The subject matter of this specification can be embodied in, among other things, a locking apparatus for a rotary actuator includes an outer housing comprising a cylindrical interior surface having a recess. A rotor is disposed within the outer housing. The rotor has an interior cavity and a port extending radially from the interior cavity to the cylindrical exterior surface. A piston is disposed for reciprocal movement within the interior cavity between a first position and a second position and includes a first portion having a first thickness, a second portion having a second thickness larger than the first thickness. A key is disposed for radially reciprocal movement within the port and includes a radially proximal end and a radially distal end. The radially proximal end contacts the first portion and the radially distal end does not extend into the recess when the piston is in the first position.