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 Manufacturing’s Precision Grinding is Unmatched!

There are numerous types of grinding techniques used to produce specific shapes and finishes on a variety of both metallic and non-metallic components.  Specializing in the manufacture of hot gas path turbine engine parts, Hi-Tek Manufacturing has developed unparalleled grinding technologies in the areas of continuous dress creep feed and plated wheel CBN profile grinding.

The company’s grinding equipment includes a continuous dress creep feed that operates up to a staggering100 HP with a 20″ wheel, 4-axis continuous dress creep feed, 5-axis CBN, 1 & 2 spindle cylindrical verticals, and CNC surface grinders.

Creep feed grinding is similar to a milling operation where large stock removal is possible to exacting shapes and profiles.  Various types of abrasive wheels are used from aluminum oxide to ceramic composite.  By employing diamond dress rolls to continuously dress the wheel surface, precise shapes are achieved by the clean cutting abrasive wheel.

With CBN (cubic boron nitride) plated wheels, radial shapes and features can be easily produced on intricate turbine engine nozzles, blades, and other components.  Sometimes referred to as “superabrasive” grinding, Hi-Tek Manufacturing utilizes a number of these CNC 5-axis grinding machines on a variety of parts.

A key to the successful grinding by Hi-Tek Manufacturing is the use of central fluid filtration systems.  These filters provide water soluble coolant for creep feed grinders and grinding oil to the CBN or superabrasive grinding operations.  Each machine receives fluid to the grinding or cutting zone at the same concentration, temperature, pressure, and cleanliness to ensure uniformity in grinding operations across all machines.

Contact Hi-Tek today to learn more about the high quality grinding services provided by an ISO 9001:2008 certified company.

5 Myths About Manufacturing Jobs

There are plenty of myths regarding manufacturing, the jobs available, and the future of the sector. Some of these myths are no big deal – the myth that the U.S. can’t compete with China, for instance, doesn’t drive people away from a manufacturing career path. In truth, we do compete with China, but while we can’t beat them when it comes to sheer quantity, we can beat them in quality. What hurts the most are myths that drive people away from manufacturing careers; careers that could be great for them to get into. If you are considering launching into a manufacturing career and you hear these myths, you need to ignore them.

Manufacturing Jobs are Low-Skill Jobs

In the past, many manufacturing jobs have been simple, hands-on, singular tasks. Turning wrenches, hammering, and manual assembly jobs were representative of the activities a worker would be required to do every day. In the modern manufacturing climate, workers are just as likely to be programming machines as welding pieces together. They will shift from one task to another, sometimes over the course of a single day. These are skilled jobs and require flexibility and highly developed skills.

Manufacturing Jobs are Dead-End Jobs

Most manufacturers are not interested in hiring workers who do not see themselves growing within the company. Innovation, the evolution of talent, and ideas are leading the sector into the future, and companies get it. Many companies hire with the idea that the new employees will learn and advance within the company as well as offer various educational opportunities for continued growth.

Manufacturing Jobs Don’t Pay Well

A century ago, manufacturing jobs were low-paying jobs with few benefits, and that has been a characterization that has been difficult to shake. Today the average manufacturing job is worth a combined $17,000 per year more in pay and benefits (including health benefits, retirement funds, pension plans, and more) than the average non-manufacturing or service industry position.

Women Aren’t Welcome in Manufacturing Jobs

Manufacturing is a male-dominated sector, and has been historically – that can’t be argued. However, manufacturing companies have been working to change that, and are not only open to more women joining the workforce, but have been actively pursuing it. This falls in line with the pursuit of innovation and evolution – manufacturers want the brightest minds, regardless of their gender.

The Manufacturing Job Means Working in a Dirty Environment

In the early days of manufacturing, many times the conditions were deplorable.  Lighting and air quality was poor at best, and unsafe working conditions were the norm.  No longer.  Today the manufacturing work environment is clean, safe, with temperature and humidity controlled environments.  Modern machine tools are computer controlled and ergonomically designed to reduce fatigue.  Companies realize that in order to produce the highest quality products, the work environment and operating conditions have to be of the highest standard possible.

What debunking all these myths demonstrates is that a career in manufacturing has a lot to offer. Whether at Hi-Tek  or any of the thousands of other manufacturers across the country, manufacturing workers are incredibly satisfied with their jobs, and continue to demonstrate that a career in a manufacturing job was their best choice. Manufacturing offers great jobs, and manufacturers are looking for more workers to fill them.

CNC Turning Technology- Hi-Tek is on the “Cutting” Edge!

The average lay-person is not well informed as to the great strides made in the latest computerized milling capabilities. A case in point is CNC turning, which is a form of machining in which a sharply pointed cutting tool is placed parallel to the surface of a material that is simultaneously being rotated. The rotation (or “turning”) is executed by a lathe that securely spins the part being machined. This process allows for one single-point tool to cut, remove and shape the material being machined into a myriad of parts.

The beauty of “turning” is in its ability to create a myriad of complex shapes. Examples include shapes that are tapered and contoured, threaded and filleted to name just a few. Once upon a time, (not too long ago), this process required the skilled and steady hand of a trained operator who applied the cutting tool manually. Now, with computer numerical controlled technology or “CNC” computers, automation performs these tasks resulting in near perfect creations that cut waste, errors and labor costs.

Hi-Tek Manufacturing has adopted the latest in technology to ensure the best in precision CNC turning services and the company capably handles a variety of parts of various sizes and materials to meet the most exacting of standards demanded by customers. Hi-Tek’s vertical and horizontal turning centers have 2, 3, and 4-axis capabilities offering the finest in live tooling. The in-house equipment includes features such as large swing turning, central cooling systems, automatic tool changers, tool probing and more.

At Hi-Tek, turning requirements can be met beyond expectation with such services as contour, taper or straight turning and boring, and also external or internal threading applications. Hi-Tek also excels in the utilization of high-temperature aerospace super alloys, cobalt and nickel based metals and alloy forgings.

Give Hi-Tek a call today to learn more about reaping the benefits of the very highest standards in turning technology.

The Latest in Milling Technology- Hi-Tek Lives Up to its Name!

Should you not be familiar with this cutting-edge technology, CNC milling is a unique form of “computer numerical controlled” (or CNC) machining. This advanced form of milling is a machining process that performs both drilling and cutting, (as do traditional cutting and drilling machines), but in this case there is sophisticated and highly accurate automation of the machine tools. All operations are undertaken by precisely programmed commands that are encoded into the machine’s computer memory. In other words, human error is greatly diminished as there is no longer any need for manual control utilizing hand wheels or levers. Even mechanically automated cams are vastly improved upon with this state-of-the-art equipment. With computer numerical controlled technology, computers, rather than people, perform the integral part of the process of milling control, resulting in fewer mistakes and savings on labor.

Hi-Tek Manufacturing is a prime example of a cutting-edge company that utilizes the most advanced tools and technologies, like CNC machining. And Hi-Tek provides their customers with the very best in the latest CNC milling services, even with large and complex parts having thin cross-sections. Equipment utilized includes 3, 4, and 5-axis vertical machining centers and 5-axis horizontal machining centers, all of which make Hi-Tek one of the most comprehensive milling service providers in the country!

Hi-Tek performs masterfully such tasks as drilling, boring, contouring and profiling, counter-boring, countersinking, reaming, and tapping and works with components up to 60″ long, 48″ wide and 44″ high so clients can be assured that what they need can indeed be provided. Hi-Tek works primarily with high-temperature aerospace super alloys, cobalt and nickel based metals, and single crystal and conventional castings. Contact Hi-Tek today to learn how they can help you to realize quality and quantity at competitive prices.

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.

US Manufacturing and how it affects companies like Hi-Tek

Sustainable U.S. Growth
U.S. manufacturing ended last year with its best performance since 2010 following the end of the Great Recession. Now manufacturing has leveled out to what many economists consider a more sustainable pace of growth. Most factories here in the U.S. have adjusted to less than robust overseas demand and have come to reap the benefits of a more steady domestic market. These manufacturers have greeted 2015 with a new sense of optimism and have generally dismissed concerns over a December slowdown in growth as just a temporary blip on the economic radar screen. Still, the Institute for Supply Management has stated that its purchasing managers’ index for 2014 averaged a very impressive 55.8, again the best level since after the 2007-09 recession.

The Rest of the World
This all comes amid concerns regarding a global economy that has slowed down and could result in less demand for U.S. goods. Paul Dales, a senior economist at Capital Economics, stated that it “makes sense that manufacturing activity should be coming off the boil when global demand has eased and the dollar has risen.” He goes on to assure however that the “strength of domestic demand will ensure that industry and the wider economy still perform particularly well in 2015.”

Positives
Indeed, for most sectors of the U.S. economy, the recently lower prices of oil and other energy related products have been a big boon since they trigger much lower input costs for companies.
One company that has exploited opportunities afforded to it as a result of these economic changes is Hi-Tek Manufacturing, a firm that is known for its superior manufacturing and support of component production for the world’s major gas turbine and airframe manufacturers. Their highly engineered, complex components and assemblies for aircraft engines, airframes and land based industrial gas turbines have continued to see increased demand here in the U.S. and around the globe as well.

Call us today to start a conversation about our products and services.

Ohio Manufacturing

Ohio supplies the world with durable goods. These six leading export industries account for the 60% or $28B of the State’s total exports of $46B. In 2011, Ohio’s leading export was Machinery and it generated revenue of $8.5 billion. In about half of Ohio’s 88 counties, 12.6% or more of all workers are employed in manufacturing.

Industry leads the way in solid waste reduction and recycling. Reduction and recycling include source reduction activities, reuse, recycling, composting and incineration. Industry is an enormous consumer of recycled materials, such as metals, glass, paper and plastics; thus manufacturers are strong advocates for improving recycling systems in Ohio and the U.S.

Manufacturers have invested billions of dollars in environmental control technologies and more efficient processes, which has significantly reduced emissions. Ohio manufacturers have made tremendous progress in reducing toxic releases to the environment, every year.

The leading Ohio industries in terms of dollars of product shipped are: iron and steel mills and ferroalloy manufacturing ($14,557 million); petroleum refineries ($12,532 million); aircraft engine and engine parts manufacturing ($8,818 million); plastics products manufacturing (nec) ($7,977 million); soap and cleaning compound manufacturing ($6,802 million); and motor vehicle metal stamping ($6,488 million).

Ohio ships more than 20% of all U.S. production in these nine product categories:
Rubber product manufacturing (nec), structural clay product manufacturing (nec), pressed and blown glass and glassware manufacturing (nec), iron and steel pipe and tube manufacturing, custom (metal) roll forming, machine tool (metal forming types) manufacturing, rolling mill machinery and equipment manufacturing, motor vehicle metal stamping, and aircraft engine and engine parts manufacturing.

THE FUTURE OF HIGH POWER, HIGH CONSTRAINTS WELDING: THE FIBRE LASER

Welding is a process without which most of the modern world would be bereft of its technology and innovations. Everything from high rises to aerospace assemblies to vehicles and intricate medical devices make use of welding. It is an affordable, easy to leverage means by which structural integrity can be maintained and joints are provided with a degree of support to hold firm large structures.

Almost all forms of welding demand a continuous inflow of fuel to ensure a steady flame or arc and a high intensity of concentrated power to eliminate the probability of fusion defects. In particular CO2 welding results in low quality of the welded joints and splattering. In a bid to overcome these shortcomings of conventional processes, laser welding has emerged as a preferred choice. Nd:YAG in particular has been frequently leveraged in electronics, medical and fluid coupling industries.

THE ARRIVAL OF THE FIBRE LASER:

The latest trend in high power, high constraint welding is the use of fibre lasers. They consist of continuous wave (CW) or quasi-continuous wave (QCW) pump light sources coupled to rare earth metal doped optical fibres. The doping converts the light beam to a laser beam that is largely comprised of photons emitted due to spontaneous transitioning of electrons.

This output travels at a very fast pace through the fibre and is pulse shaped down to sub-millisecond resolution for defined spot welding. It is capable of joining very hard aerospace (Nickel and Titanium based) alloys with zero tolerance for cracks and porosity.

THE ADVANTAGES OF FIBRE LASERS:

Fibre lasers are catching on because they have a wide array of advantages recommending them over conventional options:

  • They have a very small wavelength of 1 um and thus a correspondingly high frequency. This allows for unprecedented power density.
  • Fibre lasers have high processing speeds and get the job done faster and more efficiently.
  • Since the output is delivered through an optical fibre, mirror manipulations are not needed and less power is lost through reflection and scattering.
  • Fibre lasers are brighter than their Nd: YAG counterparts and the beam can thus be shaped and focused with great accuracy to boost concentration.
  • Boasting better absorption by good conductors, fibre lasers offset their initial high investment with low operation and maintenance costs.
  • Last but not the least, fibre lasers can effortlessly weld dissimilar metals with the help of filler wires which allow for alignment of disparate pieces to provide an excellent join.

 

Hi-Tek Manufacturing has been a vanguard in Electrical Discharge Machining, Laser Processes, NC Milling, CNC Turning, CNC Grinding and Associated Process Support Services. It brings to the table high quality industrial fibre laser models which can easily revolutionize difficult welding under constrained (misalignment of pieces, danger of rapid oxidization of welded joints and so on) conditions. Call us at (513) 459-1094 to know more.

 

HI-TEK Manufacturing, Inc. Receives NADCAP Accreditation for Heat Treating

Receiving Nadcap accreditation for heat treating completes our major investment to provide full service to our OEM Turbine Engine customers” stated Barry Nehls, Sales and Marketing Manager. “Process timing is critical for our customers,” Nehls went on to say, “and the addition of in-house heat treating greatly enhances our ability to produce made complete components.”

The scope of this Nadcap Accreditation includes not only heat treating but brazing, hardness testing for heat treating, an pyrometry capabilities. “The timing and logistics cost reductions represent a huge savings to our customers,” Nehls added.

HI-TEK MANUFACTURING received Nadcap accreditation for demonstrating their ongoing commitment to quality by satisfying customer requirements and industry specifications.

“Achieving Nadcap accreditation is not easy: it is one of the ways in which the aerospace industry identifies those who excel at manufacturing quality product through superior special processes. Companies such as Hi-Tek Manufacturing work hard to obtain this status and they should be justifiably proud of it,” said Joe Pinto, Executive Vice President and Chief Operating Officer at the Performance Review Institute. “PRI is proud to support continual improvement in the aerospace industry by helping companies such as Hi-Tek be successful and we look forward to continuing to assist the industry moving forward.”