M E T A L  M A N U F A C T U R I N G  P R O C E S S

Aluminum Blade Manufacturing Process

Aluminum blade shanks are turned to finished dimension on a CNC lathe. This machine is capable of processing over 100 blades a day and provides the reference dimension for all subsequent manufacturing.
High-speed, high precision 5-axis CNC mills cut the airfoil shape. More than three hundred unique airfoil designs are actively produced on these machines. In addition to contour, the mills control thickness, width and angle of the blade chord.
Blade shank and counterweight features are milled and drilled on a CNC horizontal mill. To assure accurate feature location, this mill probes the blade shank area before machining.
Blades are inspected using a programmable CMM to confirm airfoil geometry. Inspected features include airfoil shape, leading edge alignment, face alignment, thickness at specified locations, width, blade angle, etc.
Blades are visually inspected to assure total quality compliance before shipping.

Steel Hub Manufacturing Process

A high horsepower CNC lathe provides the reference feature for all subsequent machining operations. This lathe is used for three critical operations in steel hub manufacturing and is equipped with the latest generation control and tool probing options.
Alloy steel hub forgings are heat treated in a salt bath to achieve ideal mechanical properties.
This 60 horsepower four-axis lathe routinely turns parts that weigh over eighty pounds yet controls tolerances to within +/- 001 inch.
Critical features on steel hubs are confirmed to be in specification before and after plating operations.
Steel hubs are the core of the propeller and carry centrifugal loads of fifty thousand pounds. Here, a propeller assembler installs blades and retention clamps on a turbine engine propeller.

Aluminum Hub Manufacturing Process
Forging halves are milled to precise specifications before being assembled.
Blade retention features are milled on a fourth-axis equipped CNC milling center.
Flourescent penetrant inspection verifies that no material defect exists