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3. Drill 7000 holes through the
skin using an automated drillonly
machine.
4. Cleco every fourth hole in the skin.
5. Take out all 1750 clecos at
completion of drilling.
6. Separate the layers and
hand deburr the three sets of
skins and the doublers.
7. Manually deburr OML (outside
mold line) side of the three sets of
skins.
8. Manually deburr IML (inside
mold line) side of the three sets
of skins.
9. Manually deburr doublers on
both sides.
10. Prepare and seal the bulkheads
(the skins are not present).
11. Apply the doubler and seal again.
12. Apply skins back onto aircraft
substructure.
13. Hand-insert the Hi-Lok fasteners.
The new process, which requires
50% fewer crane moves, is as follows:
1. Prepare the bulkheads by
applying the faying surface seal.
2. Attach the doubler and apply
seal for the doubler.
3. Locate the aircraft skins onto the
substructure.
4. Drill and install fastener in oneup,
one-pass fashion.
With a reduction in setups and
adjustments, the new process involves
less manual interaction, less idling, and
fewer minor stoppages, the companies
say.
Patrick Ponticel
The Brown Aerospace DIFF end effector is shown with the cover open (left) and with
the cover closed.
Shown are the center barrel gantry automated fastening machine and C17 Globe
Master III bottom barrel inverted for the skinning process.
Quenching a thirst for better heat treating
IQ Technologies Inc.’s IntensiQuench
process for steel parts can best be
described as a water-quenching
method resulting in an optimized
level and depth of compressive
surface stressed with acceptable
part distortion in a throughhardened
part.
The process was “discovered” by
Nikolai Kobasko, Director of Technology
at IQ. He sought an alternative
heat-treatment method for hardening
steel parts through the use of pure
water quenchant or low-concentration
water/salt solutions. The generally
accepted cooling liquid had been oil,
making heat treating occasionally
hazardous and environmentally
unfriendly.
Prevailing wisdom has been that
only a slow quench could limit
distortion or cracking of metal parts,
and that water could not cool the metal
evenly enough to avoid distortion
28 Aerospace Engineering October 2003
Tech focus
to either the surface or deep within
the metal.
But what Kobasko found is that pure
water or a water/salt solution intensely
agitated (at a rate several hundred
times that used for conventional oil
quenching) kept distortion to a minimum,
provided that it was interrupted at
the point of maximum compressive
surface stresses. A team led by
Kobasko found that very fast and
uniform part cooling actually reduced
part cracking and distortion while
improving surface hardness, depth of
hardness, and durability of steel parts.
In addition, the process allowed for the
use of less alloy steel, resulting in parts
that can be made lighter but stronger
and more cost effective.
IQ has since developed computer
models for intensive quenching that
project the optimal time for interruption.
Patrick Ponticel
The first production furnace in the U.S. using the IntensiQuench process is owned
by Euclid Heat Treating Co.
Measurement time cut in half with new bore gage
The only family owned aircraft manufacturer
in the U.S., Schweizer Aircraft
Corp. is using an electronic bore gage
from Fowler/Bowers to make parts
inspection more efficient and reliable.
The maker of helicopters, agricultural
and reconnaissance aircraft, and
special-purpose unmanned vehicles,
Schweizer (also a subcontractor to
Boeing, Northrup-Grumman, Sikorsky,
and Lockheed-Martin) is giving closer
attention to upgrading its in-processing
inspection operations, particularly those
that can be performed directly on the
production floor by manufacturing
personnel.
“We need instruments that can help
us to continually produce parts of
known value,” said Jeff Waters,
Inspection Manager at the 400-person
company. The bore gage from Fowler/
Bowers has helped Schweizer halve the
time it takes to check tolerances of as
little as 0.0005 in for the many
precision-machined products it manufactures.
“The company formerly relied
on vernier-type inside micrometers for
this assessment program, but we found
inconsistent results,” Waters said.
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