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With decades of experience in the aerospace industry, HKAA 5-axis CNC machines are in widespread use by manufacturers of aerospace tooling including layup molds, machining fixtures, assembly jigs and friction stir welding fixtures. Our customers have utilized HKAA machining to manufacture parts, components and tooling for almost every type of aerospace application from general aviation to space travel.
Parts for aerospace applications are designed to maximize strength and minimize weight. That usually results in a lot of machining. Throw in the complex geometries, tight tolerances and exotic alloys specified in the drawings, and you can see why these parts are difficult to make.
Impro does a lot of precision machining of aerospace parts. Some go through familiar CNC processes like turning, milling and grinding, but 5-axis machining often provides the best manufacturing route.
Precision machining aerospace parts means addressing three challenges:
Producing complex features: Pockets are needed for mass reduction, while complex contours minimize space needed in the aircraft and provide the necessary functionality.
Maintaining tight geometric tolerances: Not just dimensions but also the relationships between features are tightly toleranced to achieve the required levels of performance.
Minimizing cycle time: Many part designs call for extensive material removal, but the alloys used, such as 7000 series aluminum, titanium, and superalloys, are challenging to machine. High speeds are necessary to minimize costs.
The major benefit is the ability to machine features on multiple faces and at angles other than 90° without removing and refixturing the part. This saves time and improves accuracy. It also reduces lead time because batches of parts aren’t queuing for a series of machining operations.
5-axis positioning can also reduce machining time, by allowing optimization of the milling cutter geometry to maximize the metal removal rate. This is especially beneficial when the volume of metal to be removed, combined with poor machinability, will result in long cycle times.
True 5-axis machining with simultaneous positioning also enables machining of parts that could not easily be produced any other way. This gives the design team more freedom to achieve mass and performance goals and so contributes to improved part design.
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Powder coating is a dry finishing process, using finely ground particles of pigment and resin electrostatically charged and sprayed onto surfaces. Cured under heat, it creates a durable, uniform, and attractive finish, popular for its environmental and performance benefits.
Black oxide, a conversion coating in surface finishing, chemically forms a protective black layer on metals, primarily ferrous alloys. It enhances corrosion resistance, reduces light reflection, and adds decorative appeal. Applied through hot or cold processes, the finish is often sealed with wax or oil to boost durability and protection.
Chromate conversion coating, often known as Alodine or Chemfilm, is a surface treatment for aluminum and its alloys. It forms a thin, protective chromate layer, enhancing corrosion resistance, promoting paint adhesion, and providing electrical conductivity. Commonly used in aerospace and automotive industries, it offers a decorative finish with minimal dimensional change.
DLC (Diamond-Like Carbon) coating is a nanocomposite finish that imparts a hard, wear-resistant surface to materials. Mimicking properties of natural diamond, it offers exceptional lubricity, corrosion resistance, and a reduced friction coefficient, making it ideal for automotive, tools, and precision components.
Brushing in surface finishing uses abrasive brushes to create fine, consistent lines on metal surfaces. This mechanical process enhances appearance, masks defects, and prepares surfaces for coatings. Offering various textures, from short to long grains, brushing ensures aesthetic refinement for various applications.
Titanium anodizing is a surface finishing process that modifies the oxide layer on titanium components. Enhancing corrosion resistance and biocompatibility, it also adds vibrant, interference-based colors without dyes or pigments. Popular in medical devices and aerospace, it combines aesthetics with functional benefits.
Passivation is a surface finishing process that treats stainless steel with a mild oxidant, removing iron contaminants and enhancing its natural oxide layer. This strengthens corrosion resistance and prevents unwanted reactions in environments like the medical, food, and aerospace industries.