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What Are Important Aerospace Machining Certifications?

A precision aerospace company manufacturing an aerospace component has a tremendous amount of responsibility. The partnership that contract manufacturers have with the aerospace industry really is an extension of processes that encompasses procedural integrity with public safety as the highest of priorities.  The aerospace industry demands the highest levels of quality, reliability, and safety and to meet these stringent requirements that machining companies are required to hold for doing business. For example, an aerospace company manufacturing turbine blades requires a certification like AS9100 for several critical reasons. Turbine blades operate under extreme conditions of temperature and stress, making even the slightest defect a potential catastrophic failure. An AS9100 certification ensures that the manufacturing process adheres to rigorous quality standards, from material sourcing to final inspection. This certification provides assurance to both the company and its customers that the blades are produced consistently, reliably, and in compliance with industry best practices. Industry certifications are necessary for the aerospace industry and other critical industries like the medical device and automotive sectors. These certifications are followed by aerospace machinists as it is essential for component manufacturers to meet these requirements to maintain their position in the supply chain. The following table indicates the importance that each certification has:

CertificationImportance for the IndustrySpecial Notes
AS9100 SeriesAS9100 is the single most important Aerospace certification. Establishes a quality management system specifically tailored to the aerospace industry. Demonstrates a commitment to consistent, high-quality products and processes.Covers design, development, production, installation, and servicing. Builds upon ISO 9001 with additional aerospace-specific requirements.
NADCAP (National Aerospace and Defense Contractors Accreditation Program)Accredits specific processes and materials critical to the aerospace industry, such as heat treating, welding, and non-destructive testing.Focuses on technical excellence and adherence to industry best practices. Requires ongoing audits and assessments.
SO 13485Ensures the safety and effectiveness of medical devices used in aerospace applications.While not exclusively for aerospace, essential for companies manufacturing medical devices used in aircraft.
ITAR (International Traffic in Arms Regulations)Regulates the export and import of defense-related articles, including aerospace components with military applications.Compliance is mandatory for companies involved in the manufacturing of military aerospace components. Requires strict security measures.
Other Industry-Specific Certifications (e.g., material-specific, process-specific, environmental)Demonstrate expertise and commitment to specific areas of the aerospace industry.Examples include certifications for titanium machining, surface treatment processes, or environmental management systems.
ISO 9001ISO 9001 provides a robust framework for quality management.The aerospace industry has specific requirements that necessitate a more specialized standard. This is where AS9100 comes in. It builds upon the foundation of ISO 9001 and incorporates additional criteria tailored to the unique challenges and risks of aerospace manufacturing.

Obtaining and maintaining these certifications is a significant investment for machining aerospace parts, but essential for building trust with customers, accessing new markets, and ensuring product quality and safety. Audits to ensure that the standards to each certification are being followed are done every two to three years. Depending on the specific products or services offered, companies may pursue additional certifications, such as those related to specific materials titanium, aluminum, copper. CNC companies may also seek certification for post processing services like anodizing, plating, powder coating, surface treatments and others or environmental management (e.g., ISO 14001). It is a commitment when certified to manufacture precision aerospace components but also it is one of public safety. The parts CNC manufacturers provide support for countless industries in addition to aerospace, by providing products and services for the medical, automotive, consumer, transportation, dental, optics and so many more.

 

Importance of Precision in the Aerospace Industry

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Safety is the number one reason and precision is the top priority for any aerospace company. Aerospace machinists know this from the time they begin their careers in manufacturing. Machining aerospace components is taken very seriously for reasons we all expect. You would not want to board a plane if the parts and structure were processed just a “good” level. Transportation in general has followed stringent guidelines to ensure public safety and employees who operate and provide the services we all request and enjoy. There are three basic reasons precision is so critical in aerospace:  

  • Safety: This is why the number of people traveling by air increases just about every year is due to the safety records of the airline industry. For internal to external use, every aerospace component produced by a precision aerospace company, or a third-party supplier must function flawlessly to the intended design. If aerospace components do not fit properly or defects contribute to failures, the results can be catastrophic. The industry prides not only on the quality of their products, but in the process that ensures inspections and scheduled parts replacement. It is safety that keeps the standards to the highest levels. 
  • Reliability:  Imagine how many times the airline doors are opened and closed or the countless times the seat buckles are engaged. These cycles of use would be short if not for precision manufacturing. Aerospace components are made with the functionality of the designed part and what material will be needed. These factors are then manufactured by highly skilled aerospace machinists. Working with CNC technology, the knowledge of methods and materials prevent the occurrence of defects. All parts go through rigorous test and inspection before approved for service.  
  • Quality of Operation: An aircraft’s performance is greatly measured during flight. How much does it weigh or how much drag there is affects fuel efficiency. Using precision manufacturing contributes to the overall performance by producing properly shaped wings, by the rivets that hold panels together, by the precise fit of the doors and windows and so many more factors. A sub-par operation record could indicate a problem that could flag larger issues thus grounding a fleet of aircraft until resolution was done. 

The aerospace industry indicates it takes from 500,000 to millions of individuals parts that make up a commercial aircraft depending on the make and model. Under the umbrella of safety, reliability, and quality of operation, precision manufacturers and precision aerospace components function as a key element in the aerospace industry. Every aspect of machining aerospace parts for engine components, flight controls, landing gear, door hinges, panels screws and so on, require precision for the aircraft to operate without malfunction and provide the passengers with that premium reliable performance we expect and demand. 

How Are Aerospace Parts Manufactured?

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The quick answer to the question: “How are aerospace parts manufactured?” is “very precisely and with much oversight”. The industry is regulated by many U.S Government regulations. Not only pertaining to the function of the industry in its service to the public, but to the actual aerospace components, like nuts and bolts. There is no part in any aircraft that does not have a specific method to produce, material to use and the precision required for its optimum performance. Aerospace companies rely on partnerships with outside manufacturing service providers. Together they form a bonding relationship that proceeds on the notion that it is in the public and employee’s safety that regulatory standards are governed by such as the FAA or Federal Aviation Administration, FAR or Federal Aviation Regulations, SAE or Society of Engineers and Aerospace Standards, AS9100 or Aerospace Quality Management System Standard and others. Machining aerospace parts can be very satisfying to the countless individuals involved. To give a number there are about 1 million workers just in aerospace and they contribute to about 900 billion in sales revenue for the United States. The process of manufacturing can be long and at times seem tedious, but all is for the safest and pleasurable experience the public can receive. A review of how precision aerospace components are manufactured is:

  • Concept, Design and Engineering-The ideas come forward for breakthroughs in aerodynamics or perhaps for a better arm rest. Each idea goes to engineering groups of mechanical, electrical, materials, metallurgy, chemical disciplines, and many others. With computer aided design or CAD CAM software, 3D models are made, and evaluations performed.
  • Material choice- For structural parts, materials like aluminum, titanium or steel are used. But there may be other areas where composite materials are best. There may be a need for a gasket or the use of new adhesives and epoxies. All will go through critical review before the correct choice is made.
  • Manufacturing methods- Once the concept is approved and the material selected, there will be a phase for research and development or R&D. This can be many months or perhaps years of testing and evaluation. Once the testing phase is done and the machining of aerospace parts is approved, Production manufacturing can take place. Aerospace machinists will use manufacturing methods such as:
  • CNC Drills-Used to create holes, slots, and other geometry. Cutting through or programed depths.
  • CNC Lathes– Rotating the material while tooling inserts cut the shape. Good for cylinders and similar shapes.
  • CNC Milling– Used in 3,4, and 5 axis machines. Can produce very complex parts.
  • CNC Routers– Sheets of materials are cut and drilled by this method.
  • CNC Laser Cutting– Also good for cutting sheets of materials, especially in thinner gauges.
  • CNC Plasma Cutting– Used for industrial applications and can cut many material types.
  • CNC Threading– To produce precision threads for screws, bolts, rods and other parts where secure and precise connections are needed.
  • CNC Waterjet-Using high-water pressure and abrasives can cut various materials with no heat affect.
  • Quality Control– All parts whether manufactured for aerospace components, the medical or oil and gas industries to name a few, will have quality levels that the manufactured parts must meet. The tolerances that these components require vary per the use and environments that they will be subjected to. A standard tolerance may apply to something neither critical nor structural and might be held to a +/- ( ±0.025 mm or less). A mid-level tolerance may be asked to hold parts to a +/- ( ±0.005 mm to ±0.0125 mm) and a critical or tight tolerance may be held to a +/- ( ±0.0005 mm to ±0.0025 mm).
  • Finishing- Some parts may need a finishing process to add more protection from wear or to prevent rust and corrosion. Aerospace machinists will use anodizing, powder coating, electroplating as methods to finish a part.

Once assembled and the selected parts are in use, a precision aerospace company works diligently to review and replace parts on a scheduled plan, often before the estimated life span of the part is met. This is to ensure that the operation of the aircraft and all the supporting subsystems perform flawlessly and, in the end, give passengers confidence in these well-managed systems resulting in satisfaction from the experience and continued patronage.

Common Aerospace Machined Parts Issues

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Common Aerospace Machined Parts Issues and How to Address Them

Machined parts are critical to ensuring proper functionality in the aerospace industry. Just think, four missing bolts can cause a door to fly off in midair. In the aerospace industry, precision and reliability are paramount. When machining aerospace parts, the parts used in aircraft and spacecraft must meet stringent quality standards to ensure safety and performance. However, even with advanced technology and rigorous processes, several common issues can arise in aerospace machined parts. For aerospace machinists, understanding these issues is crucial for preventing failures and ensuring the longevity of aerospace components. Here, we dive into some of the most common problems and how they can be mitigated.

1. Material Defects

Issue: Machining aerospace parts often requires materials with specific properties, such as high strength-to-weight ratios, resistance to extreme temperatures, and corrosion resistance. Material defects, including impurities, inconsistencies, or internal stresses, can compromise the integrity of the parts.

Solution: Rigorous material selection and testing are essential. Implementing thorough quality control measures, such as ultrasonic testing, X-ray inspection, and chemical analysis, can detect material defects early in the manufacturing process. Additionally, working with trusted suppliers who provide certified, high-quality materials can reduce the risk of defects.

2. Dimensional Inaccuracies

Issue: Precise dimensions are critical in aerospace machined parts, as even minor deviations can lead to assembly issues, misalignment, and operational failures. Dimensional inaccuracies can arise from tool wear, improper machine calibration, or thermal expansion during machining.

Solution: Regular maintenance and calibration of machining equipment are vital to maintaining dimensional accuracy. Employing advanced CNC machines with real-time monitoring and feedback systems can also help in achieving precise dimensions. Additionally, implementing strict inspection protocols, such as coordinate measuring machine (CMM) verification, ensures that all parts meet the required specifications.

3. Surface Finish Defects

Issue: Surface finish quality affects the aerodynamic performance, fatigue resistance, and overall aesthetics of aerospace parts. Common surface defects include roughness, waviness, and surface irregularities, which can result from improper machining parameters, tool wear, or contamination.

Solution: Optimizing machining parameters, such as cutting speed, feed rate, and tool path, can improve surface finish. Regularly replacing worn tools and using high-quality cutting fluids also contribute to better surface quality. Post-machining processes like polishing, grinding, and coating can further enhance the surface finish.

4. Residual Stresses

Issue: Residual stresses induced during machining can lead to part deformation, dimensional instability, and reduced fatigue life. These stresses can result from improper cutting techniques, uneven material removal, or rapid cooling.

Solution: Employing stress-relief processes, such as heat treatment or cryogenic treatment, can mitigate residual stresses. Additionally, using balanced cutting techniques and gradual material removal strategies can minimize the introduction of stresses during machining. Simulation software can also predict stress points and help in planning machining processes to avoid these issues.

5. Tool Wear and Breakage

Issue: Tool wear and breakage are common in the machining of aerospace materials, which are often hard and abrasive. This can lead to poor surface finish, dimensional inaccuracies, and increased downtime.

Solution: Utilizing high-performance cutting tools made from materials such as carbide or polycrystalline diamond (PCD) can withstand the rigors of aerospace material machining. Implementing tool monitoring systems that detect wear and breakage in real-time can prevent defects and reduce downtime. Regular tool maintenance and using appropriate cutting fluids can also extend tool life.

6. Contamination and Cleanliness

Issue: Contaminants such as chips, oils, and foreign particles can compromise the performance and reliability of aerospace parts. Cleanliness is especially critical in assemblies involving tight tolerances and sensitive components.

Solution: Establishing stringent cleaning protocols, including ultrasonic cleaning, solvent baths, and cleanroom environments, can ensure parts are free from contaminants. Implementing proper chip management systems during machining, such as chip conveyors and high-pressure coolant systems, can prevent contamination at the source.

Conclusion

Addressing the common issues in aerospace machined parts requires a comprehensive approach involving material selection, precision machining, thorough inspection, and stringent cleanliness standards. By understanding and mitigating these issues, aerospace machinists can produce high-quality aerospace components that meet the rigorous demands of the industry. Continuous improvement in machining technologies and processes will further enhance the reliability and performance of aerospace machined parts, ensuring the safety and success of aerospace missions.

For more information on how BlueRing Machining can assist with machining aerospace parts, feel free to contact us. We are committed to being a trusted and reliable aerospace machinist, providing precision and quality in every component we produce.