• The Need
  • Solution
  • Impact
The Need
Customer need

Manufacture of a complex sheetmetal fabrication part for aircraft engines, that requires the assembly of 32 child parts of multiple raw material such as nickel, stainless steel & cobalt alloys (hi-temp alloys)

High number of welding at various conditions and stages (550 Spot welding, 38 GTAW welding),

Multiple stages of Non-Destructive Testing (NDT) inspection (Fluorescent penetrant inspection and Radiography inspection) for GTAW welding

Intermittent brazing and heat treatment operation

Detailed concept of tooling to archive complex profile and quick assembly time

Aerospace
Solution
What we did

Avalon approached the project with a thorough input study, gap analysis and identification of potential failures as per customer blueprint requirements. The team created a detailed process design that included:

Creation of a Process flow diagram

Stage-wise manufacturing process consisting of individual part, sub-assembly, and assembly with process-controlled tools with poke yoke mechanism

Stage-wise inspection gauges to control CTQ

Control plan linking manufacturing process step to critical inspection

Complete welding cell, training, and qualifying a welding operator

Establishing and qualifying source for brazing and heat treatment process

Impact
Final outcome beneficial to customer and us
  • Created the first FAI in six months
  • Successfully delivered 2000 units in one year.
  • Developed complex engine sheet metal fabrication facility with NADCAP certification