We produce metallic Aircraft detail parts mainly processing aluminum alloys, stainless, carbon and tool steel, titanium and plastics. We utilizes a broad manufacturing capabilities; machining , bending, routing, stretch forming, welding, shot peen chemical surface treatment, painting, harness.
In addition the special processes we have in house tooling capability to manufacture tool to manufacture sheet metal parts, jigs and fixtures as well
We also support all manufacturing with all types of cutting tools and support equipment.
1- MACHINING, METAL CUTTING
Machine shop is equipped with -3,-4,-5 axis CNC machine centers , multi-axis turning , mill-turn m/c ' s , CNC or manual grinding , boring , routing , honing , EDM ,waterjet , material sawing CNC or manual cutter grinding machines.
The shop has been experienced with manufacturing complex monolithic parts , machining thin walled or formed skin panels , precision hole processes , tooling parts , fixtures , welded structures , standard or special cutter producing.
· HIGH SPEED MACHINING (HSM) CNC M/C's
In Aircraft industry , to produce monolithic , complex , big beams , bulkheads our shop is equipped with HSM machine centers .These machines are have horizontal structure , 30.000 rpm and 100 KW power with 2 pallet systems to decrease set-up times , and MQL or high pressure internal coolant systems
· 3 HEAD, GANTRY 5 –AXIS CINNINATI PROFILER
There isn't a commercial aircraft flying that hasn't been touched by a Cincinnati Profiler! These multi-spindle, multi-axis contour milling machines apply decades of 5-axis experience from an extensive, worldwide, installed base. Structures and spindles tailored to material (aluminum, steel, and titanium), full 5-axis contouring capabilities, 15 m x-axis, 3 parts at the same time.
· SKIN ROUTER 5-AXIS CNC MACHINE WITH SPECIAL FLEXIBLE TOOLING SYSTEM
Machine offers speed, accuracy and performance to producing aircraft large, formed, rolled or flat skin panel parts from, graphite composite, aluminum. The machining processes are trimming and drilling. The machine is equipped with flexible tooling system to hold each skin panel what kind form, parts have.
· SKIN PANEL MECHANICAL MILLING CNC 5-AXIS MACHINES
To reduce the cost of chemical milling and environmental problem a new approach is apply mechanical methods to manufacturing of aircraft skin panels. The 5 axis CNC bridge type double pallet machines are using to produce formed skin parts in one set up with vacuum tooling.
2-SHEET METAL PART MANUFACTURING
In the scope of Sheet Metal Manufacturing; aluminum, steel and titanium sheets are routed/punched, formed, bended, joggled, stretched, welded using specialized equipment and machinery. The parts are surface finished following all the necessary operations. The Hydroforming Machines are used to manufacture complex shaped parts and the stretching presses are used to manufacture the large skin panels of air platforms.
Stretching is the process of forming the aluminum sheets of fixed or rotary wing platforms, using a special stretch forming machine. The part is kept inside/on the molds while the sheet is held by fixed or stationary jaws.
· Diaphragm (Hydroforming) Forming
The hydroforming machine is used to manufacture complex shaped parts, since it's a high cost process. The parts are attached to specified tools and formed under hydrostatic pressure.
· Stack Router
The stack routers perform the end routing and drilling operations for mainly aluminum sheets. The machines work on a 3-Axis system and allow machining of multiple sheets simultaneously.
· Profile Routing
Profile routing machines are CNC controlled 5 axes machines. Various profiles (L,U,Z,T, etc.) can be drilled, end routed and surface machined using these machines.
· Welding Operations
Two main welding operations and performed within Welding Workshop; TIG and Spot welding. Two or more different types of materials weld by using tungsten electrode in TIG Welding process, Aluminum, steel and titanium materials welded using this method. Spot welding is combination of two or more titanium or steel parts using the conversion of electrical energy to heat energy.
· Pipe Manufacturing
Pipe Manufacturing Workshop can perform bending, swaging, flaring and welding of pipes used in fuel, oil or air transfer systems within aircraft platforms.
3- CHEMICAL AND METALLURGICAL PROCESSES
A wide range of surface treatments are available for aluminum, steel and titanium detail parts in our facilities. In our NADCAP certified facility, we are continuously improving our Technologies by means of quality, cost, safety and environment.
Our coating capabilities about improving the corrosion resistance of aluminum:
- Tartaric-Sulfuric Acid Anodizing
- Boric-Sulfuric Acid Anodizing
- Chromic Acid Anodizing
- Phosphoric Acid Anodizing
- Chemical Conversion Coating
Some of our other capabilities:
- Chemical Conversion Coating of Titanium
· Chemical Milling
In our NADCAP certified facility, chemical milling process is being applied on formed aluminum parts according to design requirements. Purpose of this process is to reduce the weight of the part while maintaining structural strength and integrity.
· Heat Treatment
In our NADCAP certificated heat treatment facility, we perform below processes according to customer requirements:
Aluminum Heat Treatment:
Solution Heat Treating
- Artificial Aging
- Stress Relieving
Steel Heat Treatment:
· Shot Peening
The process is to compress the surface of the metal by hammering parts with a certain speed, angle and time using balls from different materials. The purpose of the process is to increase the fatigue life of the material, to prevent corrosion stress and cracks. In our NADCAP certified facility, shot peening is applied by using fully automated machine.
The main purpose of paint applications is to increase the surface resistance for the parts in addition to meet the cosmetic outlook expectations of the customers.
After the completion of chemical surface applications for the metal parts and the surface preparations of the composite structures, the paint application is performed in automatically with Automatic Painting Robots or manually in the Detail Parts Paint Shops, depending on the geometry of the parts. When the assembly operations for the detail parts are completed, the assemblies are called "Components" are painted including top-coats in the specialized buildings. The aircrafts, helicopters and unmanned vehicles are also painted in these paint shops. As a requirement for the Aerospace Industry, all paint shops and chemical process facilities are subject to NADCAP Certification Audits.
Automatic Painting Facility
The automatic painting facilities have the latest technology for the horizontal robotic painting process. They provide high quality and cost savings in the paint application technology. The detail parts are painted either with water based paint or with the solvent based paint using the Automatic Paint Robots. The chemically processed parts are fed to cabinet on the front side of the facility. The robots are applying the paint on a dual axis following the sensing of the parts. The parts are fed to furnace horizontally for curing. Finally, the parts are cured and the paint process is completed.
5-CUTTING TOOLS AND SUPPORT EQUIPMENTS
All manufacturing and assembly areas are supported with cutting tools and equipments of production.
The analyze, research, trial, tracking the problems and solutions, design, stock control and procuring of the cutting tools used for milling, turning, drilling, cutting, edge cutting etc. operations are done for all factory. The need of the production areas is analyzed and the best solutions are applied. This department has the capability of doing precision 3 dimensional measurements, micro hardness measurements and spectral alloy analyzes of cutting tool materials. The laser marking operations can be done on the cutting tool.
The repair, maintenance and qualification operations can be applied for all kind of pneumatic tools used in the production departments. The tools required for the production can be analyzed according to the usage area and procurement can be done. The pre dimensional tests can be done by 3D prototyping.
The design, manufacturing, setup and activating operations of precision hole boring systems and equipments can be done for assembly areas to decrease the workmanship and increase the component quality. The modernization of automatic drilling units can be done and activated.