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Using Dymax SpeedMask, accessible within the UK from adhesives specialist Intertronics, has enabled German plane engine producer MTU Aero Engines AG to cut back its masking course of time from 4 hours down to only 14 minutes.
The brand new high-precision, automated arrange has met close to zero tolerance in software, whereas eliminating a listing of hundreds of silicone and metallic components beforehand used as masks.
Up to now, MTU masked its components manually earlier than subjecting them to intense processes corresponding to thermal coating or shot blasting. This concerned affixing adhesive tapes, silicone rings, masks, or metallic covers in a course of that required each time and care. Nonetheless, rising demand and more and more advanced shapes made it difficult for MTU to ship exact and cost-effective short-term safety for delicate part surfaces.
The staff has since mixed robotic arms with Dymax SpeedMask for a fully-automated, high-precision course of, by which the liquid SpeedMask is utilized onto their intricate components after which cured with UV gentle in seconds. As soon as floor therapy is full, SpeedMask might be eliminated with out leaving any residue. In addition to growing pace and lowering manufacturing prices, the brand new software methodology has improved the sustainability of the method by lowering the error fee to almost zero.
“Even with probably the most skilled operators, the handbook software of masking tapes, rings and covers might be tedious and labour-intensive,” defined Matt Baseley, technical gross sales government at Intertronics. “With this usually comes inconsistent outcomes that, for essential and sophisticated components like blisks, can imply the distinction between being airworthy or being scrap.
“SpeedMask presents return on funding predominantly by means of its pace of software and elimination, and the truth that rework arising from leakage or residue round tapes isn’t required,” he added Baseley. “Due to this fact, it not solely saves labour round software and elimination, nevertheless it additionally probably saves a complete step within the course of.
“What MTU have put collectively, between their automated system and their selection of fabric, is basically savvy engineering. It combines a number of best-in-class applied sciences to create one thing that may considerably profit their productiveness for years to come back. Congratulations to MTU for attaining such substantial course of enchancment.”
Dymax SpeedMask Short-term Masking UV Resins can substitute tape, wax, lacquers and fixtures to supply dependable safety in opposition to most metallic ending processing environments. They are often utilized and cured in seconds to cut back labour, remodeling, and scrap. They’re additionally environmentally- and worker-friendly, and straightforward to automate.
The adhesion of SpeedMask resins each seals and protects machined, floor, or polished surfaces throughout tumbling, peening, abrading or cleansing processes. Grinding and peening masks get rid of exterior injury to edges and surfaces and inner cavity overseas object particles (FOD). The resins additionally seal cavity openings and forestall contamination from acid, alkaline and plating options, in addition to the particles from air plasma spray, HVOF, peening and grit blasting.
To attain the tightest tolerances in SpeedMask functions, Intertronics recommends the preeflow eco-PEN or ecoSPRAY for volumetric shelling out or spray valves. These applied sciences are extremely repeatable, have an accuracy of ±1%, >99% of the time, are viscosity unbiased and simply automated.
For extra data go to: https://www.intertronics.co.uk/product/speedmask
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