Aerospace parts, especially those destined for use in aircraft engines, are some of the most challenging to machine. The combination of hard materials, high precision, and extensive metal removal, (for mass reduction), demands advanced machine tools and deep machining expertise.

This blog discusses our ability to undertake precision machining on some of the most challenging types of parts. Whether you’re in the market for aircraft engine components or other hard-to-make parts, it showcases our capabilities.

The Machining Challenges

All aerospace components need to be strong and light. Those going into engines also need high temperature strength and excellent fatigue and corrosion-resistance.

These requirements push engineers towards materials like stainless steel, titanium, and the superalloys. They have the properties needed but tend to be difficult to machine. Toughness and temperature resistance complicate chip formation, and titanium in particular has a “gummy” nature that causes built up edge on cutting inserts.

The other challenge is part geometry. The drive to minimize mass results in features like thin ribs and deep pockets. Contoured surfaces are needed to optimize fluid flows, and fitting components into tight spaces results in complex shapes.

In parallel, many geometric features are tightly toleranced for both fit and function. There are high demands on surface finish too, where ridges and grooves could act as stress raisers and lead to premature failure.

The Impro Approach

There are six aspects to Impro’s approach to machining these parts:

• Machine tools
• CAD/CAM
• Tooling
• Inspection
• Secondary processing
• Expertise

Machine tools

We’ve invested in an extensive array of CNC machining capabilities. Of particular relevance to aircraft engine parts, we have 4 and 5 axis machining centers capable of milling complex contours to very high precision.

CAD/CAM

We use advanced software tools to develop the CNC part programs our machine tools need. These let us minimize machining time while reducing tool and workpiece deflections to maintain tight tolerances.

Tooling

Challenging alloys need advanced cutting inserts and specialized chipbreakers. State-of-the-art tool presetting equipment ensures each tool offset is determined precisely and transferred to the machine tool.

Inspection

Machined components are inspected for dimensions and defects like surface finish faults. Eddy current and magnetic particle technologies are used to check for cracks.

Secondary processing

Heat treatment is often an essential element in making high-precision components. This is not just to raise hardness but to relieve stresses that can cause deformation. Surface treatments, like passivation and chemical etching, are also often needed after machining. Impro has resources for performing these processes and more.

Expertise

Technology is a vital element for success in high precision machining, but it’s not the only one. Just as important is a high level of CNC programming and machining expertise, coupled with experience in working with difficult-to-machine alloys. As a leader in CNC machining of challenging geometries and alloys, Impro has these in depth.

Typical Products

We can produce many of the components used in aircraft engines. A partial list includes:

• Turbine blades
• Rotors
• Casings
• Motor housings
• Drive Shafts
• Flanges and adapters
• Support brackets

If the parts you need aren’t on this list, please contact us as it’s likely we have machined them in the past. Evene if they are new to us, we almost certainly have the ability to produce them to the standard required.

Precision Machining Experts

Aircraft engine components are hard to machine, because they’re made from challenging materials and to tight tolerances. Impro has both the machining technology and the expertise to produce them at the levels of quality needed. If you need parts for aircraft, or other difficult applications, we can help. Contact us for details.