Aerospace Structural Bracket: 5-Axis CNC Titanium Manufacturing
Bracket Materials
Aerospace bracket manufacturing uses Ti6Al4V for structural brackets (895 MPa, 40% lighter than steel) and 7075 aluminum for weight-critical non-structural parts. Buy-to-fly ratio 5:1 to 10:1 typical.
AS9100 quality system. NADCAP NDT: fluorescent penetrant for surface cracks, X-ray for internal defects. Full material traceability from mill.
| Material | Strength | Weight Saving | Use |
|---|---|---|---|
| Ti6Al4V | 895 MPa | +40% lighter | Structural |
| 7075 Al | 570 MPa | +60% lighter | Non-structural |
| Inconel 718 | 1,240 MPa | Standard | High temperature |
| SS 15-5PH | 1,100 MPa | Standard | Corrosion |
5-Axis CNC Process
Tomlinson fixtures minimize vibration for thin-wall titanium. High-pressure coolant (70 bar) for chip control. Cutting speed 30-60 m/min with carbide tools. Probe-based in-process inspection for critical features.
Temperature compensation for ±3μm accuracy. Adaptive machining for stock removal optimization. Surface finish Ra 0.8-1.6 for fatigue-critical areas.
| Parameter | Value | Benefit |
|---|---|---|
| Spindle Speed | 15,000-24,000 RPM | High speed |
| Coolant | 70 bar | Titanium chip control |
| Accuracy | ±3μm | Temperature comp |
| Fixtures | Tomlinson | Vibration dampening |
Quality and Certification
FAI per AS9102 with CMM dimensional report. NDT: FPI per ASTM E1417, X-ray per ASTM E1742. Material cert per EN 10204 3.1. Lot traceability. Edge break 0.1-0.4mm for stress relief.
Surface roughness verification for fatigue-critical areas. Full documentation package for customer approval.
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