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Aviation Restoration

Toby Gilbert

I'm currently in the beginnings of a project on weld repairing Rolls Royce Merlin engines

I was hoping for any information related to restoration of old aircraft, any information on certification of repairs on old aircraft, any information on the merlin engine specifically or weld repairing aluminium (the part of the engine in question is a cyiinder head of cast aluminium RR50, an alloy specification no longer manufactured.

Anything from government papers, academic papers to just general advice would be fantastic.

Thanks in advance for your help

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    I'm not an aircraft person, and I can imagine as the penalty of failure being higher, so must the standards be, but if it helps the welding up of small defects and damaged threads of alloy heads for smaller cars and motorbikes is very much a done thing.

    It is however quite a specialist activity involving pre-heating the whole head and the use of TIG and lots of current - the problem is that aluminium being a far better thermal sink than say cast iron, and the heating must be very even or thermal expansion stresses and permanent distortion results - if working anywhere near the gasket surface it will need to be re-skimmed level afterwards on a suitable mill so there needs to be enough 'meat' left for that to be possible without cutting into any vital parts.

    It might be worth a few calls to any local engine rebuild works that offer this service to get an experienced  opinion on the damage (which is not clear to me from the photo) and if it would be considered sensible to fix if it was a car engine. 

    Mike

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  • 0

    I'm not an aircraft person, and I can imagine as the penalty of failure being higher, so must the standards be, but if it helps the welding up of small defects and damaged threads of alloy heads for smaller cars and motorbikes is very much a done thing.

    It is however quite a specialist activity involving pre-heating the whole head and the use of TIG and lots of current - the problem is that aluminium being a far better thermal sink than say cast iron, and the heating must be very even or thermal expansion stresses and permanent distortion results - if working anywhere near the gasket surface it will need to be re-skimmed level afterwards on a suitable mill so there needs to be enough 'meat' left for that to be possible without cutting into any vital parts.

    It might be worth a few calls to any local engine rebuild works that offer this service to get an experienced  opinion on the damage (which is not clear to me from the photo) and if it would be considered sensible to fix if it was a car engine. 

    Mike

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