofbest practice techniques.
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1. Bellows sealed gimbal family
2. CATIA model of bellows joint
3. CATIA model of telescopic duct
4. Finite element analysis (FEA)
5. Rectangular bellows
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3
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Anti-ice ductBellows - sealed gimbal joint
An aircraft pneumatic duct system is required toaccommodate loads and movements arising from internalpressure, temperature extremes, and airframe movement.To avoid fatigue failure of the ducting, flexible joints areincorporated to absorb expansion and angular movements.Flexible solutions are needed in the pneumatic systemducting from tail to wingtips, applications for which Senior Aerospace Bird Bellows have provided solutions.
FLEXIBLE SOLUTIONS FOR PRESSURE DUCTINGJOINT APPLICATIONS
Plain bellows Flexible ECS duct
Vibreaker
Vibreaker
Bellows - sealed ball joint
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Bellows - sealed gimbal APU air intake duct
Telescopic duct
Tolerance take-up unit
Tolerance take-up unit
Piccolo tube
Bellows - sealed gimbal
Wing ducts Braided bellowsBellows - sealed gimbal
Bird Bellows
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A COMPREHENSIVE PRODUCT SOLUTION
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PLAIN BELLOWSBellows are used primarily to absorb axialmovements and can also be used forangular or lateral offset, or misalignment.Unsupported bellows have manyapplications including aircraft fuelsystems and APU air intake and exhaustapplications.
BRAIDED BELLOWSBraided bellows are designed toaccommodate lateral and angularmovement with absorption of pressureend loads, offering a cost effectivesolution for moderate deflections inlow-pressure systems. Titanium bellowscan be supplied with stainless steelbraid to minimise cost.
NON-BELLOWS VIBREAKERJOINTSTo complement the range of bellowsbased components, Bird Bellows aremanufacturers of Vibreaker parts formajor aircraft build programmes.
The Vibreaker uses a non-metallic sealmoving in compression on a polishedsurface to achieve a fluid tightassembly. Produced in both stainlesssteel and titanium, vibreakers allowrotation in addition to angular andlateral movement.
Bird Bellows
EXTERNALLY PRESSURISEDBELLOWSIn this type of joint, the duct pressure is transferred to the outer surface of the bellows, the pressure being held by the outer casing. This type of unit hasapplications where lateral movement must be accommodated in a rigid duct.
PRESSURE BALANCED BELLOWS Pressure balanced bellows are designed toabsorb axial and lateral deflection withouttransmitting pressure loads to adjacentducts. The ability to eliminate end load dueto pressure is particularly valuable wherespace is limited and where ducts cannot be adequately restrained. Alternativeconfigurations are available.
BELLOWS SEALED BALL JOINTSBall joints can be used in lower pressuresystems to save weight; the ball jointallows angulation through 360 deg. andwithstands duct end loading.
RECTANGULAR BELLOWSRectangular bellows accommodaterelative movements on low-pressuresystems and provide a long-life and firesafe alternative to non-metallic APU airintakes. Other configurations can bedesigned for specific applications.
DUCTING SYSTEMSBird Bellows manufacture completeducting systems for ECS, bleed air, air start, anti-icing and fuel transferapplications in civil and military aircraft.Duct systems are produced in titanium,stainless steel and nickel alloys andsupplied as components or aircraft kitsready for assembly into the aircraft.Specific experience of engine test ductingis offered to power plant manufacturers.
GIMBAL BELLOWSGimbal bellows act as universal joints inthe duct and offer angulation through360 deg. Together with absorption ofduct end loads. The Senior AerospaceBird Bellows gimbal joint has beendeveloped for minimum weight whilstretaining the advantage of full bellows-sealed construction, and is suppliedwith vee flanges or weld ends.
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Quality Assurance is fundamental to the ethos of
Senior Aerospace Bird Bellows. Proven systems
have been in place since the inception of the
Company.
Great emphasis is placed uponunderstanding the customerrequirements and application. Our qualityassurance systems are approved toAS9100 and EASA Part 21 Section A,Subpart G.
Good systems and procedures areimportant but the quality of personnel isvital. Senior Aerospace Bird Bellows enjoysthe services of committed and highlymotivated people in all areas. In particularthe Quality Inspection Team is dedicatedto the monitoring of all processes and to ensuring that only fully acceptableproduct is despatched to customers.
With our own radiography, dye penetrantand pressure test facilities, together withmass spectrometer leak detection andthree-axis measuring resource, we arewell equipped to perform all requiredtests and checks.
MAJOR QUALITY APPROVALS
AS9100
BS EN ISO 9001: 2000
ISO14001
EASA Part 21 Section A, Subpart G
Performance Review Institute AS7110(Nadcap) for Welding
Performance Review Institute AS7114(Nadcap) for Non-destructive testing
Additionally, Senior Aerospace Bird Bellowsis approved by many customerorganisations including the following:Rolls-Royce; BAE Systems; Airbus UK;Airbus France; Airbus Deutschland; PFW;Agusta Westland; Honeywell; ITP; ITD; EADS Military; Aircraft ServicesLemwerder; Israel Aerospace Industries;Embraer; UAV Engines.
A WORLDWIDE REPUTATION FOR QUALITY
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FOR THE AEROSPACE INDUSTRY
WHERE TO FIND US
M1
M1
A1(M)M1
M180
M6M54
M5
M4M5
M4
M3M5
M40
M4
A1(M)
M25
LONDON
BIRMINGHAM
M42
M69
CONGLETON
DERBY
MANCHESTER
SHEFFIELD
M6
M11M25
M50
From M6 J18, A54 to Congleton,Radnor Park Estate is signpostedon the left, via Back Lane. From M6 J17, A534 to Congleton,Radnor Park is signposted on theleft via Box Lane, turn right ontoA54 and then left to Radnor ParkEstate via Back Lane.
Senior Aerospace Bird BellowsRadnor Park EstateCongleton, CheshireCW12 4UQUnited Kingdom
T +44 (0)1260 271411F +44 (0)1260 [email protected]
CONGLETONA34
A34
A534
A54
BA
CK
LAN
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3RD
AV
EN
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2ND AVENUE1ST AVE
NU
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GREENFIELDINDUSTRIAL ESTATE
ENTRANCE
RADNOR PARKINDUSTRIAL ESTATE
ENTRANCE
M6
18
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SENIOR AEROSPACE GLOBAL OPERATIONS
