Industry(s): Marine
Application(s): Engine Cooling Systems
Processes: CNC Machining, Washing, Leak Testing, Assembly, Inspection and Testing, Packaging
Aerostar Global Manufacturing specializes in providing high-precision components for various industries, including automotive, aerospace, and industrial applications. One of the critical components manufactured by Aerostar is the Cooling Housing, designed to meet the stringent requirements of modern engine systems. This case study highlights the design, manufacturing, quality control, and inspection processes involved in the production of the Cooling Housing, demonstrating Aerostar’s commitment to excellence and customer satisfaction.
Project Overview
- Project Name: Cooling Housing Manufacturing and Assembly
- Part Number: E100091
- Customer Industry: Marine Recreational
- Objective: To manufacture and assemble high-quality Cooling Housings with consistent performance and durability, adhering to the customer’s specifications.
Challenges
The primary challenge was ensuring the Cooling Housing met the rigorous standards of performance and reliability required by the customer. The housing needed to withstand high pressures, temperatures, and various environmental factors while maintaining structural integrity. Additionally, the component’s complex geometry required precise machining and assembly processes to achieve the desired fit and function.
Solution
Aerostar leveraged its advanced manufacturing capabilities and expertise in high-precision machining to develop a robust solution for the Cooling Housing. The project involved close collaboration between Aerostar’s engineering, quality, and production teams to ensure all specifications were met.
Quality, Inspection, and Measurement Steps
- Receiving Inspection: Materials were thoroughly inspected upon arrival to ensure they met the required specifications. This included visual inspections for any defects, contamination, or rust.
- In-Process Inspection: During the manufacturing process, several inspection points were established to monitor critical dimensions and characteristics. For instance, the use of a refractometer verified the wash solution concentration during the washing phase.
- Final Inspection: A detailed final audit was performed on each assembled Cooling Housing. This included a visual inspection for correct identification, product defects, and proper packing. Leak tests were also conducted to ensure the housing met the required pressure specifications.
These steps often intertwine with manufacturing steps to ensure a feedback loop exists between the production process and quality controls. Discrepancies detected during quality checks can lead to modifications in the manufacturing steps.
Manufacturing Steps
- Material Ordering and Management: The raw materials for the Cooling Housing were ordered and managed through Aerostar’s supply chain to ensure timely availability.
- Machining: The Cooling Housing was machined in-house, with precision tools ensuring the complex geometry was accurately achieved.
- Washing: The housing underwent a thorough washing process to remove any contaminants, using specific instructions to ensure cleanliness.
- Leak Testing: Each Cooling Housing was subjected to an air decay leak test to verify that no leaks were present, ensuring the component’s reliability in the final application.
- Assembly: The housing was assembled with additional components, including press barbs and expansion cup plugs, using Loctite retaining compounds to secure them in place.
- Packaging: The final product was carefully packed to prevent damage during transportation, with all packaging materials inspected for quality.
The steps in manufacturing are often revisited based on the results of the quality checks. For example, if an intermediate inspection detects an issue, the material may go back to the assembly stage.
Manufactured Components and Parts
- E100009 Cooling Housing (Machined)
- E800092 Press Barb (0.625″ x 1.75″)
- E800075 Expansion Cup Plug (1.190″)
- E800076 Expansion Cup Plug (0.755″)
- Loctite 540 Retaining Compound
- Loctite 609 Retaining Compound
Results
The successful production of the Cooling Housing not only met but exceeded the customer’s expectations. The rigorous inspection and quality control processes ensured that the final product was free from defects and ready for high-performance applications. Aerostar’s ability to deliver a reliable and high-quality component strengthened its relationship with the customer and opened opportunities for future projects.
Conclusion
This case study on Cooling Housing exemplifies Aerostar Global Manufacturing’s dedication to quality, precision, and customer satisfaction. By leveraging advanced manufacturing techniques and stringent quality control measures, Aerostar continues to deliver components that meet the high demands of its customers across various industries.
