Market Segment:
Energy Solutions
Our partner is a manufacturer of gas turbine control systems used in industrial applications. Addit is responsible for a project involving the production of precision aluminum components forming part of critical control systems, where reliability has a direct impact on the safety and operational stability of the equipment. Although the components feature relatively simple geometries, they belong to a category of products with exceptionally stringent quality requirements, where even minor deviations may affect functional performance.
The key challenge of the project was the development of the entire manufacturing process in accordance with rigorous U.S. certification requirements and the validation of all special processes. Addit implemented and validated chromate conversion coating, anodizing, painting, and zinc plating processes while expanding the quality assurance system to include coating adhesion testing and corrosion resistance testing performed in accordance with MIL standards. For selected products, salt spray testing is carried out on every production batch and constitutes a mandatory acceptance criterion.
The project also included the preparation of comprehensive quality documentation, Process FMEA analyses, and PPAP documentation, demonstrating the capability of the manufacturing process to consistently maintain the required quality parameters during serial production.
Scope of the Project:
- analysis of technical requirements and development of the manufacturing process in accordance with U.S. quality standards
- implementation and validation of special processes, including chromate conversion coating, anodizing, painting, and zinc plating
- development of coating adhesion and corrosion resistance testing procedures in accordance with MIL and ASTM standards
- expansion of the quality assurance system to include laboratory testing, including salt spray testing
- preparation of Process FMEA analyses and PPAP documentation for the manufacturing process
- manufacturing and inspection of precision aluminum components with stringent quality requirements
- quality testing of every production batch requiring corrosion resistance verification
- ensuring full compliance of manufacturing processes with customer requirements and the standards applicable to mission-critical applications
