Product Solution

Ball Joints

A ball joint is a flexible joint providing angulation over a range of movements. A solution for duct articulation needs, these ball joints are bellows sealed for leak free service with maximum reliability, and engineered for the lowest possible bend.

Product information

Our ball joints are supplied individually but can be designed and manufactured as part of a system. We develop in conjunction with our clients’ engineers, ensuring all application needs are fulfilled and achieving critical design criteria including bending, space envelope, weight and fatigue life expectancy. They are suitable for pneumatic and fuel systems, airframe and engine, and we supply predominantly to the Aerospace industry, with clients including Airbus and Embraer.

Key product features

  • Lightweight, small sizes
  • We cover the range of temperatures and pressures typically required for ball joints
  • Available in titanium, CRES and high temperature nickel alloys

The development process begins by taking the customer’s requirements around duct diameter and volume of space. The products are designed with size, material, pressure, temperature, number of cycles and angulation in mind, with angulation replicated to ensure there is no clashing of components. The design is then tested with a stress analysis. A set of tooling is then designed and manufactured to produce individual components, with each tool trialled and each assembly measured against the drawing for total compliance. We manufacture a number of units for test purposes, and when this process is complete, the gimbals go into production.

All systems and components are put through a rigorous qualification programme to ensure the design meets operational and environmental requirements. The test report is written and signed off by the customer for approval. Our comprehensive internal test facility, coupled with strong relationships with a number of test houses, allows us to manage the complete qualification process.

Our highly experienced team of engineers have found many solutions for challenges presented by ball joints. By taking view of the whole system, we can use our knowledge and experience to recommend the best type and where they should be fitted.
The more involved we are in the process, the more we can utilise our knowledge and experience to optimise the design. This in turn has a positive impact on weight, cost and efficiency.

  • Rolls Royce SABRe
  • Airbus
  • Embraer
  • BAE Systems
  • Leonardo
  • Bell
  • GKN
  • Dresser
  • Honeywell
  • Baker Hughes
  • Part 21 Subpart G Production Approval – UK CAA
  • AS9100 Rev D Quality Systems Aerospace – BSI
  • ISO9001
  • ISO14001 2015 Environmental Management System- BSI
  • Nadcap AS7114 Non Destructive Testing – PRI
  • Nadcap AS7110 Welding – PRI

Senior Bird Bellows have adapted a gated New Product Introduction Process, which is based on AS9145. Many OEMs are now beginning to use this process.

Our Capabilities

We design innovative, cost-effective engineering solutions, specialising in the design of bellows, bellows assemblies, gimbal bellows, flexible joints and aerospace bleed air ducting systems. Our team of experienced engineers cover all parts of the process, from system analysis and concept to detail, qualification and production supply. This enables us to fully optimise the design of the system, using our extensive knowledge and experience to maximise efficiency and minimise weight and cost.

With a production area of 60,000 square feet, our dedicated team of experienced engineers have access to leading technology and resources to create a range of high quality, high performing products to operate in extreme environments and applications. Our fully equipped site houses a wide range of production machinery including; a CNC tube bender, various CNC lathes and machine centres, and robotic spot welding and polishing. Furthermore, our new production process based on AS9145 means we can offer high standard products that are producible and repeatable in a timely manner.

Our thorough material selection process ensures maximum efficiency and safety is achieved for every application. Our scope of materials include: stainless steel, nickel alloys, Hastelloy®, Incoloy® 825, Monel® 400 and titanium Gr.2. The specific selection is based on the requirements of the part and the environment it’ll be based in, including the pressure and temperature levels it will undergo. It is imperative that the right materials are selected for each project, as parts failure is simply not an option.

Our on-site testing and qualification facility is purpose-built and highly adaptable to ensure maximum performance of all our products. Our leading technology enables us to provide extensive testing across all products, meeting the demand for application conditions during product qualification. Typical tests include: endurance at elevated temperature, cyclic fatigue, proof/burst and rupture, 24/7 cycle testing, high temperature and pressure, subzero and icing, helium leak detection, radiography, dye penetrant, air under water, mass spectrometer leak detection and three-axis measuring resource.

Discuss your project with our Sales Engineers
Telephone:
+44 (0)1260 271411
culture of quality

A worldwide reputation for quality and trust

Our team of highly skilled, highly motivated people take real pride in their work. This maintains the high standards we’re known for as we continue to strive for Zero Defect and 100% satisfaction. Our dedicated Quality Team cover everything necessary to maintain compliance, meet our customers’ needs and continually improve our business.

Learn more about our quality culture
HSE Commitments

Committed to high levels of health and safety in everything we do

Every member of the Senior Bird Bellows team is dedicated to developing our strong safety culture, taking a responsible attitude towards our HSE responsibilities. This commitment to ‘doing the right thing’ will help to transform our sector into a safer, more responsible and eco-friendly industry.

Learn more about our HSE commitments