Tag Archives: CNC specialty machining

Hi-Tek Manufacturing Offers Customers Nadcap Welding Audit Accreditation

Hi-Tek Manufacturing has served the gas turbine industries since 1980. Our commitment to giving customers the highest quality products is evident with our ISO certifications and Nadcap accreditation. ISO certification means a company follows international standards to ensure their products or services are reliable, safe, and high quality. Companies who do business internationally can then understand the quality they are getting when purchasing from and ISO certified company from another part of the world.

Nadcap

Nadcap, which stands for the National Aerospace and Defense Contractors Accreditation Program, was started in 1990 by SAE International. It is a cooperative accreditation program which is used globally for anyone in the defense, aerospace engineering, or closely related industries. Administration of the program is done by the Performance Review Institute (PRI).

Membership within Nadcap includes prime contractors that are responsible for coordinating with suppliers in the aerospace industry to develop audit criteria for products and special processes that are industry wide. Nadcap then, through PRI, provides independent certification of manufacturing processes for aerospace and related industries. This distinction helps to provide customers and consumers with the highest quality manufactured components possible.

It all begins with an audit by an approved auditor who is an industry professional. Any concerns or issues that arise during the audit are reported and PRI administers and closes the report with the supplier. When this is done, PRI presents the information to a special process task group. This group is made up of industry professionals who review and vote on it to be approved or denied.

Nadcap provides accreditation for a wide range of industries related to aerospace and defense industries such as coatings, composites, heat treating, nondestructive testing, welding, and more. PRI is headquartered in the U.S., but has offices in London, Japan, and Beijing.

Hi-Tek Manufacturing offers Electrical Discharge Machining, Laser Processes, CNC Milling, CNC Turning, CNC Grinding and Associated Process Support Services. Hi-Tek Manufacturing also offers quality standards, certifications, and inspection services for a variety of processes, including welding. Contact us for more information on how we can meet your needs.

Hi-Tek Manufacturing, Inc. Installs New 5-Axis Horizontal Milling Center

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 CNC 5-Axis Niigata Horizontal Trunnion horizontal milling machine.  The milling center, Model HN63E-5X, supplied by SNK America, Inc. of Mt. Prospect, IL., compliments existing Niigata HMC’s installed just three years ago.  This new advanced machine was on display at the 2016 International Manufacturing Technology Show in Chicago and purchased directly from the floor.

CNC 5-Axis Niigata Horizontal Trunnion horizontal milling machine

The heavy duty machine has been specifically designed for machining difficult materials such as high nickel alloy HGP turbine engine components.  The machine features a boxed guideway rigid structured machine with 900nm of torque at 6,000 rpm, designed specifically for hardened metals.  The machine boasts the following features/benefits:

  • A tilting table trunnion design with full 5-axis contouring capability for complex parts with extended reach to machine intricate five-face, multi-faceted components.
  • Single work set-up which increases productivity while maintaining geometries for optimum accuracy.
  • Rugged design and construction with heavy duty 5-axis trunnion table supported by high load type roller bearings, solid boxway construction with massive thick-walled, heavily ribbed frames.
  • Rigid horizontal spindle configuration – standard 35 HP, 6,000 rpm
  • Standard 62 tool capacity (expandable to 128 tools for growth) and pallet changer
  • Simultaneous 5-axis contouring with Niigata Advanced Controller
  • Pallet size is 24.8” x 24.8” to support a maximum workpiece size of 37.4” x 31.5” and a permissible mass of up to 2,200 lbs.

The new horizontal machining center shipped directly from the IMTS show to Hi-Tek in Mason, Ohio.  “The SNK America, Inc. installation team has been outstanding,” said Rich Hawk, Hi-Tek Maintenance Supervisor.  He went on to add that “the attention to detail and installation was flawless with excellent training of the Hi-Tek maintenance staff.”

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.

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 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.

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.

We’re Doing Something Right When it Comes to Quality!

At Hi-Tek Manufacturing, we take our business very seriously. Since 1980, we’ve been serving the gas turbine industries, offering conventional and non-conventional CNC specialty machining for Hot Gas Path Components.  We’re a Six Sigma based company, working to ISO, AS, and NADCAP Standards. We deliver the highest quality and most cost-effective solutions to aviation and land-based turbine manufacturers.

What makes Hi-Tek Manufacturing unique in our industry is our passion for quality, and the fact that we monitor and maintain quality control ourselves. We do not outsource the QC function; everything is done in house, using several quality tools. (Take a look at the “Quality” page on our website for more detailed information.)

One of the performance-driven metrics we use is “Total Monthly Defects” – see the chart posted here:

hi-tek 1-2013A “defect” is defined as any part non-conformance that requires disposition prior to shipping the part to our customer. Dispositions that may be included in this performance metric are rework, repair or scrap. The chart above reflects a Total Monthly Defects performance goal of 1% and the corresponding Hi-Tek Manufacturing actual performance for the 10-month period of April 2011 through January 2012.

Looking at our performance, we know we’re doing something right when it comes to quality! We’re avoiding non-conformances and we’re meeting our quality performance goals every day.  Our customers know they can count on high-level performance and exceptional quality when you work with Hi-Tek Manufacturing. We’ve got the QC function under control in house, and we wouldn’t have it any other way!

We invite you to contact us to learn more about our quality standards. Email us at sales@hitekmfg.com or call us at 513-459-1094.