Background 

Eaton teamed with Airbus to develop an internal  qualification framework for Eaton’s manufacturing fuel scavenge jet pumps using laser powder bed fusion technology. The process also had to demonstrate that Eaton’s newly manufactured pumps would perform in accordance with original component specifications, customer requirements and EASA and FAA airworthiness standards.

Challenge

Before the project launch, the industry lacked defined paths for qualifying a new additive manufacturing technology for aluminum jet pumps and certifying an additively manufactured product for a commercial aircraft fuel system. Many suppliers were not familiar with materials and processes used in additive manufacturing environments or how different variables impacted product performance. 

Solution

It was clear that a new framework was required to address all aspects of developing additively manufactured jet pumps — from machine, material and process requirements to part qualification, acceptance criteria and overall validation of the value stream. Developing the qualification framework, system and creating Eaton’s first dedicated AS9100- approved aerospace additive production facility required new collaborations among Eaton’s internal cross-functional teams as well as an open, collaborative approach with Airbus

Results

After completing the qualification process, Eaton’s additively manufactured fuel scavenge jet pump received approval from EASA and FAA for commercial flight. Eaton’s additive process not only reduced pump weight by 30% but also decreased component assembly time and eliminated potential leak paths such as seals and threaded joints by consolidating 11 parts into a single part. Eaton has deployed the qualification process to other customer programs across the space, military and commercial industries. With a longstanding pedigree in casting and machining, Eaton is incorporating additive technology across the business as a complementary manufacturing process that will benefit customers on both new product development programs and optimized production processes for legacy programs. Eaton also is using additive processes to improve repair options for aftermarket customers, such as cold spray technology to repair older and more unique parts.