Manufacturing Metal Aircraft Parts
The aerospace industry is considered one of the most complex and precisefields of engineering inthe world.In this industry,metal aircraft parts hold a
special position, and it can be said that without these parts, safe and reliable flight would not be possible. Manufacturing metal aircraft parts requires
strict adherence to standards , use of advanced technologies , and multi – layered quality control . This article reviews the process , importance , and
challenges of producing these parts.
Role of Metal Parts in Aircraft
Although the use of composite materials in aircraft manufacturing is expanding today, a large portion of the main structure of the aircraft— including
the fuselage, wings, landing gear, spars, engine mounts,and key connections—is still made from metals.Aluminum alloys,due to their lightweight and
good corrosion resistance , are the most widely used metals in the aerospace industry . In parts requiring very high thermal or mechanical strength,
special steels, titanium, and even superalloys are used.
Stages of Manufacturing Metal Aircraft Parts
Material Selection:
For each part, the appropriate alloy is selected according to the type of load and working environment.7000-series aluminums (like 7075)are common
in load-bearing structures, alloy steels in landing gear, and titanium in parts near the engine.
Initial Cutting and Shaping:
Metal sheets, billets, or rods are first cut precisely to form the initial shape of the part. This is done with special saws or CNC machines.
Mechanical Forming:
In this stage,processes such as rolling, bending, stamping,or extrusion bring the part closerto its final geometric shape.Deep drawing and roll forming
are widely used in wing and fuselage manufacturing.
Precision Machining:
After initial forming, the part is mounted on 5-axis or more CNC machines to create holes , threads , pockets , and other precise geometric features.
Tolerances in these operations are sometimes within a few microns.
Heat Treatment:
Many aerospace alloys require heat treatments such as annealing, quenching, and tempering to achieve the necessary strength and toughness. This
must be performed according to precise charts and instructions.
Surface Finishing and Testing:
Some parts are polished after machining or coated with corrosion-resistant and wear – resistant layers (such as anodizing, chrome, or nickel plating).
Quality Control and Non-Destructive Testing (NDT):
Each part undergoes precise dimensional inspections and NDT tests (such as penetrant liquids , magnetic particles , or ultrasonic testing) before
delivery to the assembly line.
Challenges of Manufacturing Metal Aircraft Parts
Extremely Tight Tolerances:
In aircraft manufacturing , the smallest dimensional error can cause unwanted stresses and reduce the part’s lifespan . Therefore , both machines
and human operators must work with the highest level of precision.
Sensitivity to Micro-Cracks:
Microscopic cracks in metals can grow under flight cycles (pressure and temperature changes) and lead to sudden failure . Therefore , NDT tests
and complete documentation of each part’s history are vital.
High Cost of Materials and Production:
Special alloys like titanium are very expensive. Additionally, machining these materials is time – consuming and costly due to their hardness.
Iran’s Move Toward Self-Sufficiency in This Field
In past decades, many metal parts used in Iran’s air fleet were imported . However , thanks to the efforts of knowledge- based companies and
domestic factories, today a significant portion of these parts is produced domestically . Equipping advanced CNC lines , achieving controlled heat
treatment processes, and successfully performing NDT tests according to international standards are among the major achievements in this
field. Moreover, in some military and drone projects , production of parts with special alloys and complex designs has also been realized,
marking a significant step toward localization.
Final Remarks
Manufacturing metal aircraft parts is not just about making a simple metal piece; it is a combination of materials science , mechanical engineering
, quality control, and strict aerospace standards. Continued investment in this field will help Iran reduce its dependency on imports and potentially
increase its share in the global aerospace supply chain in the future . Ultimately , this trend can transform the country’s industrial infrastructure
and create new export opportunities.
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