US aviation equipment manufacturer × Honscn Precision: Inconel 600 high-temperature alloy rivets break through the bottleneck of aviation-grade precision processing
2025-06-07
Customer Background: Zero-defect Manufacturing Mission in the Aerospace Field
The customer, headquartered in California, USA, is a benchmark in the global aviation equipment manufacturing industry. It specializes in providing key components for some mainstream aviation manufacturers. Its products must pass the AS9100D aviation quality management system certification. This cooperation focuses on Inconel 600 high-temperature alloy rivets, which are used to connect the combustion chambers of commercial aircraft engines. They must maintain zero failure in extreme temperature cycles from -253℃ to 980℃, while meeting the stringent requirements of rod diameter tolerance ±0.01mm and surface roughness Ra≤0.4μm. The special nature of the material and the aviation-grade standards constitute a double technical barrier.
Project Challenge: Three Difficulties in Traditional Cold Heading Processes
(I) Processing Dilemma Caused by Material Properties
The unique properties of Inconel 600 nickel-based alloys have become a "stumbling block" in processing:
- High-strength work hardening: The room temperature tensile strength is ≥650MPa. During cold heading, the hardness increases by 35% for every 10% deformation, causing the mold life to drop sharply from 50,000 times for conventional steel to 500 times, and the cost to surge by 40%;
- Dimensional accuracy is out of control: After the first piece was cold headed with 6.3mm raw material, the rod diameter tolerance reached ±0.06mm (the customer required ±0.01mm), the head height deviation exceeded ±0.05mm, and the roundness error rate of the key transition zone reached 30%;
- Surface quality defects: The surface roughness of the cold headed part Ra≤1.6μm, and there were 3 visible cracks on the edge of the head, which could not pass the aviation-grade fluorescent penetration test (the detection sensitivity must be ≤0.05mm).
(II) Traditional process paradox of efficiency and quality
- Although the cold heading process has the advantage of a daily production capacity of 50,000 pieces, the qualified rate is only 65%, and the rework cost accounts for 25%, forming a "high output and low quality" dilemma, which cannot meet the "zero defect" requirements of aviation parts.
Solution: Process revolution from cold heading to precision turning
(I) Full-process process reconstruction strategy
Innovative breakthroughs of the joint engineering team:
- Raw material upgrade and process route optimization:
- The diameter increased from 6.3mm to 11mm, and AMS 5540 certified Inconel 600 bars (grain size ≥ 7, sulfur and phosphorus impurities ≤ 0.001%) were selected to reserve sufficient material margin for precision machining;
- Abandoning the single cold heading process, the composite process of "automatic lathe rough forming + CNC finishing + surface finishing" was adopted to balance precision and efficiency.
- Precision machining technology breakthrough:
- Automatic lathe rough forming: Through C-axis indexing technology, the nail head contour is formed in one time, 80% of the machining allowance is removed, and the rough machining tolerance is controlled at ±0.03mm, laying the foundation for fine finishing;
- Swiss high-precision electric spindle fine finishing: equipped with a 20,000rpm electric spindle (radial runout ≤0.002mm), using a stepped fine turning method, feeding in 3 times to reduce the rod diameter tolerance to ±0.008mm, and the head height tolerance to ±0.015mm;
- German vibration polishing process: adding 0.3mm zirconium oxide abrasive, after 4 hours of finishing treatment, the surface roughness is reduced to Ra≤0.3μm, reaching the mirror standard of aviation parts.
(II) Aviation-grade quality control system
Multi-dimensional detection technology:
- Full-size scanning with image measuring instrument: non-contact measurement of 12 key dimensions such as nail head diameter, rod length, taper angle, etc., with an accuracy of 0.001mm;
- 100% detection with GE fluorescent penetrant line: ensure that the surface crack detection sensitivity reaches ASME B16.24 Level 2, achieving zero defect delivery.
Process parameter database:
- Establish an exclusive processing parameter library for Inconel 600, optimize 20+ sets of cutting parameters through orthogonal test method, increase tool life by 3 times, and achieve CNC processing efficiency of 2,000 pieces/day.
Project results: Redefining aviation fastener manufacturing standards
(I) Comparison of core indicators and industry benchmark data
| Test Parameter | Client Requirement | Cold Heading Result | CNC Finishing Result | Performance Improvement |
|---|---|---|---|---|
| Shaft Diameter Tolerance | ±0.01mm | ±0.06mm | ±0.008mm | 20% tighter than required |
| Surface Roughness | Ra≤0.4μm | Ra≤1.6μm | Ra≤0.3μm | 25% smoother than standard |
| Crack Detection | Zero defects | 3 visible cracks | 0 defects | 100% compliance |
| Yield Rate | ≥99.5% | 65% | 99.8% | 53.5% higher than before |
| Daily Output | - | 50,000 pcs/day | 2,000 pcs/day | Optimal balance of precision and speed |
Client Trust & Supply Chain Expansion
"Honscn Precision’s team demonstrated deep aerospace manufacturing expertise—they didn’t just solve Inconel 600 machining issues, but set a new standard for high-temperature alloy fasteners."—Michael Carter, Client Quality Director
Industry Impact: Cracking the Code for High-Temperature Alloy Machining
This case showcases Honscn Precision’s leadership in aerospace-grade high-temperature alloy fastener manufacturing, ideal for extreme environments like engine hot sections and aerospace structures. By integrating material certification, process innovation, and practical quality control, we deliver components meeting AMS, AS9100, and other strict standards—powering the next generation of aircraft with reliability and safety.
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