Overcoming Challenges in Fabricating Aerospace Components

The Component in Focus

An aircraft “cooler duct” is a specialized duct used to channel air to specific components of an aircraft. In this case, the part marries various materials through various manufacturing processes and must operate in a high-temperature, extreme environment.   

This part posed a number of unique challenges beginning with the fact that so many manufacturing processes were required to produce the component. After a series of design for manufacturability (DFM) exchanges, we settled on a challenging design utilizing titanium. Titanium is widely used to produce aerospace components due to its exceptional strength-to-weight ratio, excellent corrosion resistance, high-temperature tolerance, and fatigue strength.  

Challenges Faced During Aerospace Component Fabrication

This complex design required various production processes combined with the difficulties associated with working with titanium, in particular, the welding process. To make the production of this component possible, we collaborated with a local welder who possessed specific knowledge about welding titanium. Titanium welding poses several challenges including:

• Oxygen contamination – Titanium is reactive to oxygen, which causes it to become brittle and prone to cracking.
• Shielding gas – The welding process requires shielding the weld from oxygen with an inert gas, like argon or helium.
• Clean welding environment – The welding area must be clean and contaminant-free. 
• Melting point – Titanium has a high melting point and low thermal conductivity, so it’s important to maintain enough heat to fuse the metal properly.  

Geometric Complexity

In addition to the challenging welding requirements, this part was geometrically complex. Before welding could even begin, strict requirements had to be met – each half had to be machined to precise specifications to ensure exact alignment and structural integrity. Once the duct had been welded, the design required further precision operations in the form of machined holes with strict positional tolerances. By utilizing our advanced 5-axis machining centers, we achieved the necessary accuracy to meet these exacting standards. 

Developing Innovative Solutions

Our team navigated numerous challenges throughout the development process. Each hurdle required creative problem-solving, collaboration, and a commitment to delivering a high-quality aerospace component that met all stringent industry requirements. 

• Working with Titanium – Titanium is a notoriously difficult material to machine. For example, it is prone to hardening from the heat of the tool which makes the material more abrasive. Our expert team has the knowledge and state-of-the-art equipment to prevent this from becoming a problem.
• Design for Manufacturability – (DFM) is a strategic approach to optimizing product designs for efficient manufacturing. By considering production capabilities, materials, and processes early in the design phase, DFM reduces cost and waste, improves efficiency, and minimizes potential production issues. This practice streamlines the transition from concept to production while maintaining the high-quality standards necessary in the aerospace industry.
• Welding Titanium – Titanium is challenging to weld because the material reacts to oxygen and nitrogen in the air. Therefore, skilled welders are required to handle the task. We were successful in joining the two halves because we partnered with a local welder who was experienced in the intricacies of titanium welding. 

Inside the Fabrication Process

The process began with three hot-formed titanium pieces carefully trimmed to ensure accurate alignment. The trimmed parts were then expertly welded together with two additional press brake formed pieces, creating a part capable of withstanding the demanding conditions of aerospace applications. Once the two halves were joined, the component underwent additional machining operations in our 5-axis machining center to achieve the final specifications. This multi-step process ensured the completed component met stringent performance, durability, and quality standards required for aerospace components. 

The duct, constructed from two hot-formed titanium halves, is an excellent example of partnering to develop a complete solution that adheres to aerospace industry standards. Throughout the production process, every step is aligned with stringent aerospace certifications, guaranteeing that the component meets or exceeds the quality, reliability, and performance standards required for extreme environments as the industry demands. 

Delivering Excellence 

The success of this project has strengthened our partnership with the customer, which resulted in repeated awards of this duct due to our proven performance and reliability. Our collaboration has also fostered increased engagement in design for manufacturability (DFM) discussions. Furthermore, our demonstrated capabilities have positioned us as a trusted partner, leading to consideration for additional programmatic work. 

Re:Build Cutting Dynamics is an Experienced Fabrication Partner

At Re:Build Cutting Dynamics, we are proud to develop the most complex components. Our team’s expertise combined with our diverse machining capabilities, allows us to deliver solutions that meet the stringent demands of the aerospace industry. Whether navigating intricate designs, ensuring material integrity, or meeting tight tolerances, we excel at turning challenges into opportunities. Trust us to bring your most ambitious projects to life with unmatched quality and reliability. Contact our team today to discuss your needs.