Category Archives: Equipment

Hi-Tek Manufacturing, Inc. Installs New 6-Axis CNC CBN Grinding Machine

Hi-Tek Manufacturing, Inc., leader in the production of aviation and power generation hot gas path turbine engine components, have just completed the purchase and installation of a new 6-Axis CNC CBN grinder.  The grinding machine, Model 930E100, built by the Campbell Grinder Company of Spring Lake, Michigan, joins the growing list of grinders, both CBN profile and Creep Feed Continuous Dress, as Hi-Tekexpands its overall grinding capability.

New 6-Axis CNC CBN grinder

This latest acquisition boasts a thirty-six inch “X”, “Y”, and “Z” axis travel with rapid traverse speed of up to 300 inches per minute and a positional accuracy of 5-microns.  In addition the machine is built with an automatic tool changer with a capacity up to 10 grinding wheels, as well as up to 12 inch milling and drilling tools.  The “C” axis (rotary table) is 40” in diameter with a bearing capacity up to 2,000 lbs. and run out both radially and axially of 2.5 microns.  The grinding spindle is 60 HP with a driven speed up to 7,200 rpm.  Options include wheel dresser capable of utilizing roll or disk dressing tools, part probing, automatic tool and nozzle changer, CO2 fire suppression, and large, epoxy coated enclosure with interior lighting.

The new grinding machine has been installed in the newest area of the plant expansion completed in 2012.  Hi-Tek recently installed a 22,000 gallon central oil filtration system that will provide temperature controlled grinding oil at 150 psi at the grinding wheel nozzles, filtered to 5-microns or less.

“This sophisticated grinding machine is just the latest in capital expenditures required to support recent sales growth,” said Barry Nehls, Hi-Tek Manufacturing, Inc. Sales and Marketing Manager. “Over the next three to five years we anticipate doubling our current grinding capacity in both CBN profile and creep feed grinding. This grinding machine is well suited for the large nozzles and blades required for the newer generation gas turbine engines,” he added.

Hi-Tek Manufacturing, Inc. has been serving the aviation and land based power generation OEM marketplace for over 36 years and is located in Mason, Ohio.

The Name in Electrical Discharge Machining (EDM) is Hi-Tek!

EDM, an extraordinary technology, alternatively referred to as “spark machining” or “wire burning”, is a manufacturing process in which innumerable kinds of shapes are obtained utilizing electrical discharges or, what laypeople might call, sparks. In this seemingly magical process, material is removed from the piece being worked by a series of rapidly repeating current discharges between two electrodes that are separated by a dielectric liquid,  which is basically an electrical insulator in liquid form that can be polarized when an electric field is applied.

Electric Discharge Machining is surprisingly quite simple to explain when broken down:  An electrical spark is initiated between an electrode and the piece that is being shaped. The spark that is visibly emitted produces extreme heat that melts almost anything it contacts. This electrical spark is highly controlled and localized so that only the surface of the material being worked is affected. The liquid medium serves to cool and flush away any eroded metal particles eventually leaving behind a finished product.

Hi-Tek Manufacturing’s state-of-the-art electrical discharge machining services offer over 100 EDM machines that perform a wide variety of processes from the most staggeringly complex to simple, one-off operations. Hi-Tek’s equipment list consists of in-house designed and built fast hole machines, multi-axis CNC sinker machines, 3-axis sinker machines, a variety of EDM plunge equipment, and wire EDM machines. Holes can be produced as small as 0.001” and hold the true position to +/- 0.0005” and diameter tolerance to +/- 0.0002”.

The electrode manufacturing capabilities at Hi-Tek can produce stamped copper, brass tubes and rods, graphite, and tungsten rod electrodes and process holes in various forms such as cooling, round, shaped, pin seal, tip and non-line of sight, as well as non-hole features like slots, grooves, pockets, and notches. In other words, Hi-Tek is a one-stop shop!

To learn more about Hi-Tek’s cutting-edge electrical discharge machining (EDM) services, call today and discover why Hi-Tek lives up to its name.

HI-TEK OFFERS CUTTING EDGE MULTI-AXIS LASER MACHINING FOR PRECISE AND CONTROLLED APPLICATIONS

Boasting compounded efficiency and pinpoint precision, multi-axis laser units work extremely well with Computer Numeric Control (CNC) machines to create 2D and 3D custom welded and cut parts. From producing stamped components to metal spinnings and unique part designs, flexible and easy to manipulate, multi-axis lasers have expansive XYZ travels and are put to a large number of uses in the aircraft, military and small and large land-based turbine engine industries.

HI-TEK MANUFACTURING AND ITS CAPABILITIES:

Hi-Tek Manufacturing was founded in the 1980s and since then has stood for unparalleled customer service excellence and the adroit use of technological advancements to create custom goods that adhere strictly to the specifications set forth by clients.

Where laser processing is concerned, Hi-Tek possess years of experience in dealing with single axis Nd:YAG and CO2 units. Of late however it has started specializing in multi-axis prototypes that can bring to life the movements specified by the G-code of CAD programs and render them with exceptional accuracy to produce trepan and percussion cooling holes, among other features.

Hi-Tek multi-axis lasers bring power outputs that vary between 400W and 4000W to the table and allow engineers and specialists a vast range of heat intensities to utilize. This flexibility results in etchings that vary from barely conspicuous product codes and company stamps to intricately carved spirals that retain their form yet do not break free from the larger surface of the super alloys, cobalt and nickel based ferrous and non-ferrous metals, and non-metallic materials that are deemed robust enough to serve as the blank canvas for the lasers.

An additional capability pioneered by Hi-Tek is laser ablation, the removal of thermal barrier coatings or TBC’s from hot gas path turbine engine components.  The precision and control of the laser beam allows the operator to “scrub” away the TBC while leaving the conductive bond coat in place for subsequent drilling operations.  Diffuser shapes are easily scrubbed into coatings of various thicknesses to meet the most demanding airflow requirements.

INTERNATIONAL STANDARDS MET:

Hi-Tek Manufacturing Laser Processing end products are at par with ISO 9001:2008, AS 9100 and NADCAP standards. With impressive axis travel numbers of 96″ x72″ x 36″, the multi-axis lasers are ideal fits for the production of hot gas path and structural components like high pressure and low-pressure turbines and combustors.

If you would like a custom quote please contact us here and allow us to serve you as per our industry best practices.

Learning More about How Gas Turbines Work

Hi Tek Mfg gas turbineGas turbine engines are versatile and trustworthy engines, as they are used for a number of different industries, such as helicopters, ships, locomotives, tanks and small power plants. There are, of course, many different types of turbines, such as steam, wind and water turbines. Specifically, a gas turbine uses a pressurized gas to spin the turbine.

In all modern gas turbines, the engine produces its own pressurized gas by burning fuel such as propane, natural gas, kerosene or jet fuel. The heat produced by the burning the fuel expands in the air, and the rush of this hot air is what spins the turbine.

Gas turbines are made up of three basic parts:

  1. Compressor – Compresses the air to high pressure
  2. Combustion area – Burns the fuel and produces high-velocity gas
  3. Turbine – Extracts the energy from the gas flowing from the combustion chamber

In an axial-flow gas turbine engine, air is sucked in by the compressor, which is a cone-shaped cylinder with small fan blades attached. As the air is pushed through the compression stage, its pressure rises significantly.

One major advantage of gas turbines is that they have an excellent power-to-weight ratio compared to other engines. In other words, the amount of power you receive from the engine is good compared to the engine’s weight. On another positive note, gas turbine engines are much smaller than their reciprocating counterparts of the same power, saving space and energy.

Introducing New Technologies and Processes

At Hi-Tek Manufacutring, we’re committed to customer satisfaction by investing in newer, more improved technologies. This is why we’ve recently installed the first of what will eventually lead to many Diode Pumped Fiber Laser machines. The lasers have such features as an Articulating Beam Director, Shaped Hole Drilling, Ablation thru TBC coating and Drilling on the Fly capabilities. Initial results have already shown a decreased processing time compared to the more traditional technology.

Hi Tek new technologies

We’ve also recently installed two GM Vacuum Furnaces. The features include 36” x 36” x 48” working chambers, an operating range of 1,100° to 2,400° Fahrenheit and 10-6 Torr Ultimate Vacuum. Our company plans to utilize these furnaces for brazing and heat treating operations. These vacuum furnace installations will provide increased capacity and make room to improve Hi-Tek’s lead-time for complete products. Again, our focus is dedicated to providing the best value services to our customers.

Hi Tek new technologies 2

Introducing the LASERDYNE 795XL: Making Advanced Manufacturing Even Better

Laserdyne 795 XL Hi-TekFor over 30 years, we at Hi-Tek Manufacturing have been providing our clients with the most precisely and expertly engineered complex components and assemblies in the industry. While we achieve this through our years of expertise and history of quality, it is also with an eye toward the future of technology and innovation. With that in mind, we’re excited to announce our latest capability; through the acquisition of the high accuracy LASERDYNE 795XL laser system, we can now expand our offerings with higher productivity and lower operating costs.

Called a “value creator” by Mark Barry of Laserdyne, this fiber laser system expands our capabilities and allows us to add capacity for hole drilling at very low angles to the surface in uncoated and thermal barrier coated heat resistant materials, which is immensely valuable in the turbine engine industry. In addition to the advanced drilling it will provide, the system is designed to cut and weld medium to large 3D parts with its unique moving beam design—the first and only standard built multi-axis laser system to guarantee volumetric accuracy in high-speed operation.

Specifically, the system integrates a 12kW fiber laser, significantly improving drilling and cutting applications over earlier systems, while adding energy efficiency. Its BeamDirector®3 features a contouring head design with C (rotary) axis motion of 900 degrees, and D (tilt) axis motion of 300 degrees. It also includes a new design of encoder for improved accuracy and repeatability, higher assist gas air-flow, adjustable mirrors for easy and accurate beam alignment, and cassette mounted lens and cover slides for fast and accurate changeover.

According to Scott Stang, our Manufacturing Technology Manager, “This acquisition is the result of our never ending effort to procure the best manufacturing solutions for our customers.” We are confident that utilizing this technology will make our work for our clients that much more significant.