AEROSPACE
However, the toughness that makes Inconel such a valuable material also makes it incredibly difficult to machine. “It is not unheard of for cutting and
shaping tools to be broken or deformed when used on Inconel,” explains Chris Belle. “In other cases, the Inconel’s outer layer may work harden too quickly in response to machining, resulting in an imperfect shape for the Inconel. “Of course,
custom engineered solutions, and on- site services for the aerospace, defense, power generation, oil and gas, life sciences, and semiconductor industries. According to Chris Belle the key
to minimising or eliminating weld failures for these critical applications is achieving very consistent, high- quality weld prep every single time. He says: “The more inconsistent
the machining, the more weld process challenges you will have, potentially resulting in weld failures. Unfortunately, materials such as Inconel only increase the chances of joint misalignment, poor prep angles, and contamination.” Inconel is an alloy composed of 58%
minimum in all weights of nickel with significant chromium and molybdenum. It is extremely resistant to oxidation, corrosion, and scaling in high-temperature environments and so is an ideal material for use in rockets and spacecraft.
advanced alloys are very expensive, so getting the weld prep right the first time is absolutely critical.” To properly
shape, cut, and work with Inconel, the machinist must understand its properties and how to compensate for its limitations. Specialised facing and cutting equipment with tool bits are often required. “Without all of these components,
machining pipe and tube made of advanced materials can become a major bottleneck in the aerospace manufacturing workflow,” states Chris Belle.
Prepping for Welding Although manual welding techniques are still used, particularly for larger pipes, most welding is performed by semi-
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automated orbital welding machines with closed weld heads. To create the weld, a generated arc is rotated mechanically 360° around the pipe or tubing in a continuous process. Orbital welding is prized in aerospace for producing reliable, high quality, repeatable welds that meet stringent criteria. However, there is very little room
for error when prepping pipe or tube ends for orbital welding, with little allowance for gaps or non-square surfaces. “In addition to the specifications from the
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