Industry(s): Aerospace, Agriculture, Automotive, Heavy Truck, Marine, Power Generation
Application(s): Engine Components
Processes: Chamfering, Deburring, Sanding, Die Grinding, Surface Finishing, Parts Washing, Leak Testing
At Aerostar Manufacturing, we’ve developed an advanced air intake connection assembly procedure, emphasizing impeccable quality and precision as marked by our ISO 9001-2015 certification. Our method starts with an intensive visual inspection, followed by detailed checks of product dimensions and surface finishes using specialized equipment. Continuous assessments for accuracy are paramount, including a 40psi leak test and barcode verification. Leveraging tools like Attribute Gages, CMM, and Barcode Scanning Systems, we guarantee that every product meets or surpasses industry benchmarks, ensuring our clients obtain an unparalleled final product.
At Aerostar Manufacturing, we’ve pioneered a rigorous air intake connection assembly procedure, emphasizing adherence to our ISO 9001-2015 certification, showcasing our dedication to unmatched quality and precision.
The process initiates with a meticulous visual inspection, ensuring product accuracy, quantity, and identification while meticulously examining for potential damages, contamination, or rust. Following this, rigorous inspections for diameters, threads, milled faces, and precise locations are carried out using tools like Attribute Gages, Variable Gages, and Coordinate Measuring Machines (CMM). Every aspect of the surface finish, including visual defects, is thoroughly inspected.
Our commitment to perfection doesn’t stop there. Repeated checks for diameters, threads, milled faces, and locations are executed, utilizing both Variable and Attribute Gage Inspection. We emphasize SPC Control for major characteristics and rely on Variable Gages and CMM for detailed inspections of diameters, heights, or lengths. The runouts are meticulously examined using a CMM, and we ensure there’s no oversight of machining or casting flaws.
To maintain cleanliness and accuracy, we employ the Millipore Inspection Method and a refractometer to ensure the wash solution’s concentration. We then conduct a 40psi leak test, adhering to a maximum allowable leakage of 3cc. Before implementing the barcode, each part undergoes an inspection for any debris or excess liquid. A rigorous check is then executed for label quality, barcode accuracy, placement, adhesion, and the Barcode Scanning System verifies correctness. The finale of our process entails a comprehensive visual review for the accuracy of the product, shipping containers, packaging integrity, and any discrepancies.
Our process’s backbone is the advanced equipment, including Attribute Gages, Variable Gages, CMM, Refractometer, and Barcode Scanning System, ensuring each product meets or exceeds industry standards. This devotion to excellence assures our clients receive a top tier final product.
Project Overview
Quality, Inspection, and Measurement Tools
- Initial Visual Inspection: Confirm correct product, quantity, and identification. Inspect for damage, contamination, or rust.
- Dimensional Inspection: Verify dimensions such as diameters, heights, and thread sizes using gages and/or CMM (Coordinate Measuring Machines).
- Surface Quality Inspection: Evaluate the surface finish using visual methods or attribute gages.
- Cleanliness Verification: Use standardized methods to verify cleanliness of parts.
- Leak Test: Evaluate the leak rate under specified pressure conditions.
- Barcode and Labeling Inspection: Validate barcode quality, label orientation, and text readability.
- Final Audit: Re-confirm product identification, check for defects, and verify packing and packaging integrity.
- Pre-Shipment Inspection: Confirm correct product, quantity, and identification prior to shipping. Inspect for damage, contamination, or rust.
Equipment and Tools Used for Quality and Inspection Steps
- Attribute Gages
- Variable Gages
- Coordinate Measuring Machines (CMM)
- Refractometer
- Thread Gage
- Calipers
- Barcode Scanning System
- Visual Inspection Tools
Often performed just after receipt of raw materials or components. Sets the quality tone for subsequent manufacturing steps.
Manufacturing Steps
- Material Receipt and Storage
- Initial Machining: Milling, drilling, and other forms of material removal.
- Intermediate Machining
- Advanced Machining: More precise and complex operations.
- Washing/Cleaning
- Final Machining and Finishing
- Leak Testing
- Labeling and Barcoding
- Packing
- Final Audit and Shipping
Equipment and Tools Used for Manufacturing Steps
- Milling Machines
- Drilling Tools
- Endmill Holders
- Carbide Drills
- Shrink-Fit Holders
- Spotting Tools
- Cleaning Solutions and Equipment
- Barcode Printers
- Packing Materials
Ongoing machining often involves intermediate quality checks. Final machining steps are usually followed by the most rigorous quality inspections.
Manufactured Components and Parts
- Castings
- Milled Parts
- Threaded Components
- Drilled Components
- Finished Assemblies
Project Gallery
