A “Power By Victor” LIMITED EDITION VI™ Engine Overhaul incorporates advanced Cryogenic Processing Technology for enhanced parts performance. Designed to meet maximum engine durability, power and fuel efficiency demands. With Victor’s patent issued FAA accepted unique Limited Edition VI™ engine processes we are able to advance engine reliability, longevity and fuel efficiency while adding significant aircraft value.
To reduce residual parts stress and improve engine performance, Victor Aviation has a unique F.A.A. accepted patent issued process to test parts over a 600 degree range in temperature from -300 to +300 degrees Fahrenheit.
This non destructive testing process is performed in a computer controlled vacuum insulated cryogenic processing chamber over a several day period in a Liquid Nitrogen atmosphere with real-time ultrasound material monitoring.
This testing process can relieve residual parts stress, detect for improperly machined or heat treated parts by measuring material volume changes, provide for longer engine life, better fuel efficiency, and improve engine performance.
Victor Aviation has a wide array of powder coating colors available, designed to provide a tough, durable and beautiful finish for your "Power-By-Victor" Limited Edition VI™ engine. Custom RAL colors are also available upon request. Customers may choose select colors and design their engine according to their own personal request.
The electrostatic powder spray process, is universally accepted and specified as the Best Available Control Technology (BACT). While powder coatings have many advantages over other industrial finishing methods from both a process and performance standpoint, it is also an environmentally friendly process. Victor Aviation continues to lead the way in being an environmentally friendly company and helps other companies build a roadmap for a cleaner future.
Vibratory stress relief testing is performed by vibrating engine parts at a sub-harmonic vibration frequency while real-time monitored with a full domain spectrum analyzer. This process measures changes in residual stress concentrations of engine parts. Subsequent to manufacturing processes such as grinding, machining, casting and hardening high concentrations of residual stress may develop.
During the life of a part these stresses may cause a part to distort or prematurely fail. This F.A.A. accepted testing process is also used to provide for more reliable magnetic test indications during non destructive testing of engine parts as a result of any shifting of material composition due to stress changes. Using this process can improve parts longevity and durability by neutralizing residual stress and enhances parts performance.
Shot peening is a F.A.A. accepted process accomplished by the pneumatic impingement of metallic, glass or plastic shot on critical engine parts. As a result of this process the parts fatigue strength and resistance to stress corrosion cracking is improved by enhancing parts residual surface compressive stress.
Nearly all fatigue and stress corrosion failures originate at the surface of a part, but cracks will not initiate or propagate in a compressively stressed zone. Compressive stresses are beneficial in increasing resistance to fatigue failures, corrosion fatigue, stress corrosion cracking, hydrogen assisted cracking, fretting, galling and erosion caused by cavitation. As a result of this unique process, critical stressed surface areas prone to stress corrosion cracking are shot peened to provide for longer lasting more durable parts life.
Parts are NDT tested using eddy current electromagnetic induction on electrically conductive engine parts. This process is very effective especially on non magnetic materials such as aluminum castings, crankcases and housings. The advantage of this method is that it can detect fractures or porosity problems beneath the surface of the material that are not detectable by surface inspection techniques on magnetic and non magnetic parts. Eddy current uses alternating electrical current flowing through a coil at a chosen frequency and generates a magnetic field around a coil or probe. When the coil is placed next to a conductive material, eddy current is included in the material. If a flaw in the conductive material disturbs the eddy current circulation such as a crack or porosity problem, the magnetic coupling with the probe is changed and a defect signal can
be read by measuring the coil impedance variation.
Using high frequency high speed sound waves, parts are scanned to gauge their integrity, check for flaws and material characterization.
A pulse-echo ultrasonic measurement can determine the location of a discontinuity within a part or structure by accurately measuring the time required for a short ultrasonic
pulse generated by a transducer to travel through a thickness of the material.
The pulse then reflects from the back or surface of the discontinuity and is returned to the transducer and can identify flaws internally in a part. Using ultrasonic high speed ultrasonic velocity testing can significantly improve engine longevity by detecting sub surface flaws that could have developed into future parts failure.
The principle of acoustic resonance inspection is used to determine the vibration signature of a part when exposed to an external force or striker. Every part has its unique vibration signature or resonant frequency. If there is an internal or external change or imperfection to a part, the frequency of the part will change. Resonant inspection can detect imperfections such as cracks, porosity, material density or heat treating problems. To determine a parts vibration signature, a striker will contact the part and a microphone will record the resonant frequencies generated on a full domain spectrum analyzer. Frequencies can then be compared to the frequency of a perfect part reference standard, and sets of identical part numbers can be matched for frequency response. This allows Victor’s technicians to match parts to matched resonant frequencies for better parts performance.
Extracting maximum performance from the valve train is essential for best power, smoothness and longevity.
As an engine’s valves open and close, the contact angle between the valve and the rocker arm becomes critical to proper valve operation and engine performance.
Any valve side loading can decrease cylinder efficiency and reduce available horsepower. Victor’s LIMITED EDITION™ VI Engines are precision machined for minimum valve side loading for better power, performance and reliability. To help achieve consistency, valve spring pressures and heights are matched for more efficient engine operation. The hydraulic lifters and
camshaft are matched for identical bleed down rate timing to assure uniformity of independent valve overlap and maximum throttle response.
Internal engine parts are very sensitive to the effects of corrosion which can cause premature failure of the engines camshaft, hydraulic lifters and gears. Iron manganese phosphate coating is a F.A.A. accepted process of acid etching a lubricant into steel parts to reduce friction, provide for corrosion protection while improving fuel efficiency. When new parts are installed in an engine there are initial contact surface break-in effects.
Phosphate coating will assure a smooth initial contact break-in effect and also improve parts pitting fatigue life. Friction is reduced by the smoothing of the asperities of the mating gear surfaces and aids in keeping the gear tooth surface shape. This chemical conversion treatment forms a crystalline coated surface which provides for a significant improvement in contact fatigue strength and can greatly improve engine parts life.
Crankcases are straightened, then precision milled and final machine bored utilizing precision boring equipment to assure proper alignment and size.
The journals are also finish tested for size and journal geometry by airflow differential procedures to assure a precision fit of the bearings to crankcase halves. This procedure minimizes piston side loading, reduces bearing wear and provides equal loading on crankshaft main journals.
This line boring process reestablishes the centerline of the crankshaft axis, thereby insuring the centerline is parallel and equidistant to the cylinder deck planes for enhanced engine performance.
Engine thrust may be increased by reducing the amount of power wasted in attempting to offset counterbalancing forces induced by out-of-balance internal components. Improving parts balance allows the engine to deliver more power to the propeller and the engine becomes more efficient with less wear on internal moving parts. “Power-By-Victor” Black Edition V™ Engines are uniquely real-time motion balanced by Victor’s A.S.E certified master machinists to within one gram.
With this F.A.A. accepted process, individual parts and cumulative reciprocating mass weights are balanced, to provide for the best longevity and smoothness of the engine. Balancing not only
improves thrust but also reduces pilot and passenger fatigue by lowering the amplitude of various vibration frequencies generated by the engine.
Engine testing at Victor Aviation is the most extensive procedure used in the industry and performed over a several day cycle process. Victor’s state-of-the-art mobile engine testing apparatus, incorporates a thrust velocity load cell that measures the actual thrust force of the propeller. Engines are installed into a hydraulically activated engine mount, with engine accessories, induction system and exhaust system installed, to simulate real-time engine test parameters.
Using an electronic load cell wafer, the engine’s real-time thrust velocity is recorded at all engine speeds.
During the test process special dyes are put into the oil system and examined under a black light canopy to detect for any discrepancies. Engines are tested at maximum power and must meet Victor’s rigid test standards assuring the highest level of quality control.
Internal engine components move at varying rates of motion and produce different frequencies. These components can be individually revealed by plotting vibration amplitude against frequency. The breaking down of vibration signals into individual frequency components is called frequency analysis, a technique which may be considered the cornerstone of diagnostic vibration measurements. Using a full domain frequency analyzer the frequency and amplitude of a components vibration level can be detected using a tri-axial piezoelectric accelerometer. This F.A.A. accepted testing process enables Victor’s technicians to not only test for complete engine balance but isolate exactly what internal engine components are in need of correction. This level of engine vibration analysis by far exceeds industry standards and enables Victor's technicians to identify engine design and component problems allowing for a smoother running engine.
Volumetric efficiency testing measures airflow into each cylinder and allows Victor Aviation to match cylinders for maximum power so that the pilot can have the benefit of using all available power uniformly and efficiently with all cylinders. With this F.A.A. accepted process of polishing and removal of surface flashings of the intake and exhaust systems, a significant improvement in volumetric efficiency is available.
After cylinders are volumetrically balanced all cylinders produce uniform airflow to provide for improved uniformity of power distribution. Air flow balancing is performed at multiple valve lift openings to assure for the best in engine fuel efficiency. Such precision tests are virtually unique in the aircraft industry to “Power-By-Victor” Black Edition V™ Engines.
A hydraulic valve lifter is a device that converts the rotary motion of the lobes of the camshaft to linear motion to actuate the engines valves while taking up the slack in the valve train.
Valve train clearances change with temperature as the engine heats up and cools down, so the hydraulic lifters have to constantly compensate for thermal expansion of the crankcase, cylinders, pushrods, valves and other valve train components.
By the precision matching of hydraulic lifters with identical bleed down rates to a properly profiled and matched camshaft assembly, Victor's technicians can assure uniformity of independent valve overlap timing and maximum throttle response. This allows for smoother engine operation, improved fuel efficiency and increased engine performance.
Precision machining and matching piston rings can create a power advantage by maximizing dynamic engine compression while still maintaining good oil control. This involves both proper ring selection for the intended use and diamond cutting machining procedures when gapping your rings.
Piston ring sets come pre-gapped from the parts manufacturer and are not matched to precision fit a cylinder bore. That simply isn't precise enough where gaps should be accurate to within 0.001 inch or less for best engine power.
Victor's technicians precision match piston rings to each individual cylinder bore using highly specialized diamond cutting and finishing techniques to close tolerances. This process assures better cylinder compression and enhanced cylinder performance.