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Strategic Business Unit

Combustion Systems

Description

Doncasters Combustion Systems Division manufactures highly engineered turbine engine ready components and systems for the power generation and aerospace industries. We can provide OEM customers with "one stop shopping" for their combustion system components and high temperature needs. We are committed to the long term success of our customers. We believe in value-added partnerships where we work with the customer's design team to solve complex design and manufacturing challenges. Additionally, we continue to support our customers during all the phases of the product's lifecycle – from research and development, during production, and later in field service support for repair and overhaul. The Combustion Systems Division has strategic manufacturing locations in the United States in Indiana, Illinois and California as well as in the UK.

GCE is a manufacturer of industrial gas turbine combustor components which include liners, end caps, aft frames, flow sleeves, transition ducts, impingement shields, stator assemblies and exhaust collectors. Manufacturer of aerospace structures and specialised support assemblies. Processes include tooling, kirksite die casting, vacuum furnace heat treatment, acid cleaning, drop hammer metal forming, 2000 tonne hydraulic press forming, robotic welding and plasma cutting, 5 axis CNC machining, multi-axis laser processing, real time x-ray and inspection services. Inspection and project management of engine ready parts.

Materials

High nickel alloys
Stainless steels
Aluminum alloys
Nickel and cobalt based superalloys
Castings, forgings and solid bar

Principal markets

Industrial gas turbines
Aerostructures
Other specialized engineering structures

Capacity

High alloy steel sheet metal forming to 3/8” thickness.
Sheet metal structures to 8‘ diameter and 1500 lbs.
Machining 4’x4’ to 3000 lbs and machining to 50".
High alloy steel sheet metal forming to 3/8” thickness.
Sheet metal structures to 36” diameter

Technology

Complete CAD services linked to CAM using CATIA, Unigraphics, Solid Edge, AutoCad and SurfCam.
Robotic welding and plasma cutting
CNC turning, machining and punching
Multi-axis laser processing
Real time x-ray inspection
Air flow and hydrostatic pressure testing
Computer coordinate measuring
Complex fabricated metal components and assemblies specializing in high temperature and corrosion resistant alloys
Robotic and manual welding
Certified Non-Destructive Testing (NDT) capabilities

Facilities

Kirksite foundry die forming
Heat treat vacuum furnace facilities
Acid cleaning facilities
110-2000 tonne hydraulic press facilities
4-8 tonne drop hammers
Shear brakes and roll forming machines
6 and 7 axis laser systems
5 axis CNC horizontal and vertical machining centers
4 axis CNC horizontal and vertical lathes
Plasma robotic and water jet cutting
6 axis robotic welding
High temperature coating facilities
Coordinate measuring machine
NDT radiographic and x-ray machines
CMM inspection facilities
Wide range of sheet metal forming and fabricating equipment
Hydraulic forming
Shear brakes and roll forming machines
Water jet cutting
Laser cutting and drilling and welding
Robotic and manual TIG welding
Multi-axis CNC precision machining
Horizontal and Vertical CNC precision turning
Special Processes and Capabilities:
Heat treat vacuum furnace facilities
NDT inspection facilities
Radiographic
Ultrasonic
Real-time X-ray
CMM , FPI

Accreditations

ISO 9001:2000 certification
Loyd’s Quality Assurance Ltd. Applicable to Sheet Metal for Aerospace and Power Generation
NACAP certification for NDT
OEM approvals : General Electric Power Systems, Siemens Power Systems, Solar Gas Turbine, Northrop Grumman, Lockheed Martin and more.