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Aliens in action case studies

CASE STUDY 1

The Client
A leading global aerospace prime with a strong presence in both commercial and military markets.

The Component
The component was part of an engine actuation system for a single engined plane and, being a single line component, was flight critical. The manufacturing process was complex, requiring high tolerances and surface finishes to be achieved after a casting.

The Challenge
Casting supply was unreliable because it the part was tricky to cast and only small quantities were required. The part suffered from porosity and distortion both before and after heat treatment.

Lead-times were long, yield was poor and the finished product was extremely expensive.

The solution
Graves saw benefits from developing the component from readily available bar stock which would eliminate all the delivery problems associated with casting at a stroke.

The process route was redesigned including route planning, tooling design, cnc programme construction, process control and a quality plan.

The first batch of components were manufactured successfully and released with a first article inspection report.

The Result
• Dramatically reduced lead time, including planning time!
• Improved process stability
• Reduced variability in the manufacturing process, uniformity and finish
• Reduction in number of suppliers in the chain
• Removed yield loss due to casting porosity
• Superior product within required lead time
• Costs saving across the supply chain

 

case studies

CASE STUDY 2

The Client
A leading global aerospace equipment manufacturer supplying jet engine control systems.

The Component
This highly complex part had traditionally been manufactured by the customer because of the difficult manufacturing process and importance of low variability.

The in-house process required the manufacture of a high precision sleeve and end fitment.

The sleeve was manufactured from a malleable nickel alloy billet which was machined to a very thin and fragile structure. Tolerances for flatness and squareness were tight!

The end fitment was manufactured from a solid billet, machined to a thin walled structure then nitride hardened in specific areas.

The two components were aligned and beam welded to form the whole assembly which was then completed by a turning process.

The Challenge
Yield was poor due distortion caused by the beam welding process.

Graves took on the manufacture of this assembly with the aim of reducing losses through tighter controls during manufacture.

The Solution
The root cause of the problems was maintaining tolerances during the beam welding process. Calculations were made for fusion weld shrinkage and distortion accounted for. Tooling was designed and manufactured to keep the components accurately aligned during welding.

Tight tolerance processes were moved to post welding to ensure the tolerances and surface finishes could be maintained.

The Result
• The first 100% yield batch of this component - ever!
• Product variability reduced and process capability increased dramatically
• Overall acquisition costs substantially reduced.