Pdf

High roller – A component journey

Aerospace bearings

Ball and roller bearings are essential to high-precision rotary components in aircraft, and need to deliver exceptional durability and consistent performance despite changes in temperature and air pressure. Materials used are customised based on the end application, including high temperature, stainless steels and more exotic alloys, such as Inconel.

High roller
Bearings

Bearings are shaped and machined from rods of metal plates and wires.

Heat treated

Bodycote icon The surface area to be heat treated is prepared – areas which are not to be heat treated are selectively masked with copper plating.

Hardened

Bodycote icon The surface is hardened via a specialised nitriding process during which nitrogen is diffused into the surface to increase resistance to in-service stress and fatigue.

Inspected

Bodycote icon After heat treatment, the masking is removed and the surface cleaned before inspection to ensure the part meets strict aerospace quality specifications.

Shape

For the perfect shape and smooth finish, bearings are put through final lapping and polishing processes.

Engine

End applications include landing gear, engine, control surfaces, and other parts or components.

Bodycote component journeys

This is just one example of how Bodycote brings together the huge wealth of knowledge and expertise from across the Group to provide the vital engineering services our customers need.

For more component journeys visit www.bodycote.com

Bodycote icon Denotes the parts of the component journey undertaken by Bodycote.

Inner strength – A component journey

Medical implants

The stress on a hip or knee joint when a person jumps off a chair is equal to around 100 tonnes per square inch. Our bones, effectively composites, absorb such stresses regularly and effectively for much of our lifetime. When joints fail, they are often replaced with metal alloy implants. These implants must be incredibly strong, biocompatible, and able to last the lifetime of the patient. A combination of heat treatment, hot isostatic pressing and coating makes this possible.

Inner strength
Cobalt

Cobalt chromium alloy billets are investment cast to form implant shape.

Castings

Bodycote icon The castings are thermally sprayed with a biomedical coating to allow a bond to form between the implant and body tissue, promoting bone growth.

Implants

Bodycote icon The implants are then HIPed to eliminate porosity, improve fatigue life and enhance the bonding of the biocompatible coating.

Solution

Bodycote icon Solution and ageing heat treatment is used to strengthen the implant.

Joints

End application – joint replacement.

Bodycote component journeys

This is just one example of how Bodycote brings together the huge wealth of knowledge and expertise from across the Group to provide the vital engineering services our customers need.

For more component journeys visit www.bodycote.com

Bodycote icon Denotes the parts of the component journey undertaken by Bodycote.

In gear - A component journey

Pinion gear

A pinion gear is a critical automotive component used in virtually all transmission units. During use, a vehicle places heavy demand on its transmission, requiring a fast and reliable response to the drive controls.

The gears require high strength and wear resistance in order to withstand the stresses applied to each gear during use. Bodycote's heat treatment processes, in particular Low Pressure Carburising (LPC), enable modern transmissions to deliver high performance and seamless response, even reducing noise during gear changes.

In gear
Steel

The gears begin life as low alloy steel.

The gears are machined to shape using a shaving or hobbing method.

Measured

Bodycote icon The gears are dimensionally measured before heat treatment to monitor and maintain repeatability of distortion. The gears are then heat treated using LPC to enhance functionality by adding a 'case depth' to provide strength and resistance to wear and tear.

Drums

Bodycote icon The gears are quenched using nitrogen gas to minimise part distortion, then tempered to relieve internal stresses.

Inspected

Bodycote icon The parts are inspected and tested for surface hardness, core hardness and effective case depth.

Peeled

Bodycote icon The gears are shot peened to add residual stress – this allows the parts to withstand more wear and tear. The gears are measured again after heat treatment to check any distortion is within limits.

Gears

The gears are assembled into the transmission unit.

Automobile

End application – automobile.

Bodycote component journeys

This is just one example of how Bodycote brings together the huge wealth of knowledge and expertise from across the Group to provide the vital engineering services our customers need.

For more component journeys visit www.bodycote.com

Bodycote icon Denotes the parts of the component journey undertaken by Bodycote.