Global aerospace engineering 3 Dedicated services …

1 PRESSURE DUCT SYSTEMS & FLEXIBLE JOINTS FOR THE aerospace INDUSTRYPRESSURE DUCTFOR THE aerospace INDUSTRYBird BellowsCONTENTSG lobal aerospace engineering3 Dedicated services and facilities4 Flexible solutions for pressure ducting joint applications6A comprehensive product solution8A worldwide reputation for quality 10 AIRBUS 2006 - Photo by ExM Senior is an international manufacturing groupwith 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 technologycomponents and systems for the principaloriginal equipment producers in the worldwideaerospace, diesel engine, exhaust system andenergy markets.

2 >Modal testing>Insulation and heat transfer analysis>Fatigue analysis>CAD/CAM>CATIA Version 5>3-D modelling>EDI capability>InventorBird 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 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 >Extensive product development facilities for future growth>Full materials capability>The total resources of Senior aerospace in Europe, North America and SE AsiaRESOURCESS enior aerospace Bird Bellows is a worldleader in the design and manufacture of metal bellows, bellows assemblies andaerospace products.

3 As one of the most respected names in the industry,Bird Bellows is uniquely positioned tomeet the demands of our customers forprecision engineered and development and product testingfacilities are among the best analysis and designpractices include:>Finite-element analysis (Ansys)>Stress analysis>Motion and load analysis>Flow and pressure drop analysis3 Senior aerospace Bird Bellows specialises in the design of bellows, bellows assemblies,gimbal bellows, flexible joints and aerospacebleed air ducting systems. Drawing on years ofdesign experience, the latest in computer-aideddesign programmes, and finite-element analysis,our engineering team has the flexibility andspeed required to respond to the needs of Bellows utilises AutoCAD 2000/3 DModelling, FEA Ansys and CATIA Version5, allowing 2D and 3D realisation ofproducts, and the preparation ofdetailed drawings and technicalspecifications.

4 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 propositions will satisfy allinternational codes of TESTINGE nvironmental testing is carried out toensure that components will performsatisfactorily in service, the degree oftesting being determined by the classof equipment and the performancetesting 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 testTYPICAL 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 systemsDEDICATED services AND FACILITIESINSULATIONI nsulation is a key component in the designof a ducting system and a significantfactor in weight calculations.

5 The ductinsulation may be either detachable orpermanently fixed, and metal cladding canbe supplied in stainless steel, titanium 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 sealed gimbal family2. CATIA model of bellows model of telescopic element analysis (FEA) bellows52435 Anti-ice ductBellows - sealed gimbal jointAn aircraft pneumatic duct system is required toaccommodate loads and movements arising from internalpressure, temperature extremes, and airframe avoid fatigue failure of the ducting, flexible joints areincorporated to absorb expansion and angular solutions are needed in the pneumatic systemducting from tail to wingtips, applications for which Senior aerospace Bird Bellows have provided solutions.

6 FLEXIBLE SOLUTIONS FOR PRESSURE DUCTINGJOINT APPLICATIONSP lain bellowsFlexible ECS ductVibreakerVibreakerBellows - sealed ball joint6 Bellows - sealed gimbalAPU air intake ductTelescopic ductTolerance take-up unitTolerance take-up unitPiccolo tubeBellows - sealed gimbalWing ductsBraided bellowsBellows - sealed gimbalBird Bellows7A COMPREHENSIVE PRODUCT SOLUTION8 PLAIN BELLOWSB ellows are used primarily to absorb axialmovements and can also be used forangular or lateral offset, or bellows have manyapplications including aircraft fuelsystems and APU air intake and BELLOWSB raided bellows are designed toaccommodate lateral and angularmovement with absorption of pressureend loads, offering a cost effectivesolution for moderate deflections inlow-pressure systems.

7 Titanium bellowscan be supplied with stainless steelbraid to minimise 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 BellowsEXTERNALLY 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 BALANCED BELLOWS Pressure balanced bellows are designed toabsorb axial and lateral deflection withouttransmitting pressure loads to adjacentducts.

8 The ability to eliminate end load dueto pressure is particularly valuable wherespace is limited and where ducts cannot be adequately restrained. Alternativeconfigurations are SEALED BALL JOINTSBall joints can be used in lower pressuresystems to save weight; the ball jointallows angulation through 360 deg. andwithstands duct end BELLOWSR ectangular 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 SYSTEMSBird Bellows manufacture completeducting systems for ECS, bleed air, air start, anti-icing and fuel transferapplications in civil and military systems are produced in titanium,stainless steel and nickel alloys andsupplied as components or aircraft kitsready for assembly into the experience of engine test ductingis offered to power plant BELLOWSG imbal bellows act as universal joints inthe duct and offer angulation through360 deg.

9 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 Assurance is fundamental to the ethos ofSenior aerospace Bird Bellows. Proven systemshave been in place since the inception of theCompany. Great emphasis is placed uponunderstanding the customerrequirements and application. Our qualityassurance systems are approved toAS9100 and EASA Part 21 Section A,Subpart 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.

10 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 QUALITY APPROVALSAS9100BS EN ISO 9001: 2000 ISO14001 EASA Part 21 Section A, Subpart GPerformance Review Institute AS7110(Nadcap) for WeldingPerformance Review Institute AS7114(Nadcap) for Non-destructive testingAdditionally, 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 WORLDWIDE REPUTATION FOR QUALITY10 Bird BellowsFOR THE aerospace INDUSTRYWHERE TO FIND USM1M1A1(M)M1M180M6M54M5M4M5M4M3M5M40M4A 1(M)M25 LONDONBIRMINGHAMM42M69 CONGLETONDERBYMANCHESTERSHEFFIELDM6M11M2 5M50 From M6 J18, A54 to Congleton,Radnor Park Estate is signpostedon the left, via Back Lane.