Meeting the Challenge: CNC Solutions for Aerospace Materials

CNC machining of aerospace materials like titanium and Inconel presents several challenges due to their unique properties. The materials used in aerospace are strong, tough, and hard, making them ideal for the aerospace industry but create challenges for the high-precision machining process.

The Nature of Aerospace Materials

Titanium is a high-strength material that does not conduct heat well. This low thermal conductivity leads to high cutting forces that cause work hardening, vibration, and premature tool wear.

Inconel presents similar challenges as it becomes harder and more brittle during machining, increasing tool wear and the potential for part deformation. Inconel generates a lot of heat, which can affect part accuracy if not correctly managed. Its high strength at elevated temperatures makes it particularly challenging to perform precise machining.

Overcoming Machining Obstacles

Machining titanium and Inconel requires specialized tooling and coatings to overcome the challenges posed by these materials. Carbide tools coated with titanium nitride (TiN), titanium carbonitride (TiCN), or titanium aluminum nitride (TiAIN) are the preferred choices for machining titanium due to their hardness and thermal conductivity.

Carbide tooling with a high cobalt content works well for Inconel due to its heat resistance and hardness. TiAIN and aluminum titanium nitride (AITiN) coatings provide heat and abrasive resistance.

Employing effective cooling methods and lubricants manages heat buildup and reduces friction. Machining techniques like climb milling often minimize tool wear and work hardening. This method exerts a down force during milling and drops chips behind the cutting tool, resulting in a better surface finish and less power required from the machine.

Adherence to Aerospace Standards and Inspection Processes

The challenges of machining aerospace materials like titanium and Inconel are addressed not only through specialized tooling and techniques but also by adhering to rigorous aerospace manufacturing standards. Standards such as AS9100, AS9102, and AS9103 play a crucial role in ensuring that machining processes maintain the highest levels of precision, quality, and safety.

• AS9100 is an internationally recognized quality management system (QMS) standard that integrates ISO 9001 with additional aerospace-specific requirements. This standard emphasizes risk management, configuration control, and continuous improvement—key principles that ensure consistent quality and safety when machining materials like titanium and Inconel, which require precise handling to avoid issues like tool wear or part deformation.
• AS9102 outlines the requirements for First Article Inspections (FAI), a critical process that verifies the first production run of parts meets stringent aerospace specifications. By catching potential manufacturing issues early, FAI reduces the risks and costs of rework, ensuring that each part produced from challenging materials like Inconel and titanium meets industry standards.
• AS9103 focuses on managing variation in Key Characteristics (KCs), which are critical features that affect the performance and manufacturability of aerospace parts. This standard helps ensure that components remain uniform and meet the necessary tolerances, even when machining materials that are prone to work hardening and heat buildup.

By adhering to these standards, CNC machine shops maintain high levels of regulatory compliance, ensuring that each part is produced with the necessary accuracy and quality for aerospace applications. This commitment to quality control is essential for maintaining the safety, reliability, and performance of aerospace components made from materials like titanium and Inconel.

Macfab’s Expertise in Aerospace Machining

Macfab specializes in CNC machining, sub-assemblies, and specialty services tailored to the aerospace industry. With deep expertise in manufacturing precision components for critical aerospace applications, we are the trusted choice for industry professionals seeking reliable, high-quality solutions.

Our commitment is to produce each aerospace component to the highest standards possible within the aerospace industry, using the latest technological advancements and the skilled expertise to handle CNC aerospace materials like titanium and Inconel.

Talk to the machining experts at Macfab for your aerospace CNC machining needs. Rest assured we offer top-tier solutions and quality adherence to industry standards.