Duncan Aviation: Unlocking An Engine’s Peak Performance

Duncan Aviation is significantly enhancing its turbine engine capabilities with the construction of a new 36,000-square-foot Pratt & Whitney Canada Designated Overhaul Facility (DOF) for PW300 and PW500 turbofan engines that is nearing completion. This expansion, coupled with strategic investments in advanced machinery, bolsters Duncan Aviation’s in-house capabilities for all of its Authorized OEM engine operations. These advancements enable the delivery of unparalleled value, quality, and faster turnaround times for everything from scheduled inspections to major overhauls and urgent AOG (Aircraft on Ground) events.

DOF Expansion Nears Key Milestones

Construction on the new DOF is rapidly progressing, with the 36,000-square-foot expansion reaching significant internal development stages. Designed by Tectonic Management Group and constructed by Hausmann Construction, the DOF is now fully enclosed, with interior work in full swing.  

The expansive new space features 12 dedicated engine maintenance bays, a new parts inventory warehouse, and significantly expanded backshops. The expansion includes new offices, conference rooms, a breakroom, modern bathrooms, locker rooms, and additional workstations available to customers.

Demonstrating Duncan Aviation’s commitment to safety and efficiency, 16 one- and two-ton overhead cranes are being installed throughout the new shop. These enhance the safe and precise handling of large engine components, improving productivity and technician safety.

Significant upgrades are also underway for the building’s utility infrastructure, including a larger evaporator drain pit for chemical recycling and a substantially upgraded fuel farm. Its 12,000-gallon tank supplies two 3,000-gallon tanks, ensuring continuous test cell operation during refueling—a significant efficiency improvement.

In-house engine capabilities are expanding with advanced tooling: an Aerospect Measurement and Stack Prediction System for compressor stack measurements, a coordinate measuring machine for precise dimensional inspections, dedicated bearing inspection rooms, a thermal spray booth for internal part repairs, and sophisticated vertical and horizontal grinders.

All existing in-house engine backshops are expanding, upgrading machinery, and are centrally located among authorized engine OEM operations. These include clean rooms, media blasting equipment, shot peening equipment, a paint booth, NDT capabilities, and a balance room, all of which enhance maintenance team efficiencies.

The new DOF test cell and control room, designed and installed by Atec, Inc., has been placed adjacent to Duncan Aviation's existing test cell. It features Atec’s next-generation small turbofan technology, offering a quieter testing environment with greater airflow and reduced environmental impact. Following pre-assembly, test fitting, and load testing, shakedown runs and commissioning are scheduled for February 2026.

The DOF will move into the new addition in November 2025, with overall project completion targeted for April 2026.

Precision and Savings with Advanced Grinding and Measurement

For engine overhaul, hot section inspections, and hourly borescope inspections, Duncan Aviation has invested in a pair of specialized grinders that work in perfect harmony. The vertical grinder, a Palmary VIG 80 Shroud Grinder, precisely grinds the inner dimensions of critical components, such as turbine high-pressure support case shroud segments and honeycomb low-pressure turbines. Custom fixtures, fabricated by Duncan Manufacturing Solutions for each engine model, ensure a perfect fit every time. Complementing this, the horizontal grinder, a Universal Cylindrical Grinder, grinds the outer dimensions of components, especially crucial for turbine blades, where clearances are 0.025 to 0.035 inches. This synchronized precision guarantees optimal engine performance and longevity.

Every measurement is then confirmed by a Zeiss Contura CMM (Coordinate Measuring Machine). This advanced CMM, equipped with an articulating sensor and multi-axis capabilities, measures complex angles and contoured shapes, ensuring that all repaired parts meet stringent OEM specifications. It also graphs geometric tolerances, aiding in thorough performance investigations. Additionally, a Sharp SC-618-2AN Surface Grinder ensures shims and spacers are perfectly flat, optimizing axial clearances—a critical assembly requirement for engine repair. This attention to detail directly translates to enhanced engine reliability and safety. Finally, new vertical and horizontal balancers will precisely balance engine sub-assemblies, leading to enhanced performance and significantly reduced vibration, which directly benefits engine longevity and smooth operation.

In-House Repairs: Speed, Savings, and Quality Control

During hot section, core zone, or overhaul inspections, some part tolerances can measure beyond allowable limits, but with thermal spray processes, their surfaces can be restored. Duncan Aviation purchased a new Metco 9M high-energy plasma system, a fully automated flame spray booth, which allows their engine technicians to add material to components. This gives them the ability to make repairs in-house rather than purchasing costly and time-consuming replacements. This not only saves time and money but also gives Duncan Aviation increased control over quality and consistency compared to older systems. The new system even incorporates an environmental filtration system, reflecting the company’s commitment to responsible practices.

Duncan Aviation’s shot peening room now accommodates two fully robotic, programmable Wheel Abrator Peening Cabinets—one for shot/cast blast and one for glass peening. These machines provide stress relief after grinding repairs by removing damage from critical rotating components such as compressor blades, impellers, and turbine disks. Their high accuracy, thanks to synchronized turntables and 4-axis arms, allows for precise restoration. The ability to repair instead of replace these life-limited components can reduce an operator’s costs by over 50% while offering faster turnaround times and superior control over quality and consistency.

The Wet Blast media cabinet is crucial for thorough cleaning, effectively removing corrosion from component surfaces, penetrating even the smallest cracks and crevices. This is particularly vital for components like the Accessory Gearbox and oil pump gear systems, where corrosion can significantly impact performance.

“These comprehensive capabilities that are now available in-house at Duncan Aviation, underscoring our unwavering commitment to providing unparalleled, cost-effective, and high-quality engine maintenance services,” says Doug Alleman, Vice President of Duncan Aviation’s Engine Operation. “We are dedicated to maximizing aircraft performance, minimizing downtime, and ensuring the long-term value of our customers’ investments, keeping their aircraft flying safely, efficiently, and economically for years to come.”