Category Archive: Uncategorized

What’s Happening With E-Mobility and E-Propulsion in 2021?

The effect of global warming is ever more visible today. Industries around the world are ramping up the urgency to deliver sustainable solutions. There is a strong focus in electrification of transportation, and the technological advancements in greener power generation methods and the distribution infrastructures.

Evidence of this global shift to sustainability can be seen in the ambitious goals made by leading manufacturers and governments globally. For example, General Motors recently vowed to end producing fossil fuel-dependent vehicles by 2035. Leading eVTOL (electric vertical take-off and landing) companies are planning on launching air-taxi services as soon as 2023, and in 2020 the United Kingdom announced it would ban fossil fuel vehicles beginning in 2030.

What Key Insights Are We Seeing in E-Mobility and E-Propulsion?

Within the next decade, the widespread adoption of hydrogen fuel cell and battery-powered electric vehicles (EV) will likely occur. While automotive companies are at the forefront of electric vehicle adoption, aerospace companies are also developing proprietary technologies behind the scenes, and many of their smaller-scale prototypes are yielding promising results.

EV

Leading automakers are currently producing more EV models than ever before, with approximately 400 new battery-powered vehicles expected to hit the market by 2025. At the same time, leading eVTOL (electric vertical take-off and landing) companies are certifying new vehicles with the FAA/EASA in preparation for a commercial service rollout as early as 2023.

The incumbent aerospace OEMs are beginning to reveal their hybrid e-propulsion and long to mid-range electric passenger aircraft concepts, and are working towards 2030 release timeline. According to a recent MarketsandMarkets forecast, by 2023 the electric aircraft market is expected to reach $122 million, which represents a compound annual growth rate of 4%. Meanwhile, UBS predicts that the electric aviation market will reach $178 billion by 2040 after experiencing a robust growth period due to the expected release of the first hybrid electric 50-70 seat aircraft around 2028.

What Are the Benefits of E-Mobility and E-Propulsion?

While their prevalence is steadily decreasing, internal combustion engine (ICE) vehicles are currently responsible for approximately 60% of the world’s air pollution. The potential environmental benefits from removing these vehicles from the road have already been demonstrated during the global COVID-19 lockdown when air pollution levels rapidly decreased.

e mobilityTo combat the global warming, electrifying the cars and airplanes are not enough. We must think of a way to make the whole energy supply chain green. Starting from how we generate fuel (or energy), transport and distribute it, and eventually how the byproduct of the fuel impacts the environment – the new greener supply chain must be a sustainable close-looped cycle.

Besides being the key element of the solution against the global warming, there are many benefits of the electrified mobilities. Electrification will directly contribute to cutting down the emission of toxic byproducts from burning the fossil fuels. Air pollution, such as soot and toxic gas in the exhaust, is an increasing health concern, especially in densely populated cities. Furthermore, extraction and production of fossil fuel generally damaging to the environment.

With the electrification of our vehicles, technology is constantly evolving. Governments around the world, including the US and EU, have issued statements that they believe electrification will bring greener technologies and innovations that will expand economic growth, creation of new types of jobs, and national security.

Contributing to the Sustainable Future

E-mobility and e-propulsion technology are becoming more visible in our everyday life and news. As the benefits of adopting these technologies become too significant to ignore, more companies are adapting their mobility solutions. In the past decade or so, we are seeing rapid increase in the number of innovations in the design of drive motors, power electronics, and transmission systems.

The new technologies emerging from the concerted electrification efforts inspire and enable new ideas and machine designs. As seen in the EVs, electric vehicles require much fewer moving parts and dramatically simplify the drivetrain design. The same benefit is anticipated for the electrified versions of aircrafts, ships, and other electrified machines.

Though simpler design borne many benefits, many fundamental challenges in high-performance rotating parts remains similar. Schenck and Test Devices serves the e-mobility and e-propulsion industries with new part manufacturing, spin testing, and rotor balancing services. These services support the development of sustainable technologies such as advanced propulsion system parts and new electric motors. As an AS9100 and ISO 9001 certified business, we have been committed to exceeding our customers’ expectations for over 40 years. To learn more about our capabilities for the e-mobility and e-propulsion industries, contact us today.

A Comprehensive Guide on CNC Machining

Computer numerical control (CNC) machining has proven itself an ideal method for mass producing metal and plastic parts. Even as other manufacturing methods like 3D printing have gained prominence in recent years, CNC machining has remained one of the most popular choices for a wide variety of fabrication needs. The aerospace sector relies heavily on CNC machining for the production of complex and mission-critical parts and components.

By leveraging the precision and automation of computerized control, CNC machining allows for the creation of intricate and accurate designs. In the past, manual machining processes relied on highly trained and skilled human operators to control the machinery. While some machine shops still use skilled machinists for prototypes, small-volume orders, or parts where repeatability or tolerances aren’t important, CNC machining has virtually eliminated the risk of human error in many manufacturing operations. Advanced programming regulates precise cutting patterns to ensure part-to-part uniformity and reliable adherence to tight tolerances.

What is CNC Machining?

CNC machining is a modern manufacturing process that takes in specific programmed instructions and uses that information to direct tooling as it cuts into the workpiece. CNC machining is not limited to one tool or piece of machinery. A spindle holds numerous tools, and CNC machines can often use multiple tools simultaneously from different angles. The term “numerical control” simply refers to the automated control of a machining process. The most common computer language for CNC machines is called G-code, though another language known as M-code is also sometimes used.

How Does CNC Machining Work?

To use a CNC machine, a skilled professional must program the computer. Once the machine has been activated, it reads through the program and enacts each of the instructions, employing a variety of tools and fabrication processes along the way. The CNC machine will follow its program under the assumption that all tools have carried out their function flawlessly. Small mechanical margins of error still exist, especially when the CNC process involves simultaneous cuts or other complex instructions. By and large, however, well-maintained CNC machines reliably perform in accordance with their programming.

machined pad

While numerical control machines of the past read instructions through punch cards, today’s CNC machines require advanced computer programming. Operators enter the instructions into a computer and save the file into the machine’s records, where it can then easily find and invoke the instructions over and over. While many technicians are familiar with G-code and M-code languages, machine shops most commonly use computer-aided manufacturing (CAM) software, which can turn a computer-aided design (CAD) drawing into usable instructions for CNC machinery. This type of software makes the operator’s job much easier.

What are the Common Types of CNC Machines?

Numerous types of CNC machinery exist, enabling machine shops and manufacturers to conduct an expansive range of automated machining processes. Some of the most common CNC machine types include:

  • CNC mills. CNC milling machines can cut a wide variety of materials in multiple dimensions. Most milling machines include an X, Y, and Z axis, which allows for exceptional detail and complexity. Cutting-edge machines may include additional axes for further precision and detail.
  • CNC turning centers/CNC lathes. These specialized manufacturing tools are ideal for creating parts with symmetry around a central axis, such as pipes and shafts. CNC technology gives lathes an added level of precision that can be used to create more intricate parts.
  • Plasma cutters. Plasma cutters seamlessly slice through material by using electricity and compressed-air gas to form a plasma torch. Plasma cutting requires conductive material, so it is mostly used to cut conductive metals such as steel, copper, brass, or aluminum.
  • Water jet cutters. Water jet cutters create an intense stream of water that cuts through tough materials. Adding abrasives to the water stream facilities cutting of harder materials, such granite and titanium.

What are Some Popular Machining Techniques?

With many CNC machining processes available, it can be difficult to determine which ones to use for a specific project. While there is some overlap, most machining methods lend themselves to specific project or design needs. Here are some of the most popular and versatile CNC machining techniques:

  • Roughing and semi-finish machining. These processes get most of the way to the final product, while leaving some excess material on the outside for fine-tuning by more precise machinery. Semi-finish machining reveals the final part geometry, but only strips the material within about 0.05” of the target dimensions. Also called roughing or rough machining, this process often uses CNC machinery to produce high volumes of roughed parts ready for final machining.
  • Turning. Turning is one of the oldest manufacturing processes, but modern CNC lathes use advanced tooling and precision control to create highly accurate cylindrical parts with numerous features. As the workpiece rotates at high speeds, cutting tools move along the length of the piece to cut away material. More advanced turning centers can conduct additional processes, such as drilling holes.
  • Milling. Milling holds the piece steady while a spindle with various cutting tools rotates around it, making precise cuts in accordance with the programmed instructions. Although the workpiece is mainly held horizontally, the cutting tool functions in the X, Y and Z directions. Four-axis and five-axis CNC milling machines have become increasingly common in recent years, offering further precision, speed, and complexity.
  • Solid Sink EDM. Unlike the other processes, which all involve direct contact between tools and the target surface, solid sink electro-discharge machining (EDM) uses a an electrode that releases a powerful discharge that forces material to strip away from the metal surface. The material must be immersed in a dielectric fluid during the manufacturing process, and the electrode requires frequent replacement.

What are the Benefits of Machining with Test Devices?

At Test Devices by SCHENCK, our skilled and experienced staff brings extensive expertise to the manufacture of safety-critical rotating components made from challenging aerospace alloys. With a great deal of experience creating or adhering to the frozen manufacturing processes used by original equipment manufacturers (OEMs) in the aerospace sector, allowing us to guarantee a high rate of repeatability across each production run.

Test Devices by SCHENCK has become a premier provider of precision machining services for aerospace OEMs. We serve a customer base that accepts nothing less than the highest levels of accuracy, quality, and compliance with industry standards. Our manufacturing operations operate in strict compliance to AS9100/ISO 9100 quality management standards.

All our customers know we can respond and adapt quickly to project changes with minimal impact on production and delivery schedules. All of our teams, including machining, spin testing, balancing, and logistics operate in unison to provide end-to-end efficiency on every project.

For more information about Test Devices by SCHENCK and our machining capabilities for the aerospace sector, please contact us today.

Why Partner With Test Devices for Your Overspeed Spin Testing Needs?

Spin testing is a critical step in the manufacture of rotating components. While some original equipment manufacturers (OEM) may have the resources to perform these testing operations in-house, many do not. As such, they have to outsource these operations to a third-party spin testing service provider. Unfortunately, this option increases the potential for tight timelines or production delays as some service providers have long turnaround times (three or more weeks) even when two weeks or less is possible. These extended estimates can typically be attributed to a lack of communication between the client and provider, which, in addition to introducing uncertainty about when parts will be delivered, reduces the likelihood of a return customer.

We reduce lead times and costs associated with overspeed spin testing.

You can improve your product build and delivery efficiency by reducing process lead times. However, efficiency is not the only factor on which you should focus. You should also emphasize reliability, which influences whether you can consistently meet your customers’ order requirements  in a timely manner.

over speed testing

Equipped with extensive spin testing experience, we have what it takes to offer efficient and reliable overspeed testing solutions. We have  to accommodate high test volumes. All work are carefully and quickly planned, tracked, and executed. In many cases, we can cut turnaround time by two or more weeks (a 33–66% reduction in lead time compared to our competitors), which makes it easier for you to meet your product delivery timelines and positively affects your cash flow.

We have a dedicated service team.

In today’s manufacturing world, flexibility and responsiveness are essential. Regarding OEMs, this means ensuring on-time delivery and remaining aware of and being able to respond to changing demands. Having a reliable production and supply chain is key to achieving these goals so you can stay ahead of the competition and retain your customers.

Our dedicated  service team is ready to help keep you on track. We quickly review and execute spin testing requests, so your customers do not have to worry about delayed shipments or long wait times between order placement and fulfillment. This reliability can help improve your customer retention rates, leading to a larger customer base and expanded capabilities over time.

We are ISO9001/AS9100 certified.

over speed testingWe are committed to providing high-quality spin testing services and products that meet or exceed our clients’ requirements. This dedication to quality is reflected by our maintenance and adherence to an AS9100/ISO 9001 certified quality management system. Our quality management system is updated on an annual basis and subjected to regular internal and external audits to ensure its robustness. We also employ certified inspectors to dimensionally inspect 100% of all hardware manufactured from drawings.

Connect With the Experts at Test Devices Today

At Test Devices, we are a trusted spin testing  and service provider for leading OEMs in many industries. To learn more about our products and services or partner with us for your overspeed testing needs, contact us or request a quote today.

What Is Rotor Balancing and Why Is It Essential?

Rotors are a critical component used to convert electric or electromagnetic energy into rotational motion. For rotors to operate reliably, they must maintain even weight distribution across the rotational axis. Too much weight on one side creates uneven mass distribution known as “unbalance”.

rotors

Rotating parts in any mechanical assembly can become unbalanced. Uneven weight distribution of a rotating component causes the part’s rotational center to be out of alignment with the geometric axis. When unbalance occurs, the operational efficiency and safety of the system in which the rotor operates are compromised. Rotor balancing can help to prevent issues caused by unbalance, reducing noise and vibration and extending the life of your system.

What Are the Various Rotor Groups?

Rotors are grouped into two categories: rigid and flexible. Rigid rotors can be balanced at lower speeds, as long as there is sufficient centrifugal force to detect the unbalance. Flexible rotors, on the other hand, deflect outward from the rotational axis, and the center of rotation moves away from the rotational axis as the speed increases. Unlike rigid rotors, flexible rotors must be balanced in stages, starting with lower speeds and slowly working up to operating speed.

Why Is Rotor Balancing Essential?

High levels of vibration caused by unbalance can cause equipment to operate less reliably, which results in increased energy usage, decreased operational efficiency, and reduced equipment service life. The force exerted by the dynamic load from an unbalanced rotor will cause wear to the rotor itself, the bearings and mountings holding it in place, and the machine’s structural support. Although the severity of the dynamic load varies depending on the degree of unbalance and the rotation speed, any unbalance can cause problems.

balancing

Vibration from an unbalanced rotor creates excessive noise and resonance, which will ultimately compromise the structural integrity of the equipment that supports the rotor assembly. The damage caused by unbalance is especially apparent in bearings, suspension equipment, support housing, and the equipment foundation. These components are typically exposed to the highest level of stress caused by the excess dynamic load due to unbalance. With ongoing exposure, these components will be more likely to suffer premature wear.

In addition, the high vibration caused by unbalance can loosen fasteners such as screws, nuts, and bolts, rendering the structure less stable. Pipes, electrical cables, wiring, electrical connections, and switches can also be negatively affected. With extended exposure to high levels of vibration, even nearby equipment and structures can be compromised, creating the potential for greater damage and injury.

What Are the Various Types of Unbalance?

When balancing your rotor, it is critical to understand the different types of unbalance. There are three types of unbalance, including:

  1. Static Unbalance. This type of unbalance occurs when the mass axis is displaced parallel to the shaft axis. Static unbalance is corrected only in one axial plane.
  2. Couple Unbalance. Couple unbalance occurs when the mass axis intersects with the running axis. This type of unbalance is typically corrected in two axial planes.
  3. Dynamic Unbalance. Dynamic unbalance is typically a combination of static and couple unbalance and occurs when the mass axis does not intersect with the rotational axis. This can usually be repaired by correcting the balance along two axial planes.

Reliable Rotor Balancing by Seasoned Professionals at Test Devices by SCHENCK

At Test Devices by SCHENCK, we are dedicated to providing our customers with expert balancing solutions for rotating and oscillating equipment in a wide range of applications and industries. With more than 50 years of experience, we have the knowledge, equipment, and skill necessary to provide superior balancing services for everything from modular drills to industrial crankshafts and wind power turbines. We are skilled in servicing equipment of all sizes, from miniature dental motors of only a few ounces to 400-ton steam turbine rotors.

rotor balancingOur expertise extends to dynamic balancing, static balancing, couple balancing, and much more. With an international team of over 900 experts, we work tirelessly to design, research, develop, and produce actionable balancing solutions for customers in the automotive, aerospace, electrical, and mechanical engineering industries. In addition, we offer maintenance services and quality control testing to ensure that your rotor equipment is operating within applicable industry standards and regulatory guidelines.

We are committed to providing superior rotor balancing services to our customers around the world. To learn more, contact us today.

Figure 1,  A Rigid Test Rotor mounted on a Schenck Hard Bearing Balancing Machine.

 

 

Top 3 Reasons to Choose Test Devices for Precision Machining Services

In modern manufacturing operations that create critical rotating parts, each step, from forging to finish machining to final inspection, contributes to the overall quality of the finished pieces. To ensure the highest level of precision and reliability of your parts, it is essential that your semi-finish machining service provider has robust manufacturing processes in places relative to producing critical rotating parts. Look for full-service shops that offer high-quality, reliable, and consistent machining services.

One-Stop Shop Full Service Manufacturing

machined padRough and semi-finish machining for the aerospace sector requires precision equipment and experienced, knowledgeable engineers and operators that can navigate difficult or unexpected challenges during machining operations.

At Test Devices by SCHENCK, we have a highly skilled and experienced staff with the expertise in machining safety critical rotating parts from the most challenging aerospace alloys. We observe strict adherence to AS9100 and ISO9001 standards. Our talented team of engineers and machinists, combined with our suite of on-site resources, allows us to provide a full-service approach to manufacturing that is unique in our industry, combining machining, inspection, and spin testing operations under one roof.

High-Quality Expertise in Precision Machining

The customers we serve demand the highest levels of quality, accuracy, and compliance with industry standards. We are the premier provider of precision machining services for aerospace OEMs, operating in strict compliance with the AS9100/ISO9001 standards. Throughout our over 40 years of experience in working with critical aerospace rotating hardware for testing and production, the Test Devices team has continued to provide unparalleled precision and reliability in sonic, rough, semi-finish, and pre-weld machining services.

At Test Devices, our operation not only conforms to the AS9100/ISO9001 standards, but we comply with various QPRs for leading jet engine OEMs. Our quality assurance team is staffed with the most experienced professionals, including on-site quality process experts, designated quality representatives, and dimensional inspection and CMM experts. From forging state to completed semi-finish machined conditions, we are committed to providing the highest levels of quality, dependability, and precision by employing controlled manufacturing processes, including:

  • Component specific CNC/CMM programs
  • Detailed operation sheets
  • Inspection plans
  • In-process control
  • Dedicated and accessible operations management
  • Direct and frequent communication with customers

Customer Focus

Being flexible and responsive to the customers’ needs and constantly changes is a necessary capabilities in the today’s manufacturing world. Whether it is a change in requirements or specifications, schedules, test criteria, or delivery times, providing exceptional customer service requires a commitment to communication. Frequent personal contact with each customer ensures that we are aligned on expectations and are meeting their needs.

All our customers are confident in our ability to respond quickly to urgent changes that could impact the manufacturing or delivery schedule. Our production manager maintains close working relationships with our customers, as well as coordinates with all departments daily on customer requirements. From machining to inspection, spin testing, balancing to shipping, every department is in lock-step throughout each step of the project.

Choose Test Devices for Your Precision Machining Services

Though Test Devices specializes in rough and semi-finishing of rotating parts in aerospace, the same high standard in the quality of work, and operational excellence could serve many other industries and customers with similar needs. Through our reputation for quality and professionalism, as well as our four decades-long history of success, our customer base continues to expand across sectors such as automotive, energy storage and generation, electronics, and medical devices.

Our dedicated and seamless production management team combined with our highly skilled and experienced team allow us to provide machining, balancing, and spin testing operations under one roof. For more information on our precision CNC machining or alloy machining services, please contact us today. To learn more about our precision machining tools or processes, please download our eBook.

Semi-Finish Machining Services

Machining in the Aerospace Industry

The success or failure of aerospace operations is dependent on the accuracy, precision, and quality of the components employed. For this reason, aerospace companies utilize advanced manufacturing technologies and techniques to ensure their components fully meet their needs. While new manufacturing methods such as 3D printing are quickly gaining popularity among industry professionals, traditional manufacturing methods such as machining continue to play a critical role in the production of parts and products for aerospace applications.

aerospace mechanic

Recent advancements in machining techniques and technologies—such as better CAM programs, application-specific machine tools, enhanced materials and coatings, and improved chip control and vibration dampening properties—have significantly changed how aerospace companies manufacture critical aerospace components. However, sophisticated equipment alone is not enough. Manufacturers must have the expertise to overcome the challenges of machining materials for the aerospace industry.

The following blog post discusses what aerospace component machining processes encompass and what machining challenges aerospace component manufacturers face.

What Does Aerospace Component Machining Involve?

In concept, machining raw material into aerospace parts and products seems simple. However, turning materials into functional components that fully meet the specifications and standards of the application necessitates extensive engineering and operational expertise.

machining aerospace

Aerospace manufacturers often invest in CAD/CAM software and automation components to achieve better part quality, process control, and production efficiency. However, while these cutting-edge technologies help deliver consistent and dependable output, company employees must have the proper knowledge and skills to use them to machine components effectively and efficiently.

What Are the Challenges of Machining Nickel-Based Superalloys?

Many critical aerospace components, such as hot sections of jet engines, are made from nickel-based superalloys, which are aerospace materials characterized by their ability to offer superior performance in demanding environments. This quality stems from their excellent strength at high temperature, toughness, hardness, oxidation/chemical resistance, creep resistance, and thermal insulation properties. While these properties make these materials an excellent choice for such components, they also make them difficult to machine. Some of the challenges faced by machinists working with nickel-based superalloys include:

  • High cutting force requirements. The high dynamic shear strength of nickel-based superalloys necessitates the application of significant cutting forces to machine the material into the desired part or product.
  • Poor thermal conductivity. Since nickel-based superalloys do not readily conduct thermal energy, the heat generated by the cutting operations migrates to the tooling rather than the chip. As a result, machine tools experience greater wear in these machining operations than the machining operations for other materials.
  • Susceptibility to work hardening. Superalloys are prone to work hardening, which leads to a greater risk of notch wear.

Given the proper engineering and operational expertise, machinists should be able to overcome these challenges and produce machined components suitable for use in aerospace applications.

Why Partner With Test Devices for Your Aerospace Machining Needs?

At Test Devices (a business unit of SCHENCK USA CORP.), we’ve produced critical rotating components for customers across a wide range of industries for over 40 years. This extensive experience, combined with our full-service manufacturing capabilities (semi-finish machining, inspection, and testing all under one roof), allows us to provide expert and reliable product solutions for major aerospace propulsion suppliers, automotive manufacturers, industrial power generation manufacturers, and numerous other industrial companies.

To learn more about our products and services and how they can benefit your aerospace application, contact us today. To discuss your requirements with one of our experts, request a quote.

The Commercial Space Economy Forecasts an Optimistic Future

With the recent manned mission of a US-made rocket, and advancements in reusable launch systems, commercial space is coming into the spotlight and showing an optimistic future.

The commercial space economy has been steadily growing in recent years for reasons ranging from financials to innovative breakthroughs in technology. Although the manned-mission is in the spotlight, in terms of segmentation of various commercial space activities, unmanned operation is forecasted to contribute a larger share of activity.

NASA

North America still leads the overall launch capability and is said to have the largest market share in the spacecraft industry. NASA’s renewed resolve in returning to the moon, and extending the reach of the manned mission to Mars, comes with a significant budget to accelerate the development of space technologies and the economy. Anticipating the future of space commerce, many entrepreneurs and pioneering companies are entering the new space race to find unique ways to provide the necessary services for this emerging industry – including the following:

 

Affordable Launch / Rocket technologies: Curbing the cost of launch is the foundation of making space accessible for commercial companies.

Satellite Internet / Communication: Most likely the development and deployment of communication technology is the most immediate opportunity for space businesses. Companies focused on improving the accessibility and the reach of wireless broadband and connectivity through satellites.

Asteroid / Moon Mining & Manufacturing in Space: The idea sounds like a science fiction story, but companies are exploring ways to extract water and rare minerals from asteroids, and the moon. Some of these companies are also involved in developing the manufacturing technologies required to build structures in orbit and on other planets.

Refueling Services: Gas stations in orbit? The capability to fuel/refuel spacecraft destined for long range target (Mars), as well as the satellites that are already in the earth’s orbit, is an essential part of space commerce and rapidly becoming a reality.

Cleaning up Space Debris: With all of the satellites and manmade machinery that we have launched and left in space, the Earth’s orbit is becoming cluttered – We need companies that can track and remove this “space junk” to avoid accidents and keep space accessible.

Space Tourism: Perhaps what most earth citizens are looking forward to the most is the ability to take a brief trip to space. Though ticket prices for space tourism are still astronomically expensive, these companies are developing ways to make it affordable and bring the space adventure to many of us.

Space Exploration / Colonization: This is probably the most popular and audacious goal amongst the leading space ventures. These companies are working on sending and settling humans and cargo beyond earth’s orbit, including the moon and mars in the near future.

 

Technology Advancements Driving an Optimistic Future 

Space entrepreneurs are exploring and pursuing ambitious goals such as colonizing other planets, mining asteroids, setting up space tourism, building manufacturing plants in orbit, as well as pursuing ways to further lower the cost of access to space – such as airplane-borne rocket and air-to-space launchers. It is clear that reusable rockets and space-age commercialization are today’s reality. Lower per-launch costs and miniaturization of payloads/satellites are opening new doors for non-aerospace and defense sectors, further demonstrating that commercial space is showing an optimistic future.

aerospace test devices

With reusable rocket technology advancements, the cost of launching a rocket has declined drastically to 33% of previous costs (from $200 million to $60 million). Morgan Stanley, a leading business analysis firm, predicts a potential launch cost of $5 million, in the near future. The global space industry is expected to generate $1.1 trillion in revenue by 2040, up from  $350 billion in 2019.

 

How Test Devices Contributes to the Commercial Space Economy?

We are the leading experts in high-speed rotor testing, manufacturing, and rotor balancing technologies, especially for aerospace applications. For decades Test Devices by Schenck, has been a dependable partner to many of the leading aerospace propulsion OMEs. Our capability in executing aerospace-grade engineering tests and managing outsourced manufacturing operations is only matched by our passion for sharing our customers’ success.

There are several operationally critical high-speed rotating parts in each rocket engine.  We both test and perform important operations in the overall component manufacturing processes. Test Devices currently performs production spin testing to satisfy NASA standard 5019 section 7.2.7 fracture critical rotating hardware.  Typical items that are associated with fracture critical rotation are turbine, Fuel pumps, and LOX impellers.

Partnering with us not only provides you with the benefits of our extensive experience and dedicated team, but you will also be working with a team that keeps quality, safety, and continuous improvement at the forefront of our business. Customers want to work with Test Devices because of our focused approach on the most demanding manufacturing requirements, whether it be spin testing, semi-finish machining, or other critical processes.

For more information or to get in touch, please contact us today.

Why Choose a Full Service Semi-Finish Manufacturer?

Test devices semi finish rotating disk

Full-Service Manufacturing: What Makes Us Unique?

Through our extensive knowledge and expertise in rough and semi-finish manufacturing, we are able to give our customers the highest quality rotating parts making us the industry leader in this category. While success in these areas does require a dedicated team, what makes Test Devices unique is our combination of experts with our suite of on-site resources. 

Other facilities can surely spin and shape products, but more importantly we are equipped with the best engineers, operators, and equipment that can handle the unexpected inevitable challenges that arise in machining. With our versatile staff and top of the line equipment, at Test Devices, we have the capabilities to execute:

The Attention You Deserve

Our staff is nothing short of thorough, detail oriented, and personable. In a fast-paced environment with changing schedules, specifications, delivery schedules, and rotating points-of-contact, we understand that change is inevitable, and we need to be able to work quickly and efficiently.

Where we stand out among the rest is our ability to adapt to our customer’s needs. We stay engaged in personal and frequent contact, ensuring that feedback is not missed and capturing our customer’s needs and any changes along the way. Our production management will ensure part shipments are made on a day to day basis, while continuing to develop and maintain relationships with our customers and meeting their demands. 

No matter how urgent the request, our customers know that at Test Devices we will respond quickly with actionable steps, as we understand these changes could have an effect on our manufacturing and delivery schedule. 

Experts on Materials

With our staff of highly trained experts, we cover a vast amount of knowledge when speaking about rough and semi finish machining of complex alloys and critical rotating parts. At Test Devices, we routinely provide finishing for the following:

  • Heat-resistant super alloys
  • High-nickel content aerospace superalloys
  • Precision critical rotating components
  • Parts within tolerances of (+-) 0.0005”
  • High-precision geometric shapes from rough forgings

Our Proven Commitment

rotating disk manufacturerDriven by our commitment to provide high quality services and products and dedicated customer service, our expert staff will see any challenge to the finish line. 

After several years of successfully providing pre-finished parts to one of our customers, a major aerospace manufacturer, Test Devices experienced an increase in un-spinnable parts. After completing a detailed and thorough inspection of the machinery, our team was able to identify the problem which was determined to be a change in machining setup by the customer. We were then able to make the professional recommendation and solve the issue.

A second example involved an issue during spin testing for a leading manufacturer of centrifugal impellers. Similar to our first example, after years of successfully delivering parts to our client, we encountered an issue when we realized a handful of parts were unbalanced. After the inspection of the machinery, we were able to determine the issue at hand and successfully resolve it. 

Why You Should Choose Test Devices

Partnering with us not only provides you with the benefits of our extensive experience and dedicated team, but you will also be working with a team who keeps quality, safety, and continuous improvement at the forefront of our business. Customers want to work with TD because of our focused approach on the most demanding manufacturing requirements, whether it be spin testing, semi-finish machining, or other critical processes.

 


To read more about our entire rough and semi-finish machining services all under one roof, click here or on that picture to get your free copy of our eBook “Unparalleled Value: The Benefits of Our Rough & Semi-Finish Rotating Disk Machining Services now.

 

 

 

Success for the HQ-1 Spin Test System

Shops and factories need to regularly test rotors to ensure excellent performance and adherence to design or production requirements. The HQ-1 Spin Tester is a purpose-built bench that incorporates all basic spin testing.

HQ-1 is designed for manufacturing environment, and most suitable for spin testing:

  • High-speed electric motor armatures
  • Small gas turbine disks and bladed disks
  • Turbochargers & turbopump rotors
  • Electronics: Munition fuses and sensors
  • Centrifuge wheels

The HQ-1 Spin Tester is an efficient, cost-effective option for facilities that need in-house, high-quality spin verification.

HQ-1 Spin Test System Overview

test-devices-spin-rig

Our HQ-1 Spin Test System offers the following components and capabilities:

  • Compact design.The skid-mounted device can fit in a 10′ x 5′ x 6.5′ envelope for easy transportation and maneuvering.
  • Ease of use.The wheel mounting arbor fits multiple exchangeable adapters so facilities can test a variety of equipment with the same unit.
  • Drive system. The system’s default drive device can run up to 100,000 RPM as a baseline speed. Our team can provide higher speed drive options upon request.
  • Turnkey solutions. The HQ-1 Spin Tester offers plug-and-play installation, easy integration, and ERP and IoT connection capabilities.

The HQ-1’s user control system makes the device easy to operate. The interface is intuitive and has manual, semi-automatic, and automatic settings. Facilities can create pre-programmed spin cycle sequences for routine testing with built-in safety and diagnostics.

The device can be operated with an optional touchscreen interface. This offers menu-style setup, one-push operation, and barcode scanning to activate specific test sequences. Test Devices can also enable spin test systems with upgrades for remote control and monitoring for more customizable usage.

Safety

Spin tests generate significant speed and force. To keep workers and adjacent equipment safe, we build our spin test systems to exacting standards. The test chamber of the HQ-1 Spin Tester has a high-strength containment shell made from steel, is fully enclosed and includes a safety door for the operator.

We also outfit the chamber with multiple safety interlocks to protect against malfunction and abnormal machine behavior during operation. The system performs self-diagnostic tests, monitors its operation and keeps an automated log of alarms.

The vibration monitoring system in the drive unit adds another layer of safety against potential and serious hazards in the high speed testing. The system detects abnormalities and interrupt the spin operation  preventing the operators from being exposed to a potentially hazardous rotor behavior. T

Contact Test Devices to Request a Spin Test System Today

Spin testing is a step to evaluate the quality of rotating parts in manufacturing, repair, and operation. The HQ-1 Spin Tester is a purpose-driven tester that includes a fully-sealed testing chamber with a robust containment, a easy to use operator interface, and dependable in-built monitoring and safety features.

Test Devices specializes in creating high-quality testing equipment to keep your facility safe and ensure you deliver high-quality finished products. We’re the leading experts in both spin testing and balancing services, and our company is ISO 9001:2015 and ASD9100D certified. Request a quote here for more information on an HQ-1 Spin Tester for your operation today.

Protect Your Turbines and Engines with Subscale Turbine Particle Test Rigs

test-devices-turbine-particle-testSolid particulates—such as sand, volcanic ash or airborne pollutants produced through the burning of fossil fuels—pose a significant risk to power turbines and jet engines employed in the industrial, commercial, and military sectors. Whether natural or manmade, these contaminants can severely impact the performance and durability of these systems and, in some cases, cause damage and subsequent failure.

 

test-devices-turbine-particle-erosion

Once inside the turbine flow path, depending on the temperature, the particles could cause different type of damages to critical operating components. For systems regularly exposed to dust and other solid pollutants, understanding the sources and mechanisms of particle-related damage is essential for engineering an effective solution to mitigate the problem and maintaining long-term optimal performance. These necessities are especially relevant due to the increasing number of military and aviation operations occurring in dry dusty environments, as well as the increased incidence tied to the presence of the volcanic ash dispersed in the flight altitude.

Particle testing is one of the most critical steps in identifying and evaluating these potential pain points. This blog post outlines the basic principles behind the testing procedure and the testing capabilities offered up by Testing Devices, Inc.

 

Fundamentals of Turbine Particle Testing

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All gas turbines take in large amounts of air and are therefore at risk of particle damage. The danger is present whether the turbine is land-based or airborne and whether or not it has a filter, as even the most advanced filters cannot contain extremely fine particles of dust or ash.

Subscale Turbine Particle Test Rig uses a purpose-built test setup to assess a durability of a turbine parts to handle these anticipated rigors before it is actually exposed to them. The goal of the test is to understand how a given contaminant entering the turbine could interact and manifest into a damage. The information that’s key to predicting and preventing catastrophic failures. Early, accurate particle testing is especially valuable as different particle types, chemical compositions, and operating environments cause different reactions and issues within the system. For example, the operating temperature affects the phase of the particulate hitting the blade surface, which determines whether erosion or deposition occurs.

After conducting a particle test, an engineer gains a comprehensive understanding of how his or her component may react to these likely environmental stressors, making it an essential step in the design process.

Key Test Rig Capabilities

At Test Devices, Inc., we specialize in subscale stimulations that are fully adaptable to a wide range of test environment conditions. Our testing rig boasts the following capabilities:

  • Max flow velocity: 370 m/s
  • Demonstrated flow temperature: over 2400º F
  • Overall exhaust mass flow rate:6 kg/s
  • Particle feed rate:2, 0.5 grams/s, and higher

Within these constraints, we work with our customers’ teams to generate actionable data that inform future revisions and production choices.

Test Devices: Leading the Industry in Performance Testing

As the demand for air transportation grows and the aircrafts venture into harsher conditions, there’s ample demand for customizable particle testing that can account for all critical environmental factors. At Testing Devices, Inc., we offer state-of-the-art testing rigs and services designed for maximum precision and control.

Request a Quote and speak with our team about your ingestion testing needs today.