At Duncan Aviation, we are significantly enhancing our turbine engine capabilities with a new 36,000-square-foot Pratt & Whitney Canada Designated Overhaul Facility for PW300 and PW500 turbofan engines. This expansion, coupled with strategic investments in advanced machinery, bolsters our in-house capabilities for all of our Authorized OEM engine operations. These advancements enable us to deliver unparalleled value, quality, and faster turnaround times for everything from scheduled inspections to major overhauls and urgent AOG (Aircraft on Ground) events.
For engine overhaul, hot section inspections, and hourly borescope inspections, we have invested in a pair of specialized grinders that work in perfect harmony. The vertical grinder, a Palmary VIG 80 Shroud Grinder, precisely grinds the inner dimensions of critical components, such as turbine high-pressure support case shroud segments and honeycomb low-pressure turbines. Custom fixtures, fabricated by Duncan Manufacturing Solutions for each engine model, ensure a perfect fit every time. Complementing this, the horizontal grinder, a Universal Cylindrical Grinder, grinds the outer dimensions of components, especially crucial for turbine blades, where clearances are as tight as 0.025 to 0.035 inches. This synchronized precision guarantees optimal engine performance and longevity.
Every measurement is then confirmed by our Zeiss Contura CMM (Coordinate Measuring Machine). This advanced CMM, equipped with an articulating sensor and multi-axis capabilities, measures complex angles and contoured shapes, ensuring that all repaired parts meet stringent OEM specifications. It also graphs geometric tolerances, aiding in thorough performance investigations. Additionally, a Sharp SC-618-2AN Surface Grinder ensures shims and spacers are perfectly flat, optimizing axial clearances—a critical assembly requirement for engine repair. This attention to detail directly translates to enhanced engine reliability and safety. Finally, new vertical and horizontal balancers will precisely balance engine sub-assemblies, leading to enhanced performance and significantly reduced vibration, which directly benefits engine longevity and smooth operation.
During hot section, core zone, or overhaul inspections, parts with incredibly tight tolerances can easily fail, but with thermal spray processes, their surfaces can be restored. The new Metco 9M high-energy plasma system is a fully automated flame spray booth that enables us to add material to components, allowing for in-house repairs rather than costly and time-consuming replacements. This not only saves time and money but also gives us increased control over quality and consistency compared to older systems. The new system even incorporates an environmental filtration system, reflecting our commitment to responsible practices.
Our shot peening room now accommodates two fully robotic, programmable Wheel Abrator Peening Cabinets—one for shot/cast blast and one for glass peening. These machines provide stress relief after grinding repairs by removing damage from critical rotating components such as compressor blades, impellers, and turbine disks. Their high accuracy, thanks to synchronized turntables and 4-axis arms, allows for precise restoration. The ability to repair instead of replace these life-limited components can reduce your costs by over 50% while offering faster turnaround times and superior control over quality and consistency.
The Wet Blast media cabinet is crucial for thorough cleaning, effectively removing corrosion from component surfaces, penetrating even the smallest cracks and crevices. This is particularly vital for components like the accessory gearbox and oil pump gear systems, where corrosion can significantly impact performance.
These comprehensive, now in-house capabilities at Duncan Aviation underscore our unwavering commitment to providing unparalleled, cost-effective, and high-quality engine maintenance services. We are dedicated to maximizing your aircraft’s performance, minimizing downtime, and ensuring the long-term value of your investment, keeping your aircraft flying safely, efficiently