Turbocharger Impeller Precision
Impeller precision below aerospace standard, high scrap rate.
Redesigned process route with aerospace-grade tolerance control.
Yield improved by 15%, scrap rate reduced to under 1%.
Large Pump Housing Porosity
Internal porosity in large pump housing causing field failures.
Optimized gating system and solidification simulation.
Scrap rate reduced from 8% to under 2%.
Titanium Implant Surface Quality
Surface quality of titanium implant did not meet ISO 13485.
Custom shell coating with strict temperature control protocol.
Passed ISO 13485 audit, surface Ra < 0.8μm achieved.
Aerospace Bracket Fatigue Life
Structural bracket failed fatigue testing at 60% of target life.
Process redesign with HIP treatment and NDT inspection.
Passed AS9100 fatigue testing at 120% of target life.
Rail Wheel Hub Dimensional Accuracy
Dimensional variation in centrifugal cast wheel hubs.
Process parameter optimization and SPC implementation.
Dimensional Cpk improved from 0.8 to 1.67.
Marine Pump Impeller Integration
Complex impeller required 12 separate machined parts.
Lost foam casting integrated all features into one piece.
Assembly cost reduced by 40%, weight reduced by 8%.