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