Digitalization presents both challenges and opportunities for the aerospace and defense manufacturing industry. Challenges include understanding how to select the most efficient and effective 3D-measurement technology for each process and integrating the data for meaningful insight and analysis. This requires diversifying with the best metrology toolbox, combining the collected data, and sharing the insights through intelligent software.
A successful digitalization strategy involves using the right technologies to accurately digitize and connect the design, engineering, manufacturing, and production processes. The opportunities brought by digitalization include leveraging data to generate more valuable insights, improve decision-making, and reduce manufacturing costs, according to research by Accenture.
However, the research also found that nearly 74 percent of aerospace and defense executives feel overwhelmed by the amount of available data.
With no one-size-fits-all metrology solution for A&D manufacturing, metrology technology contributes to this stockpile of data. Different metrology solutions are needed for different purposes, which often means A&D manufacturers are collecting data from various technologies and applications, leading to inconsistent data file formatting, making it difficult to receive data output results that are compatible in downstream applications. Poor data quality also adds to the challenge, making it hard to tell a cohesive story of what is happening with a part or process.
So, how do A&D manufacturers achieve digitalization? This critical strategy requires investing in proven 3D-measurement technology from blue-light 3D scanners, coordinate measuring machines (CMMs), computed tomography (CT) scanners, and other tools to feed data into a compatible software ecosystem.
Accurate, high-quality data ensure process integrity and repeatability. The first step is determining the right metrology solution for a specific application. Every technology has its own features and advantages. The process, application, timing, and required outcome dictate which tool will achieve the necessary results.
CMMs, long a staple within manufacturing, have been continuously modernized to meet the increasing demands of the industry. Established CMMs can provide accuracy with repeatable results by collecting X-Y-Z coordinate points where the probe contacts the surface. There are CMMs in the market achievable of less than one micrometer in accuracy and are a reliable method of confirming dimensional specifications for the particularly tight tolerances of critical aerospace turbine engine components. The programming time varies depending on part geometry, but once the measurement routine is created, measurements are fast, precise, and repeatable. CMMs can measure parts ranging from small turbine blades to large aerospace parts.
CT scanners, which use X-ray technology, are the right choice for A&D processes requiring the ability to completely digitize internal and external geometries. This capability is crucial for nondestructive testing that prevents unintended damage to a part. While the large amount of data this metrology tool collects makes it slower than others and is somewhat limited to part size and density, rendering it less than ideal for production, there are many other key applications where utilizing a CT solution is advantageous.
For example, the high-temperature blades of modern gas turbines require an advanced ceramic core and superalloy investment casting to optimize the blades’ cooling, performance, and durability. These low-flow ceramic cores have complex design features, such as multi-walls. The dimensions of these internal walls cannot be inspected with metrology technology that strictly collects surface data. CT technology for metrology offers a nondestructive method of collecting critical internal measurement and quality data from such areas. 3D metrology software then uses that data to accurately calculate interior wall thicknesses, radial heights, and cooling flow passage diameters.
Meanwhile, accurate blue-light 3D scanners are ideal for fast and precise full surface 3D digitalization of parts ranging from small to very large, including a full-size aircraft. Although this technology is limited to line of sight, full exterior surface digitalization is quickly captured in a high-resolution point cloud.
Digitalizing key aerospace components such as blisks enables faster and more efficient measurement and analysis by allowing the user to inspect data from a single blade and use intelligent 3D metrology software to automatically apply the inspection on every blade of the blisk until the analysis is complete. Measurement and analysis of guide vanes and drums can be completed with the same efficiency for significant time savings.
Digitalization also provides opportunities to update antiquated inspection processes, including traditional coating thickness measurement, that require the destruction of high-value parts, such as turbine blades. Digitalizing this process saves time and money, and the resulting data create a digital record of the part’s validation that accompanies it throughout its lifecycle.
With full surface 3D digitalization, A&D manufacturers also get an accurate geometric digital twin of their physical parts, opening opportunities to do more with their data. One digital twin application driven by 3D measurement data is digital assembly, which enables A&D manufacturers to simulate, predict, optimize, and verify the assembly and fit of parts before investing in the production and distribution of physical components. Measurements occurring at various vendor locations can be used in digital assembly to ensure proper fit and determine other production details, saving time usually lost to iteration.
After determining the best metrology tool to streamline data acquisition and achieve the desired results, the next step in the digital transformation process is combining data into a singular digital workspace for visualization and analysis within a software ecosystem.
A&D manufacturers use CMMs, CT scanners, and blue light 3D scanners for quality analysis, generally depending on the inspection requirements set forth by OEMs. Whether the goal is to measure individual parts or an entire aircraft, inspecting, analyzing, and reporting within the same software ecosystem enhances the generated insights. Combining data from multiple parts and different measurement systems into a singular reporting software generates one customizable report to tell a complete story about what is happening with each part and process. With this solution for quality data management, the information flow is organized as it travels through the supply chain, enhancing product quality and process efficiency.
Comprehensive data coming from multiple metrology perspectives allow manufacturers to remotely assemble parts and components, validating the design and simulating the finished product before incurring costs. This advantage is critical for A&D’s network of OEMs and suppliers that exchange numerous specifications for various parts and components that must fit upon assembly to avoid rework, delays and wasted production time.
Combining data from diverse metrology tools into a single software ecosystem enables the instantaneous sharing of measurement result information across machines, as well as nearby or remote plants around the world. The solution of what to do with all the data available from metrology technology is not to feel overwhelmed by it, but to understand which technology fits the application to collect accurate and repeatable data and then unify the data in a standardized space to establish data connectivity that ignites digitalization in a seamless workflow.
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