Post on 09-May-2018
Moss Vale Inc.Fabricators of tube assemblies
Guide to Products andServices
FAA Repair Station No. M0OR914NFAA PMA No. PQ2593CEDJAR Acceptance No. JAA.5365
Picture courtesy of Cirrus Design Corp.
Moss Vale Inc.
Left: A bellow formed from321 Stainless. Moss Valehas a full range of size ca-pacity for bellows manufac-turing.
Right: This is a standardproduction Induction
tube. Their manufactureinvolves cutting, coping,precision aligning, weld-ing, bead blasting, heattreating and chemical
Below: Moss Vale keeps an on hand supply of numeroussizes in Gamah, Deutsch, Flared and Flareless end fittings.
Moss Vale Inc.
About Moss Vale…
Moss Vale, Inc. is a FAA/EASA* approved Repair Station and FAA PMA* approvedPMA manufacturer. We repair, overhaul and fabricate tube assemblies and ducts.
The strength of Moss Vale is its ability to support quick turns of repair parts. Thereare several companies who say they will work parts for an grounded (AOG) aircraft,but when Saturday comes,they are no where to be found.
At Moss Vale we know what itis like for the inspection de-partment to have a late inspec-tion find for an airplane whichis due to go back into sched-uled service.
We’ll work your AOG parts.We’ll work hard to get your air-plane back in the air.
There are some facts aboutmany of the modern aircraft toconsider:
Many tubes and ducts are made out of titanium and is not as easily formed as thestainless steels and aluminums. When Boeing made the 737 they went to internalswaged fittings which require special tooling. Other manufacturers followed. Withthe advent of the 757 Boeing standardized with many tubes made out of 3.2AL 2.5vtitanium with the end fittings welded on. The days of an A&P using a hand benderat his toolbox were gone.
And let’s face it, turbine engine tubes have never been simple.
*FAA means Federal Aviation Administration, PMA means Parts Manufacturing Authorization which is a federal governmentapproval to manufacture and sell aircraft parts to the general public.
Moss Vale Inc.
About Moss Vale…
Located just outside Greater Cincinnati’s I-275 beltway, in Fairfield Ohio, Moss Vale
is a 10,000 square foot shop equipped with nine benders, associated deburr, cut-
ting, flaring, presetting, testing and end forming machinery. The shop is equipped
for medium size production runs, prototype and small run jobs.
The strength of Moss Vale’s
size is that we are small
enough to respond quickly.
People answer the phones.
At Moss Vale we use several
of the tube and duct fabrica-
tion processes.
We can bend using CNC tube
benders and coordinate design systems. Sometimes it is better to use hydraulic ma-
chines and forming tools. We can use orbital and computer welding if necessary or if
the case and process requires, hand weld with TIG or braze.
Any process no matter how “hi-tech” is correct for all situations. Aircraft mainte-
nance is not “on size fits all.” Repair Stations need to be flexible.
Moss Vale Inc.
All pictures courtesy of CirrusDesign
One of Moss Vale’s customers is Cirrus Design, a
single engine aircraft manufacturer based in Du-
luth, MN.
Cirrus manufactures a state of the art composite
aircraft that carries up to four passengers at
speeds of over 200 miles per hour.
Moss Vale started manufacturing for Cirrus
(CDC) in 2001 on the SR20 and later the SR22 class aircraft. Products manufactured for CDC in-
clude hydraulic brake lines, pitot static lines, fuel lines, welded rudder pedal components, induc-
tion system components and conduits for electrical harnesses.
In January 2003 Moss Vale was named Supplier of the
Year for Cirrus Design.
Cirrus Aircraft was the first to incorporate many new tech-
nology features. Some of these features include a safety
parachute (Ballistic Recovery System BRS), computer
controlled navigation, engine display systems, anti-
collision system, global positioning systems and anti-ice
(TKS) systems.
Moss Vale Inc.
Moss Vale Inc.
DC-8 Re-pylon Program 1991-92
The DC-8 Re-pylon Program was a program for a large aircraft modification shop to in-
stalled new engines on a 345,00 pound four-engine airliner. The program required over
one hundred new part fabrications and over 500 tubes for the first run aircraft.
Several types of tubes were required. Large hydraulic supply lines made of strong and
light weight materials, small diameter pneumatic lines were required, small soft light
weight fuel vent lines and welded branch fire extinguisher lines were among the over
500 parts fabricated by Moss Vale, Inc.
Each part required testing per a
customer supplied specification,
Douglas Process Specifications.
All aircraft grade certified mate-
rials were needed from MIL-T-
8504 Stainless Steel tubing, to
MIL-T-8808, WW-T-700/6 6061-
T6 Aluminum. All material
markings were required with
Douglas Aircraft Process Specification Materials.
Strict testing requirements per the process specifications were required on all tubes
manufactured with some independent sampling on new lots.
The largest problem was that the customer had little data available. Materials for each
part and part markings were given to Moss Vale. Many of the parts had to be fabricated
off of old line used as a pattern for the new manufactured parts.
Moss Vale Inc.
Many lines had to be custom fit on the aircraft. Soft aluminum was bent to fit the
aircraft installation and used as a pattern for a shop template. A jig template fix-
ture was fabricated in the Moss Vale shop and sent to the aircraft for a fit check.
When the proof part was verified to fit the aircraft properly, a production part was
made, pressure tested, inspected by our inspection department and re-inspected
by a Federal Aviation Administration (FAA) Designated Airworthiness Representa-
tive.
Every one of the over 500 Moss Vale, Inc. parts which were installed on the DC-8
aircraft was inspected to those requirements.
Near the completion of the first aircraft the modification center found it necessary
to make engineering changes to facilitate engine installation. The customer re-
quested redesign of a handful of parts.
Because of schedule constraints of installing engines, structural parts and tubes
many parts were needed quickly.
The DC8- Re-pylon aircraft rolled out the third week of April 1993. It was flight
tested through May 1993 and received Federal Aviation Administration approval
to enter revenue service in June 1993.
Moss Vale Inc.
Noise Modification for DC-9 Aircraft
In 1989 a manufacturer of a kit to
make older aircraft meet new federal
noise rules contacted Moss Vale, Inc.
about fabricating parts to relocate the
Engine Pressure Ratio Indication Sys-
tem and Constant Drive Electrical sys-
tem fluid coolant system.
The customer supplied the material requirements and Moss Vale, Inc. fabricated the parts
to an engine mockup. The parts were manufactured, and a FAA Conformity inspection was
performed. The first aircraft was FAA certified in June 1991 and entered service shortly
there after.
Currently hundreds of DC-9s serving
domestic and international airlines fly
with the DC-9 noise modifications and
Moss Vale, Inc. tubes.
Above: Moss Vale participated in the DC-9 Hushkit Certification.
Below: A 737 Engine certification test which has Moss Vale tubes installed
Moss Vale Inc.
Our Equipment
Moss Vale, Inc. has many benders capable of bending sizes from ¼ inch to 2 ½ inch ma-
terial.
The largest of the manual machines is
the Wallace #4 Bender which is capa-
ble of production run parts up to 2 ½
inch tubing. Moss Vale, Inc. owns two
tons of tooling for this machine in vari-
ous radii and diameter sizes.
The Schwarze Wirtz CNC bender and
two Eaton Leonard CNC benders per-
form a majority of the critical bending
applications. They use state of the art
computer controlled servos to maintain
speed, accuracy and repeatability.
Moss Vale, Inc. has a number of short run benders; two Pines 1200s, a Douglas Leonard,
a Conrac and a Parker-Hannifin 412 with plane of bend precision ability. These machines
have ¼ inch to ¾ inch capability. These
machines have short set up times with
precision for bend and rotation.
About 75% of our in-house tooling may
be used on more than one machine. This
gives Moss Vale, Inc. flexibility to run
each job efficiently.
Moss Vale Inc.
Our Equipment
Cold lubricated cutoff and deburr machines insure that our tubes are burr free and
square. Tooling in ¼ inch to 1 ¾ inch is available for this equipment.
A Bridgeport, lathe and Jancy machine al-
low Moss Vale to produce precision prod-
ucts involving holes, machined surfaces
and coped joints. They also enable devel-
opment of precision jigs and fixtures.
Four methods of end fitting installation are
swage, impact flaring, Hydraulic flaring
and rotary flaring. Beads are installed in
both Wiggins Coupling style and Military
Specification Beads. Some special sizes
and styles may involve tooling lead times.
Moss Vale Inc.
Welding
Moss Vale’s welding capabilities range from repairing a single 1/4” stainless steel line to
producing 50+ thin-wall aluminum tubes per month
Our weld operators are certified under
Aerospace Standards including AMS-STD-
2219.
Our weld operators are qualified to weld
Aluminum (2024, 3003, 5052, 6061,
Group II) from 0.020 to 0.140 and
Stainless Steel (304, 321, Group IV) from
0.018 to 0.114.
The welding department maintains three
TIG welders; a Dynasty 300, a Synchro-
Wave 250, and a MaxStar 175, and a Lin-
coln Electric 125 MIG welder. Two glass
bead blasters, a belt sander and an Oxy-
Acetylene torch are also on hand for weld
preparation and finishing.
This welder is welding 4130 Chrome-moly steel
Moss Vale Inc.
Inspection Department
Our inspection equipment starts with a SAE, MIL and National Pipe and Tube Specifi-
cations library. National Standards and Military Specs are on Microfiche for materials
and processes.
Moss Vale, Inc. can manufacture and
inspect to customer supplied specifi-
cations, Boeing Process Standards,
Douglas Process Specification, SAE
and MIL Specs.
Moss Vale, Inc. calibrates its Hydrau-
lic Test Gages to National Bureau
Standards and carries full traceability.
Other required measuring equipment
carries the same traceability.
Moss Vale, Inc. has two pressure test benches with fluid test capabilities to 10,000 psi
in MIL-H 5606 MIL Spec hydraulic fluids and Exxon 2380 oils. Testing with 500b Sky-
drol and calibrated test oils are facilitated with notice.
Inert Gas Pressure Testing can be per-
formed in house to 3000 psi.
Air pressure testing is available with
normal safety constraints to 160 psi
(Higher pneumatic test pressures can be
accommodated with advance notice).
Moss Vale Inc.
Inspection Department
Moss Vale utilizes TubeCAD Design Software and a Laser inspection system, along
with traditional height gauges, calipers, inclinometers and other inspection tools to
provide accurate inspection results.
TubeCAD is a design package
that interfaces with standard
Computer Design Software.
Tubes are dimensioned using
XYZ coordinates or standard
length rotation and bend an-
gles. Data may be coordinated
directly between both systems
and may be easily converted to
other CAD systems for 1:1
prints.
Moss Vales QC department utilizes an
Eaton Leonard Vector One Tube Inspec-
tion Center. The computer can scan a
bent tube and generate measured XYZ
dimensions, compare measured parts to
a master tube, or figure an average or a
run of multiple tubes.
TubeCAD is a registered Trademark of Advanced Tubular Technologies
Moss Vale Inc.
Tubecad
Moss Vale Engineering maintains a Computer Aided Design System as well as tube
specific Cad called TubeCAD.
TubeCAD allows the engineer to design and draw tubes using coordinate data such as
derived from XYZ datums and aircraft station data.
TubeCAD maps the tube, draws the tube,
calculates bend data and computer simu-
lates the bending process to determine pro-
duceability of the part.
It provides an excellent inspection tool and
superior drawing interface.
Drawings are programmed in TubeCAD and imported into AutoCAD.
AutoCAD receives the three dimensional data and places tubes into an installation
drawing or merely a detail parts drawing.
Standard operations for three views provide all the needed drawing requirements.
Moss Vale, Inc. is a full service Tube Shop from design prototype to production.
Call us for your development engineering needs.
TubeCAD is a registered Trademark of Advanced Tubular TechnologiesAutoCAD is a registered Trademark of AutoDesk
Moss Vale Inc.
Custom Applications
DesignDrawingPrototypeProduction
Bending Capabilities
Steel and Aluminum Pipes
One Quarter inch up to 3”
Thin Wall Tubes 3/8” to 1 ¼
Thick Wall Tubes ¼ to 1”
Solid Rod to 7/8 in mild steel
Solid Rod to ¾ in other grades
Several radii are available and may be fabricated with short lead times. If you have a specific
need let us know. If we have your specific radius and tooling we can make your part immedi-
ately.
Tube Forming Methods
37 deg. Flare
37 deg. Double Flare
45 deg. Flare upon request
Expanding
Reducing
Sizing
Beading
*Some requirements may require tooling lead-time
Bite Type Fittings
AN Aircraft Fittings
MS Military Spec Bite Type Fittings
Boeing BAC Bite Type Fittings
Deutsch Permaswage Fittings
Wiggins Couplings Fabrication
Custom End forming
Orbital Tube Welding
Moss Vale Inc.
Meeting Other Needs
If your contractual needs include hydrostatic test Moss Vale, Inc. will test your
tube assemblies in either water or hydraulic fluid or inert gas mediums.
Pressure test may be accom-
plished up to 10,000 psi in our
shop test equipment.
Moss Vale, Inc. maintains a cur-
rent specification library of MIL-
Spec, Navy, Air Force, and SAE
Standards. Fabrication in accor-
dance with your special specifi-
cation is available.
“Time is of the essence”
No longer is there a need to wait. For a quote on your prototype, short or me-
dium size production run (5,000 parts/wk or under) give Moss Vale, Inc. a call.
You’ll be glad you did!
Moss Vale, Inc. (513) 939-1970