A New Way to Laser Process Aerospace Components

Precision Aerospace, Phoenix, is a global supplier in build-to-print, complex machined sheet metal fabrications. The company specializes in welded and mechanical assemblies to the aerospace industry, primarily for engine and exhaust applications. These include diffusers, compressor housings, nozzles, seals and stators, gearbox housings, inlet and exhaust ducts, combustors and liners, plenums and eductors, impeller shrouds, and other complex 3D assemblies.

Aerospace engine manufacturers increasingly are turning to Precision Aerospace for its expertise and manufacturing capabilities to supply these fabricated engine components and assemblies.

Precision Aerospace recently installed a new Laserdyne 795 laser-processing system with a rotary table. The technology is key to a major expansion for the company to supply advanced engine components to aerospace manufacturers as the industry has experienced a surge in aircraft engine orders since mid-2021. The latest Laserdyne was acquired as part of a newly announced trade-in of a Laserdyne 780, which Precision Aerospace operated for more than 15 years.

“Our initial use of the new Laserdyne 795 system was for large combustor cover needing laser processing,” said Mark Miller, Precision Aerospace’s marketing director. “Aerospace combustors are components costing thousands of dollars each, so there is no margin for mistakes—and quality is the primary requirement. We’ve experienced an 18 percent growth over the last year with major aerospace and engine manufacturers, as well as others. So, the addition of the Laserdyne 795 gives us an even higher productivity level with high-quality results.”

The Laserdyne 795 is a 5-axis laser machining system designed to weld, drill, and cut medium to large 3D parts with a unique moving beam motion system, known as the BeamDirector.

Combining higher velocity and acceleration, the BeamDirector provides C-axis (rotary) motion of 900 degrees, and D-axis (tilt) motion of 300 degrees. The BeamDirector features improved accuracy and repeatability, eliminating potential processing errors for Precision Aerospace. The BeamDirector has higher assist-gas airflow, adjustable mirrors for easy and accurate beam alignment, and a cassette-mounted lens and cover slides for quick, accurate changeover. The robust design and improved motion control allow Laserdyne systems to maintain accuracy and repeatability specifications at all assist-gas pressures up to 20 bar (300 psi).

Constructed for high-speed operation without compromising mechanical accuracy, the Laserdyne 795 is the only standard-built laser system to guarantee volumetric accuracy in all axes, according to the company. A key feature of the new machine is its unique capability for drilling cylindrical and shaped holes, as well as bevel cutting in a wide range of materials, particularly aerospace materials such as titanium and Inconel. The system’s fiber laser combined with SmartTechniques and S94P controller provides the required pulsed peak power for drilling applications or CW output for cutting applications. With its open frame architecture and moving beam, the fully equipped 795 system (sans enclosure for maximum part size/configuration flexibility) is well-suited for Precision Aerospace’s wide range of aerospace components and assemblies.

“The changeover between multiple sets of parameters occurs in the millisecond time scale so that differing laser processes and multiple operations can be performed in the same setup. No other system provided the level of control and precision needed to consistently deliver the quality specified by our customer,” said Precision Aerospace’s Miller.

“Prima Power Laserdyne’s OFC2 Absolute mapping function was an important new feature for us to lock in quality,” he added. “It is especially important because we process hundreds of these parts, which are critical to reliable engine operation.”

OFC2 Absolute is a precision, non-contact, optical-probing, surface-mapping and measurement feature with 25-um resolution. The system pinpoints the true focus position repetitively with a longer working range regardless of the part’s surface features and condition, Miller said, adding that this enables the company to consistently provide high-quality parts to customers.

“Our previous laser process, while more than adequate at the time, didn’t have enough precision to exactly pinpoint the true focus position repetitively for today’s dimensional requirements,” Miller explained. “The new OFC2 Absolute feature has superior mapping and focal point adjusting capabilities with the updated System S94P software, allowing for accurate and repeatable focus positioning. This helps us to precisely position focus on the drilling and cutting angle and know that it is correct.”

OFC2 Absolute also has a longer working range and is capable of measuring part surfaces on an angle regardless of the surface condition, the company said.

“Many of our large parts require accuracy of +/- 0.005” (0.13 mm) and sometimes tighter tolerances, and the new Laserdyne 795 easily processes the parts within those tolerances,” Miller said. “This latest capability allows for a wider range of opportunities for improving existing processes.”

Precision Aerospace’s Laserdyne 795 with OFC2 Absolute and S94P controller provide unbeatable accuracy when it maps the part surface, according to the company. It does this to maintain the laser beam focus at the precise location of the cutting area, so there is no deviation or voids in the edge structure. Also, the OFC2 Absolute’s longer working range enables the location of reference features, such as edges, corners, and holes that can be determined using a greater, more generous stand-off between the laser processing head and workpiece, without interrupting the process.

The OFC2 Absolute function operates in conjunction with the 795 rotary table. “These capabilities provide an additional sixth axis to support consistently accurate, complex on-the-fly drilling and cutting operations with system accuracy down to 0.005” (0.13 mm),” Miller said. “What’s equally significant is set-up time has been reduced by 30 to 45 minutes using this new system. We operate the system throughout our two shifts per day. So that’s a lot of usage and time savings.”

In addition to the multiple laser systems, the company is equipped with CNC turning, a variety of lathes and mills, water jet and EDM systems, and three forming systems. It also has conventional forming presses and press brakes, as well as thermal-processing equipment and capabilities for linear fusion and robotic welding. The company plans to use the Laserdyne 795 system for welding operations in the near future.

Rounding out its quality program, Precision Aerospace has NADCAP accredited fluorescent penetrant inspection, hydrostatic-pressure testing, plus oil-flow and airflow testing.

The company is committed to using the latest technology, which is evidenced by its advanced laser processes, according to Marshall Hodge, Precision Aerospace’s president. Hodge, who has more than 30 years of experience in high-tech manufacturing, acquired Precision Aerospace in 2019.

“The circumstances we now find ourselves in is an opportunity to evolve and grow as a leading industry specialist,” Hodge said. “And that is what we are doing with our full range of processes, including our newly expanded laser capabilities.”

In the past, multi-process laser systems for welding, drilling, and cutting were more than adequate. The Laserdyne 795, however, is designed to meet more stringent requirements, including challenges unique to welding. It also provides superior cutting and drilling capabilities, according to Precision Aerospace.

The company plans to begin welding operations soon with the new system. Key features include SmartRamp, gas flow control, lens protection and an integrated air knife that makes the welding process more controllable for a superior end result.

Precision Aerospace developed new methods for processing challenging components, noted Dominic Rickard, Prima Power Laserdyne’s national sales manager. “The laser system without the enclosure not only allows the processing of large and unusually shaped parts up to 56 inches (1,422 mm) but can process the parts from all directions while employing the sixth axis of the rotary table. Without the constraints of the enclosure, it also provides the company with the ability to use pick and place automation in the future.”

Touting productivity improvements, Hodge said the Laserdyne 795 provides more opportunities for greater technological advancement going forward. And, he added, the system “enables us to support and supply a wide variety of aerospace components and assemblies. These added laser processing capabilities are an important part of our company’s capabilities resulting in enhanced customer support, improved performance and business growth.”

For More information about Precision Aerospace manufacturing capabilities, call 602-352-8658. or visit www.precisionaerospace.com. For more information about Prima Power Laserdyne products and services, call 763-433-3700. or visit www.primapowerlaserdyne.com.

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