Full overview
Client Profile
| Industry |
Aerospace & Defence Manufacturing |
| Company Size |
Large Enterprise (1,200+ employees) |
| Geography |
Bengaluru, Karnataka, India |
| Operational Context |
The client manufactures critical aluminum and titanium components for aerospace assemblies, including housings, brackets, and structural sub-parts. These components require non-destructive surface treatment with strict control over surface integrity, as fatigue life and visual inspection are key acceptance criteria for these components. |
Business Challenge
The client was dealing with typical issues that arise in the surface finishing process after CNC machining and heat treatment:
- Surface Integrity Issues: It was found that the use of conventional angular abrasives caused micro-cutting, which increased the risk of stress risers in fatigue-sensitive parts.
- Non-Uniform Cosmetic Finish: There were differences in the look of the product from batch to batch, hence it became very challenging to conduct quality inspections and customer audits.
- Dimensional Sensitivity: On the tightly tolerance aerospace components, even the slightest material removal was not allowed.
- High Rejection Rates: About 6% of the parts were found defective due to surface non-conformities at the final inspection stage.
- Audit Pressure: During aerospace OEM audits, there was a strong emphasis on the requirement for controlled, repeatable, and contamination-free blasting processes.
Solution Implemented
After a comprehensive application study and field trials under controlled conditions, we advised the change of blasting media from angular to Glass Beads.
Specific Solution:
- Aerospace-grade spherical Glass Beads (sizes 150–250 microns) are ideal for both peening and cosmetic finishing.
Process Optimisation:
- Blasting pressure was lowered to specify surface peening instead of surface erosion.
- The nozzle distance and dwell time were adjusted to maintain the dimensional accuracy.
- The media handling system was separated for ferrous abrasives to avoid their contamination.
Application Outcome:
- Beautifully finished and aesthetically clean surfaces
- Improvement of the surface compressive stress without loss of material
- Visual clarity significantly improved for dye penetrant and visual inspections
Implementation Process
Timeline: The entire process from qualification trials to mass production took 5 weeks.
Deployment Steps:
- Week 1: Tests at the laboratory and company premises on aluminum and titanium sample parts.
- Week 2: Inspection of surface roughness (Ra) and dimensions in reference to aerospace standards.
- Week 3: Completion of blasting parameters and media grade approval.
- Week 4: Production line turnover and machine adjustment.
- Week 5: Process documentation for audit compliance and operator certification.
Training: Operators and quality teams were thoroughly trained in aerospace blasting best practices and media cleanliness protocols.
Results & Impact
Switching to Glass Beads brought about significant changes:
- Less Rejections: Rejections due to finishing issues were reduced from 6% to below 0.8%.
- Surface uniformity: A thoroughly smooth matte-to-satin type finish in all lots was accomplished.
- Dimensional Stability: There was no material wear detected even at the most critical features.
- Inspection Efficiency: Having a clearer surface led to the saving of 20% inspection time.
- Audit Compliance: Customer and regulatory audits were successfully passed by the new process.
ROI & Business Benefits
- Lower Rework Costs: Less scrap and reprocessing led to a higher overall yield.
- Extended Media Life: Glass beads had much less breakdown compared to angular abrasives.
- Equipment Longevity: Wear to blast nozzles and liners was minimized.
- Payback Period: About 11 months, mainly through quality improvements and fewer rejections.
Why the Client Chose This Company
The client partnered with us due to our:
- Aerospace Application Know-How: Thorough understanding of fatigue-sensitive surface treatments.
- Data-Driven Trials: Media and parameters were backed up by quantifiable test results.
- Process Documentation Support: Help with standard operating procedures, validation records, and documentation for audits.
- Consistent Abrasive Media Quality: Steady supply of high-purity glass beads that meet aerospace cleanliness standards.
