Precision Cast Facility
AETC PCF has acquired the latest quality accreditations necessary to produce hot gas path components for both aerospace and industrial power generation markets including AS9100 and NADCAP. AETC is pro active in maintaining and developing it’s quality systems to meet the ever increasing demands of the industry.
AETC PCF has a “State of the Art” wax room facility. The wax room incorporates industry best practices and is one of the most advanced of it’s kind in operation today. Layouts to improve productivity were defined from Kaizen events and constant evaluations are employed to keep in line with best practice.
AETC PCF operates four robot dip rooms and a small manual line for mature engine programmes with low production demands. Three shell systems are constantly in use at any one time to cover the wide range of components currently in manufacture. SPC controls maintain the shell parameters whilst 100% video surveillance monitors provide records of slurry application and drainage. Mould weight monitoring is a key control characteristic which is also monitored 100% to ensure the correct mould build ups and consistency of application.
AETC PCF has significant casting experience. Since the casting facility was founded in 1969 it has produced components of varying sizes and complexities in either single crystal, directionally solidified or equi-axed grain orientations. The scope of the facility is enormous and products as small as helicopter blades with an overall length of 20mm up to industrial blades with an overall length of 600mm are in high volume production today.
Cellular manufacture and product streams have been introduced to improve efficiency of post cast manufacture. Three main product streams are in operation; these being industrial power generation component finshing, aerospace component finishing and 360 degree vane ring finishing. Kaizen events are regularly used to optimise cell layouts and improve throughput. Advanced manufacturing techniques are employed to further improve efficiency.
AETC PCF operates at the forefront of new technology and has an innovated approach to product development and introduction of new products into production. The process of concurrent engineering within the customer base is now employed on a regular basis. We have demonstrated on many occasions that this approach helps reduce product development lead times and helps eliminate potential casting problems, such as porosity, at the design concept stage.