APS164-22900 - APS FAA-PMA Forged Brake Disc

APS164-22900 – APS FAA-PMA Forged BlackSteel® Brake Disc 🛑

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Overview

The APS Aviation Product Systems 164-22900 is a premium, FAA-PMA (Parts Manufacturer Approval) approved replacement brake disc engineered for high-energy braking systems on various general and light-utility aircraft. This component is a member of APS's distinguished BlackSteel® product line, signifying a major technological and material science upgrade over the Original Equipment Manufacturer (OEM) brake disc, which this part is certified to replace (OEM P/N 164-22900). The primary engineering differentiator of the APS164-22900 is its construction: it is CNC machined from a single, one-piece forging of high-strength steel, an inherently superior design compared to lower-cost welded or cast discs.

This brake disc is the critical rotating friction surface within the wheel brake assembly, responsible for converting the kinetic energy of the landing aircraft into thermal energy via friction with the brake linings (pads). Its reliability is flight-critical, as failure under high thermal load can lead to loss of braking action and catastrophic runway excursion. The BlackSteel® proprietary heat treatment provides exceptional resistance to the severe thermal cycling, corrosion, and oxidation endemic to aircraft braking, ultimately delivering a longer service life and reduced maintenance burden compared to standard OEM counterparts.

Key Features

• One-Piece Forged Construction: Eliminates the structural weaknesses and potential failure points associated with welded or cast disc designs, creating a continuous, oriented grain structure for maximum strength.

• BlackSteel® Proprietary Treatment: Undergoes a specialized thermo-chemical treatment process (not a coating) that bonds carbon, oxygen, and nitrogen into the metal's surface layer, providing high resistance to corrosion and pitting.

• Superior Thermal Stability: The dense, uniform grain structure from the forging process significantly reduces the risk of thermal warping, heat checking, and micro-cracks under repeated, high-energy stops.

• FAA-PMA Certified: Rigorously tested to meet or exceed the performance, durability, and safety standards of the OEM specification.

• Precision CNC Machining: Ensures extremely tight tolerances for flatness and parallelism, which is necessary for smooth, vibration-free braking and even distribution of pad pressure.

Technical Specifications

• Part Number: APS164-22900

• Component Type: Brake Disc / Rotor, Main Wheel Brake

• Manufacturer: Aviation Product Systems, Inc. (APS)

• Product Line: BlackSteel®

• OEM Replacement for: Cleveland P/N 164-22900 and 164-229 (as per PMA approval)

• Material: High-Strength Forged Steel Alloy (Specific proprietary alloy)

• Finish: Proprietary BlackSteel® Corrosion-Resistant Surface Treatment

• Primary Brake Assembly Application: Cleveland Wheel Series 40-144, Brake Series 3-144A.

• Bolt Holes: Quantity: 8; Size: Typically 13$3/8$ inch (Confirm with maintenance manual).

• Minimum Wear Thickness: 0.410 inches (10.414 mm) (This value is critical and must be strictly adhered to).

• Certification Status: FAA-PMA Approved.

Aircraft Compatibility

• Primary Aircraft Models: The OEM P/N 164-22900 is primarily associated with wheel and brake assemblies used on various models, including, but not limited to, certain Beechcraft (e.g., King Air series) and Cessna aircraft, particularly those utilizing the Cleveland 40-144 wheel series.

• Verification Note: The Aircraft Maintenance Manual (AMM) and the Illustrated Parts Catalog (IPC) for the specific aircraft serial number, along with the APS PMA Supplement, must be consulted for final verification of applicability and eligibility.

Applications Section

The APS164-22900 is utilized in the following critical systems and roles:

• Main Landing Gear Brake System: Serves as the friction element within the single-disc or multi-disc brake stack, mounted directly to the main wheel assembly.

• Kinetic Energy Dissipation: The core function of absorbing and dissipating the immense thermal energy generated during taxi, stopping, and rejected takeoff (RTO) procedures.

• Skid Control Interface: Provides the smooth, uniform surface required for effective torque transmission in aircraft equipped with anti-skid systems.

Why Choose the APS164-22900 Forged Brake Disc?

Choosing the APS164-22900 BlackSteel® disc is an engineering decision based on enhancing operational safety and long-term value. Brake discs are subject to two major failure modes: thermal fatigue cracking and corrosion-induced pitting. The forged, one-piece construction drastically mitigates the former by eliminating the weak points inherent in welded designs, allowing the metal's internal grain flow to follow the contour of the disc for maximum crack resistance.17 The BlackSteel® treatment combats the latter, ensuring the braking surface remains smooth, flat, and free of corrosion-induced pitting that can lead to rapid pad wear and reduced braking effectiveness.18 Investing in this FAA-PMA upgrade ensures superior durability and reliable performance that often surpasses the OEM standard, translating directly into reduced maintenance downtime and lower lifecycle costs.19

The thermal dynamics of aircraft braking dictate the material science behind the APS164-22900. During a maximum energy stop, the brake disc surface temperature can momentarily exceed $1000^\circ\text{C}$. This rapid, localized heating creates immense thermal gradients and corresponding internal stresses. The forging process, which creates a controlled, anisotropic grain flow (where material properties are optimized in the direction of the principal stress), provides the microstructure necessary to resist the formation and propagation of microscopic fatigue cracks caused by this cyclical thermal stress.22 The BlackSteel® treatment is a form of Ferritic Nitrocarburizing (FNC), a thermochemical diffusion process that enriches the steel surface with nitrogen and carbon, forming a hard, protective compound layer. This layer increases the surface hardness and, critically, improves the corrosion potential of the steel, making it significantly more resistant to environmental attack than standard untreated or plated steel.23

Note: The APS164-22900 brake disc is a flight-critical component.24 Its thickness must be checked against the minimum wear dimension ($0.410$ inches) before installation and during all required brake inspections; a disc below this limit must be immediately removed from service. Proper break-in procedure must be strictly followed upon installation to ensure the formation of a uniform transfer layer between the disc and the brake linings for optimal friction and wear characteristics.25 Installation and inspection must be performed and certified by a licensed A&P mechanic in strict accordance with the Aircraft Maintenance Manual and the APS Instructions for Continued Airworthiness (ICA).

Documentation

Authoritative documentation for this FAA-PMA part is available from the manufacturer and the FAA:

• APS Instructions for Continued Airworthiness (ICA): Required for specific maintenance and break-in procedures.

• APS BlackSteel® Technical Data/Application Guide: Provides detailed specifications, minimum wear dimensions, and aircraft eligibility.

• FAA PMA Supplement: The official FAA document certifying the part's airworthiness eligibility as a replacement for OEM P/N 164-22900.