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No longer underground, but still steel – the aerospace sector of North-Rhine Westphalia

It’s no secret that the German aerospace industry is one of the fastest growing sectors in the country. While it generated revenues of 14.8 billion euros in the year 2000, by 2015 revenues had already reached 34 billion euros[1] and were on an upward trajectory. In contrast, it’s less well known where the heartbeat of this future-driven industry lies. Most people would probably bet on the usual suspects of Bavaria or Baden-Württemberg, however it’s actually the state more commonly associated with the coal industry: North-Rhine Westphalia (NRW).  

In fact, though it went almost unnoticed, NRW has morphed into the home of high tech in recent decades; most importantly when it comes to conquering the skies. To give some examples, the German Aerospace Center is headquartered in the cathedral city of Cologne. Not far from there you’ll find the world-leading European Transonic Windtunnel. Somewhat further westward, the RWTH Aachen University has earned itself an excellent reputation for education and research within this key industry. And recently, Defence Minister Annegret Kramp-Karrenbauer opened the Bundeswehr’s new Space Operations Centre in Uedem.

Throughout the state, countless businesses ensure short supply routes and a constant flow of new development. Whether it’s turbines, radar units or hard and software for satellite ground-control systems – NRW can build it. The state is best prepared for future challenges.

aircraft turbine

And what does all this have to do with Walzwerke Einsal?

As a manufacturer of more than 400 products, with years of experience and our headquarters in southern Westphalia, we are a reliable partner of the German aerospace industry. Right now we are expertly prepared for the demands of the future and well-acquainted with the needs of our customers in the aerospace sector. Quality, of course, comes first, but Walzwerke Einsal go one step further.

We specialise in providing individual solutions and custom dimensions starting from the smallest order size of 250 kilograms. This service is indispensable in an industry of only a few standard dimensions but where there is plenty of room for innovation. It almost goes without saying that, with us, personal consultation and outstanding customer service are always included.

An overview what we offer:

  • Custom solutions from southern Westphalia for your individual needs

  • Long-standing and wide-ranging experience with high-performance raw materials for the aerospace industry           

  • Small minimum orders from 250kg

  • Short lead times

  • Bespoke bar lengths

  • Near-net-shape geometries

  • Ample stock of many common raw materials for aeronautical engineering (nickel-based/titanium alloys, 15-5PH, 17-4PH, 13-8Mo, and many more)

  • Personal consultation and technical support around the clock

 

Savings:
  •  material
  •  tool wear
  •  lead time

= savings up to 70 % possible

Strict adherence to standard specifications – our certifications and qualifications

Aircraft construction is a highly complex process requiring optimum precision from the outset. As in many other businesses, our sector is required to comply with numerous regulations and standards. Only manufacturers who meet all necessary conditions are permitted to operate within this future-driven industry in the first place.

It therefore goes without saying that Walzwerke Einsal is a certified manufacturer. You can trust our:

  • Aerospace Certification according to EN/AS 9100
    An extensive auditing process is required before this certification can be awarded. Only when the quality, consistency of supply, product safety, documentation and numerous other aspects meet the strict requirements of EN/AS 9100 is a company permitted to supply its products to the aerospace and defence industries.
  • AMS-compliant systems engineering according to AMS 2750 and AMS-H-6875
    The Aerospace Material Specifications are the global standard for the industrial processing of high-grade raw materials. The norms regulate aspects such as temperature constancy during production and the subsequent heat treatment, as well as the instrumentation and calibration of the process measuring and control technology or system accuracy testing. The standard of quality required by the aerospace industry can only be guaranteed once these regulations have been fulfilled.
  • Authorised supplier for AEROSPACE Original Equipment Manufacturers (OEM) - For many years we have been a trusted partner of numerous OEMs in the aerospace industry. Our customers don’t just value the quality of our products but also our bespoke solutions and comprehensive service.

 

aircraft turbine

How and for which applications is WE steel used in the aerospace sector?

Aircraft are clearly exposed to a range of extreme conditions. Modern airliners ascend to heights of over 10,000 metres where the air temperature can fall to below minus 60 degrees Celsius. At the same time, their engines produce such intense heat that, despite active cooling systems, reaches temperatures of several hundred degrees Celsius – and that at a cruising speed of nearly 900 kilometres per hour.

In the face of such numbers it stands to reason that the raw materials used in aircraft construction must be capable of withstanding such strain. Raw materials such as those from our factory.

Our high-performance raw materials behave consistently across a wide temperature spectrum, thus guaranteeing the structural integrity of the aircraft. Thanks to its outstanding resistance to scaling, our Super Alloy 718, most commonly used in aircraft engines, can handle temperatures of up to 700 degrees Celsius as well as being easily worked and moulded.

In aircraft construction our materials continue to be used in those modules subject to the greatest mechanical strain – such as the wings and landing system, fuselage reinforcement of the cockpit and interior, as well as in the undercarriage.
These applications lend themselves in particular to  precipitation hardening martensitic steels, such as

1.4542/1.4548 (X5CrNiCuNb16-4 / 17-4 PH / UNS S17400 / AISI 630)
1.4545 (X5CrNiCuNb15-5-4 / 15-5 PH / UNS S15500 / XM-12) or
1.4534 (X3CrNiMoAl13-8-2 / 13-8 Mo / UNS S13800).

In the production of these grades of steel, excellent ductility, durability, purity and homogeneity are achieved by means of the electro-slag remelting process (ESR) or vacuum arc remelting process (VAR) . Warm precipitation hardening or a combination of strain hardening and precipitation hardening continue to ensure increased strengthening. Finally, these grades benefit from low delta ferrite content (δ ferrite content) of no more than one to two percent thanks to their alloying concepts.

The times in which daring pioneers took to the skies in wooden crates wrapped in canvas are long gone. Without the high-quality alloys, such as those provided by our factory, the modern aerospace industry would simply be unimaginable.

What can we do for you?

We have compiled a complete list of all products supplied by us. We are delighted to receive inquiries based on your custom dimensions and quantities starting from as little as 250 kilograms.

Our service team is also happy to answer queries relating to our various manufacturing processes or technical support. You can contact us direct via our handy online chat service. We look forward to hearing from you.

 

[1] Figures according to Statista.com; Source: Annual report of the German Aerospace Industries Association.