Dunlop Choses Doncasters for A380 Brake Investment Casting
20 June 2005 16:38
The Airbus A380 is lifting off with help from The Doncasters Group, a leading international manufacturer of precision components and assemblies to the aerospace market.
Doncasters has been selected by Dunlop Aerospace (recently acquired by Meggitt plc) to manufacture torque tubes for the A380 brake. Dunlop Aerospace, in collaboration with Honeywell Aircraft Landing Systems, is responsible for the supply of wheel and brakes for the A380.
Using its advanced centrifugal investment casting process, Doncasters is manufacturing the torque tubes, an essential part of the brake, from a complex titanium alloy. This is the first time investment castings are being used as part of a European undercarriage.
Due to the weight considerations of the A380, even ‘everyday’ aspects of the aircraft are being redesigned and new solutions implemented to meet the strict mass requirements. In this case, the torque tubes, which usually follow a design that can be forged to spec, need to be manufactured to a much more complex form - both inside and out - to meet the rigorous specifications.
Titanium investment casting was selected as the best solution for meeting the intricate design specifications. The use of titanium adds to the torque tubes’ strength whilst minimising their mass.
The tubes will deliver torque to the axle on the A380 and constitute the main structure of the brake. There are 16 torque tubes in total for each aircraft. Each tube is then lined with a special composite material to help the tubes withstand the extreme temperatures they will be operating under.
Eric J. Lewis, Chief Executive of Doncasters, commented: “Securing this important agreement with Dunlop Aerospace is testament to Doncasters’ skills and expertise in investment casting techniques. Dunlop chose Doncasters’ centrifugal technique over the more conventional methods as they were confident that it had the edge in terms of surface aspect, properties, grain size and structure, as well as being a cost effective approach.
“The use of titanium in the design of the torque tubes is also a further indication that this material is becoming more mainstream in application as designers become more confident in its usage.”
In addition to the torque tubes, Doncasters is also supplying the leading edge slat cans to the Airbus A380 Wing Build facility at Broughton, the aft pylon fairing and several parts on the Rolls-Royce Trent 900 engine.
For more information on this company:
Doncasters - Military Aircraft Components and Precision Machining Facilities
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