Electromagnetic Dent Removal
The Electromagnetic Dent Remover (EDR) works on any electrically conductive material. Though it does utilize magnetic fields to remove dents, the EDR does not rely on the material being worked on to be ferromagnetic. In fact, a non-magnetic metal such as aluminum is more amenable to the EDR process than ferromagnetic metals such as iron or steels because of its superior electrical conductivity. Thus, aluminum skinned aircraft are ideal candidates for the EDR process.
The EDR employs a highly sophisticated power supply and electromagnet to create a changing magnetic field. This induces an electrical current into the work-piece (e.g. dented aluminum aircraft panel). At just the right moment the field is rapidly reduced in strength. This sudden reduction in field strength creates a force in the work-piece that pushes it outward, much as a hammer blow from behind would do.
Usually a series of pulls is required to correct each dent. This process typically does not damage paint. Properly applied, it leaves no footprint, does not affect avionics, and can be used on a fueled aircraft. The EDR is especially useful in repairing dents in metal core honeycomb and on panels where access to the rear side of the panel is limited or nonexistent.
Even in situations where access to the rear side of the panel may be possible, economic advantages of the EDR process can be substantial due to saved time and labor. Consider for example hail damage in the top wing surface of a large airplane. While pushing the dents out from inside may be possible depending on the location, doing so could necessitate removing all fuel, some aircraft disassembly, possible tank bladder removal, reassembly, testing, and refueling.
Obviously, if the damage can be corrected by the EDR process in a matter of a few minutes to a few hours as opposed to days or weeks the savings can be huge, not only in terms of labor to make the repair but also by minimizing downtime of the airplane.
- Power Supply Dimensions: 1m x 1m x 2.1m (40"x40"x82")
- Power Supply Weight: 700kg (1,550lbs)
- Actuator/Work Coil Weight: 11kg (24lbs)
- Power Requirement: 120VAC, 20A, 60Hz (grounded neutral)
- New systems can be designed to customer requirements
- American Airlines
- Boeing Airplane Company
- USAF, 135 Production Engineering Branch, 76th Aircraft Maintenance Group
"I never cease to amaze at how few people in the industry, including operators, manufacturers and insurers of aircraft,
are aware of this technology. I have personally handled roughly a dozen claims for hail damage, bird strikes and other
sources of fuselage, wing and control surface damage on corporate aircraft...and I would estimate that I have saved over
$2,000,000 in repair costs"
- Kyle D. Moore, USAIG
"...A team from Boeing's Recovery and Modification Services came to our facility to perform dent removal on two Lear 60 model
aircraft with their [Electroimpact] Electromagnetic Dent Removal equipment. We have been pleased with the results of this process.
The two aircraft were damaged in a recent hail storm and had extensive amount of dents on the fuselage, delta fins and wing leading
edges. Some of the dents were completely removed while others were removed to acceptable Structural Repair Manual limits. The process
was time and labor saving."
- Christopher L. Rabe, Manager Quality Assurance, Bombardier Aerospace Services