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AEROSTRUCTURES

AEROSTRUCTURES

As part of our Component Total Support offering, ST Engineering Aerospace provides an extensive range of maintenance, repair and

overhaul of commercial aircraft nacelles, primarily thrust reverser,

inlet cowl, fan cowl, exhaust nozzle and other secondary structures,

as well as repair and overhaul of flight control surfaces and other

aerostructures components

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Our aerostructures MRO capabilities are centralised in our Stockholm-based facility, which is just a stone’s throw from Arlanda International Airport. Our team of aerostructures specialists have through dedication, innovation, and experience provided quality MRO services to the aviation community across the globe. We aim to deliver durable and reliable repair solutions performed to a high standard of quality at a competitive price.

We perform both minor and major structural repairs for airframe, nacelle and aerostructure components.

At ST Engineering Aerospace, we understand the importance of letting airlines and aircraft fleet owners to concentrate on their core business and maximise aircraft availability. Together with our central maxims and our value system of Integrity, Value Creation, Courage, Commitment and Compassion, our work processes are focused on meeting your requirements and creating value by enhancing operational excellence.

Complete aircraft set Boeing 767 PW4000 thrust reversers ready for delivery after

overhaul service

Complete aircraft set Boeing 737NG CFM56-7B ready for delivery after overhaul service

A330 Trent 700 Thrust Reverser undergoing final assembly

AEROSTRUCTURES

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THURST REVERSER

Aircraft Type Engine

A300 PW4000

A310 PW4000

A330 Trent 700

737NG CFM56-7B

747 PW4000

767 PW4000

787 GEnx

787 Trent 1000

INLET COWL

Aircraft Type Engine

A320 V2500-A5

A330 Trent 700

A340 CFM56-5C

737NG CFM56-7B

747 PW4000

767 PW4000

787 GEnx

787 Trent 1000

EXHAUST NOZZLE

Aircraft Type Engine

A330 Trent 700

A340 CFM56-5C

737NG CFM56-7B

787 GEnx

787 Trent 1000

FAN COWL

Aircraft Type Engine

A330 Trent 700

737NG CFM56-7B

787 GEnx

787 Trent 1000

BOEING 787 DREAMLINER GLOBAL SUPPORT ON FULL NACELLE SYSTEM COMPONENTSST Engineering Aerospace signed a long term agreement with UTC Aerospace Systems in July 2013, to provide MRO services on the Boeing 787 Dreamliner nacelle systems for both the Rolls Royce Trent 1000 and General Electric GEnx engines.

As a licensed UTC Aerospace Systems Boeing 787 nacelles MRO provider, we offer operators a comprenesive range of repair Solutions and services including but not limited to:

• Access to suite of proprietary repairs, processes, instructions and materials.

• Production based tooling to support deep level repairs and replacement of major nacelle structural elements/sub-structure components utilising proprietary production tooling

• Expanded access to stay out zones with proprietary aerostructures 350° materials

• Out of manual repair schemes, acoustic area repairs, large area repairs

• Sytems test and fault isolation• Large stock of assets (both Nacelle platforms)

to support operators needs• Maintenance-By-the-Hour, service level

agreements, ad-hoc repairs, technical assistance and scheduled overhaul offerings

Full nacelle MRO services; thrust reversers, inlet cowls, fan

cowls, exhaust nozzles, centerbody and all sub-assemblies

NACELLE CAPABILITIES

AEROSTRUCTURES

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Capabilities including but not limited to:Ailerons, doors, elevators, flaps, panels, stabilisers, slats, tabs, vanes, spoilers, radom, rudder, wing tip, winglets and more.

LOAN & EXCHANGE SERVICESWe maintain a large pool of rotable assets, consisting of nacelle and aerostructures component, such as thrust reverser, inlet cowl, fan cowl, exhaust nozzle and others for a wide range of aircraft types.

FLIGHT CONTROLS AND OTHER AEROSTRUCTURES COMPONENT CAPABILITIES

ADDED VALUE SERVICES

AT ST Engineering Aerospace, we provide overhaul and repair services for a wide range of flight control and other aerostructures related components. Our extensive knowledge and experience in

metal and composite bonding is a key element in our product portfolio

A330 Trent 700 Thrust Reverser

Boeing 737NG CFM56-7B Thrust Reverser

Boeing 767 PW4000 Thrust Reverser

A330 Trent 700 Inlet Cowl

A330 Trent 700 Exhaust Nozzle

A340 CFM56-5C Inlet Cowl

Boeing 737NG slat, wedge assembly worn out of limit due to

chafting in operations

Metal-bonding with repair doubler surface treated in anodising line per

Boeing specification BAC555

Post repair

AEROSTRUCTURES

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ENGINEERING SERVICESAt ST Engineering Aerospace, we help our customers establish pro-active maintenance programmes which improve customer fleet reliability, and reduce unplanned maintenance events and removals. Through pro-active maintenance, we help customers conduct removal plans and recommend Service Bulletin incorporations.

• Maintaining fleet reliability• Achieving product design life service goals• Avoiding unplanned maintenanance events• Avoiding unscheduled removals• Reducing risk of exposure to exchange/loan fees• Cost reduction and control

ALTERNATIVE REPAIR DESIGN AND DEVELOPMENTOur engineering specialists are committed to exploring alternatives to expensive parts replacement. Leveraging our group’s EASA Part 21 Design Organisation Authorisation, our engineers work pro-actively for the development of approved alternative repair schemes.

We also work closely with our network of US Federal Aviation Administration DER’s to provide alternative repair data and develop and approve out of manual repairs.

FIELD-SERVICEWhether it’s a complex composite repair, structural repair, special Inspection or fleet sampling overview, our dynamic team of experienced craftsmen can provide a tailor made solution to meet your requirements. Airworthiness certificates for inspections, modifications or repairs performed on site can be provided as applicable.

ON-SITE SUPPORTIt’s cost cutting initiatives or product familiarisation we can support you on site with training and information modules aimed at improving performance and optimising resources.

A300 PW4000 Thrust Reverser rigging and

trouble shooting training on-site at customer

location

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AEROSTRUCTURES

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Boeing 737NG slat assembly undergoing reassembly process

A300 PW4000 thrust reverser being installed in

transport container

Aerostructures shop, overview picture

AEROSTRUCTURES All major components are received, undocked, stripped, Inspected, repaired reassembled and tested as necessary within our aerostructures workshop. Composite work/metal bonding, mechanical accessories, hydraulic and pneumatic components, electrical wire harnesses/fire detection systems, welding, and plating works are performed in our network of in-house support shops.

IN-HOUSE CAPABILITIES

Capabilities• Disassembly/assembly tasks, including but

not limited to:- Full strip down and rebuild- Deep level repairs and major structures parts

replacement- Floor mounted assembly jigs- In-house designed and fabricated custom

shop aids- Special fastener removal and installation tools- Traditional riveting, solid rivets, blind rivet,

blind bolts- Dimensional check/verification-interface

verification with nacelle mating surfaces and contour check of Structural components post overhaul and repair

- Rigging and functional testing of thrust reversers

• Traditional structural/sheet-metal repairs- Hand-forming expertise, fitting, forming and

fabrication of detail and repair parts, shaping of complex forms utilising dual contour wheel

• Balancing of flight controls

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AEROSTRUCTURES

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COMPOSITES All metal bonding work and advanced composite repairs are performed at our composites workshop. Replacing composite parts are expensive to replace. Moisture ingress and mechanical damage are constant challenges we face with for composites. Providing competitive and durable repair solutions instead of scrapping parts calls on the skills of our dedicated specialists. From minor skinning repairs to full sub assembly restorations and rebuilds on nacelle and flight control bonded material parts, no challenge is too great.

Capabilities• Advanced composite repairs• Metal bonding• Metal bonding Surface treatment - Phosphoric acid

anodising process line BAC5555• Design and fabrication of full supporting Custom made

bond tools.• Equipped with:

- Autoclave- Air circulating ovens (Integrated for vacuum

bagging)- Controlled contamination room (Lay up/clean room)- Adhesive bond primer application area- Tensile, drum & peel test

Anodising surface treatment for metal skins, repair doublers and patches

Boeing 747 PW4000 T/R Acoustic Panel bonding to be cured in Autoclave

Boeing 737NG CFM56-7B T/R Outer Panel honeycomb

replacement

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PRECISION ENGINEERING Our in-house machine shop capabilities offer a range of procedures and processes for precision engineering. Fabrication of special tooling, bench type Assembly and Floor mounted assembly jigs and fixtures, shop aids and other special tooling is fabricated in-house to support our overhaul and repair programs. All precision machining for components serviced within ST Engineering Aerospace are carried out in our machine park which is equipped with new CNC and NC equipped machines.

Capabilities• Fabrication & repair of mandatory and special

tooling• Fabrication of bench and floor mounted assembly

type of jig/fixtures.• Fabrication & rework of repair parts

– for maintenance• Licenced welding & flame spraying • Heat treatment • Grinding• Turning• Milling• Honing• Precision drilling• Flap peening

Fabricated Boeing 737NG CFM56-7B Assembly Jigs

Precision removal of damaged IDG liner in housing through pre-

programmed CNC milling machine

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PAINTING & CLEANING Equipped with:• Spray booths. Multi functional-single/multi cell• Paint stripping – chemical & blasting• High pressure and semi-automatic washing machines• Hand wash• Separate area for application of ablative coatings/fire

protection

The application of fire protection/ablative coating is performed in a special segregated area so as to avoid silicon contamination which is detrimental to composite repairs and the application of paint systems.

Our paint and cleaning workshops are well equipped to provide support services to all our workshops

B747 PW4000 T/R Fan Duct Cowl undergoing priming

Ultrasonic cleaning of parts Flexible painting spray booths

NDT is provided to all workshops as a supporting function to the maintenance, repair and overhaul process.

The following disciplines are practiced in-house:• Ultrasonic• Eddy Current• Magnaflux• Penetrant

NON-DESTRUCTIVE TESTING (NDT)

AEROSTRUCTURES

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Examination of damage area

Ultrasonic Bondmaster NDT

inspection

Penetrant inspection process

The thrust reverser actuating system components maintenance, repair and overhaul is well supported by our mechanical workshop. Savings are made on transport costs and time saved shipping to and from sub contractors. Turnaround time is shortened since the entire repair process is carried out and managed under one roof.

Full Overhaul capability on the following Thrust Reverser Actuation systems:

MECHANICAL / ACTUATION SYSTEM COMPONENT

AEROSTRUCTURES

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Test operator undergoing hydraulic test of mechanical accessory

* Product being phased in.

Aircraft Type Engine

Airbus A300 PW4000

Airbus A310 PW4000

Airbus A330 Trent 700

Boeing 737 CFM56-7

Boeing 747 PW4000

Boeing 767 PW4000

Boeing 787* GEnX

Boeing 787* Trent 1000*From top:

Fits and clearance measurement conducted for

mechanical accessory

Boeing 737NG CFM56-7B T/R Actuator installed in test fixture to conduct final test