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a thermal barrier coating applied be- fore cooling holes are drilled with the fi ber laser. Many components require assembly, including vacuum brazing, along with heat treatment before they are shipped to customers.” “We deal with many different material specifi cations,” reported Stang. “Almost all are high-temper- ature nickel or cobalt-based alloys. Many parts are precision castings, some forgings and some sheetmetal parts ranging from 0.002" up to 0.5" [0.05–12.7-mm] thick. Many parts are TBC coated. “Part runs are all across the


Hi-Tek’s Scott Stang holds an aerospace engine component processed on the company’s Laserdyne 795XL Beam Director with fi ber laser.


CO2 laser purchased in 1995), the Laserdyne fi ber-equipped


laser system presents new manufacturing opportunities for Hi-Tek and its demanding customers. According to Stang, those customers have a very broad


range of requirements, from a single complex part to an entire program of parts needed with short lead time, manu- factured over many months with multiple releases. To handle these needs effi ciently, Hi-Tek’s services encompass a full spectrum of manufacturing capabilities including fabricating, machining, assembly and testing operations delivering “en- gine ready” assemblies. This includes managing a particular assembly’s exacting purchasing and production requirements from beginning to end. To achieve this level of customer performance, Hi-Tek Manufacturing is a PRI registered ISO 9001:2008, AS91000 and Nadcap AS7003 and AC7114 certifi ed with AC7116 Non- conventional machining certifi cation.


The Fiber Laser’s Contributions “We’re using the new fi ber laser to percussion drill, trepan, cut and weld,” said Stang. “Products range in size from small military aircraft engine applications to large distributed energy turbines and all applications in between. Many of the com- ponents require a combination of cooling hole drilling and complete assembly including the fi tting and laser welding of sheetmetal components. Increasingly, these parts may have


map—from a one-piece lot size up to production runs that last as long as six months, never shutting down. What is typical of most of our cus- tomers is their needs change rapidly and we have to change with them.”


The high-temperature materials Hi-Tek processes is especially challenging and includes Haynes 625m 188, 230 and 718. Material thickness ranges from 0.127 to 12.7 mm and are processed readily on the new fi ber laser. In addi- tion to drilling these materials, Hi-Tek’s new six-axis fi ber laser system cuts and welds medium-to-large 3D parts with combined high velocity and acceleration. The system ac- complishes a high level of quality with features that include the Laserdyne third-generation Beam Director. It provides C (rotary) axis motion of 900o, and D (tilt) axis motion of 300o. This latest Beam Director laser beam positioning capability combined with high-accuracy rotary table motion provides a six-axis system enabling new manufacturing processes while improving existing ones.


Accurate Processing For Hi-Tek, achieving a high level of accuracy from pro- totype to production stages and from one job to another is possible because Laserdyne designs and integrates all of its system features. Everything works together in a coordinated manner—the controller, software, motion system, laser and process sensors.


Of particular importance Stang pointed out, are “Laser-


dyne’s software and hardware for part mapping and focus control that enhance both the quality and cycle times com- pared to traditional methods of production.”


112 — Aerospace & Defense Manufacturing 2015


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