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Tough materials, tight tolerances, low quantities, and complex shapes—leading suppliers offer advice for navigating the energy industry’s stringent demands.

As aerospace ramps up its use of advanced composites, robots and automated manufacturing systems will assume ever larger roles in building and machining these challenging materials.

Aluminum producer Novelis today formally dedicated its customer solution center in southeastern Michigan.

Earlier this decade, the auto industry moved to lighten cars and trucks. It was supposed to be a competition between steel, long the dominant vehicle material, and aluminum. The latter got a boost when Ford Motor Co., Dearborn, Mich., bet big on aluminum, making aluminum bodies for its F-150 and Super Duty pickups.

The Copper Development Association (CDA) is eager to help shops discover and tap into the high-speed machining advantages of brass. The substantial benefits of doing so have an increasing number of shops rethinking their part materials and, when possible, converting those parts to brass.

Marshall Aerospace and Defence Group is now using 3D printing from Stratasys to manufacture flight-ready parts for several of its military, civil and business aircraft—while producing specific ground-running equipment at a lower cost than aluminum alternatives.

The well-established field of laser marking continues to break new ground with expanding business opportunities in automotive, oil and gas, medical and other industries.

It’s not too difficult to understand the importance of machining aluminum for aerospace applications. High volumes of aluminum are used, principally for structural components.

As a result of recent testing under real production conditions, brass proved to machine at extremely high speeds on today’s advanced machine tools with little evidence of tool wear, producing high-quality surface finishes and excellent chip control, reported the Copper Development Association (McLean, VA).

For Dale Mickelson, Yasda product manager at Methods Machine Tools Inc. (Sudbury, MA) and author of several books on hard milling, tackling heat-resistant superalloys (HRSAs) requires the perfect combination of machine, workholding, tooling, tool paths and coolant.