Compressed Air in Aerospace

In the aerospace industry, compressed air is a critical energy source for manufacturing, repairs, and overhauls. Its reliability and efficiency make it indispensable for powering various equipment and tools. However, contamination control is paramount, especially during the manufacturing of aerospace parts, where precision and cleanliness are crucial.

Importance of Contamination Control

Using lubricated compressors that rely on oil can introduce contaminants into the compressed air, posing a serious risk to both the quality of the products and the safety of operations. To mitigate these risks, experts at Compressed Air Systems (CAS) recommend utilizing oil-free air compressors. These systems ensure that the air used in processes remains contaminant-free, promoting the integrity and performance of aerospace components.

Applications of Compressed Air in Aerospace

Aircraft Engine Manufacturing: Compressed air powers tools and equipment used in the assembly and fabrication of aircraft engines, ensuring precision and reliability.
Aircraft Wing Structural Testing: It is used in testing the structural integrity of aircraft wings, providing the necessary pressure to simulate various flight conditions.
Ground Support Equipment: Compressed air operates ground support tools and equipment, enhancing efficiency in aircraft maintenance and operations.
Test Bench Supply: Compressed air is essential for supplying test benches, where various aircraft systems and components are tested for performance and safety.
Workholding Devices: It powers workholding devices that secure components during machining and assembly processes, ensuring accuracy and stability.

Conclusion

In conclusion, compressed air is vital in the aerospace industry, playing a key role in manufacturing, testing, and maintenance. By prioritizing contamination control through the use of oil-free compressors, aerospace companies can enhance the quality and safety of their products. Investing in reliable compressed air systems is crucial for success in this highly regulated and precision-driven field.

Piping Material Features Comparison
Piping Features	Stainless Steel(Type 304L)	Mild Steel	Blue anodized Aluminum Alloy
Weight (Dia 6inch, Length 6m)	127.2	169.6	29.142
Corrosion Resistant	Yes	No	Yes(100%)
Pressure drop (Dia 2 inch Length= 20m,Airflow=3 cubic metres/Minute, Pressure=10 bar)	0.25	0.4 Bar	0.1
Energy Efficiency	High	Low-moderate	High( Potential Cost savings of 34%)
Mechanical Strength	Very Strong	Very Strong	Strong
High-Temperature Rating	Yes	Yes	Yes
Installation Ease	Less Difficult	Difficult	Easy(High Flexibility and Modularity)
Installation Time	Approx 6 feet length per hour	Approx 6 feet length per hour	Approx 45 feet Length per hour
Work Hours/Manpower Required for a 2″ pipe and a 3000 feet piping	Approx 600 man-hours/8 men for 2 weeks	Approx 600 man-hours/8 men for 2 weeks	Approx 100 man-hours /8 men for less than 2 days
Annual Cost(Installation, Commissioning, and operation)	Approx 3000 dollars	Approx 7820 dollars	Approx 1300 dollars
Installation Cost Material%/Labor%	30% / 70%	25% / 75%	80% / 20%
Surface roughness	0.03	0.05	0.001
Special Tools Required (welder, threader, groove cutter)	Yes	Yes	No
Air Quality	High(Should the application require it, these pipe systems can help meet the requirements of ISO 8573-1: 2010 air quality standards.	Low( Not according to !SO 8573-2010 air quality standards)	High(Should the application require it, these pipe systems can help meet the requirements of ISO 8573-1: 2010 air quality standards.
Cost per meter	Almost 2 less than Aluminum	3 Times less than Aluminum	163.64 Dollars(Parker Transair)
Life Span( Will vary according to environmental factors, Pipe design, and Pipe grade.	30 years	40 years	20 years
Initial Cost of installations	Material : 30% Labor:70%	Material : 25% Labor:75%	Material : 80% Labor:20%
Maintenance	Difficult(Accumulation of rust under pipes and fittings which travels to machinery, may require preventive maintenance every week)	Difficult (Accumulation of rust under pipes and fittings which travels to machinery may require preventive maintenance every 3-4 days)	Easy (No accumulation of rust, may require preventive maintenance every 4 Weeks)