Special processes are critical in the manufacturing of aerospace components, where strict control of material properties, surface conditions and structural integrity is required.
ZRAT is responsible for the provision of controlled capabilities in a number of aerospace special processes. These processes support the production of fluid system components, tubing assemblies and precision-machined parts.
These processes are managed within a certified aerospace quality system and supported by NADCAP accreditation and qualified inspection methods.
Surface treatment processes are utilised for the purpose of enhancing the corrosion resistance, durability and overall performance of aerospace components.
Available processes include:
Aluminum alloy sulfuric acid anodizing
Stainless steel passivation
Chromate conversion treatment
These processes are currently operated under NADCAP accreditation, ensuring compliance with aerospace industry requirements.
Further surface treatment processes are being introduced in a phased manner as part of ongoing expansion of capabilities.
Heat treatment processes are applied to control material strength, hardness and microstructure, ensuring components meet aerospace performance requirements.
Available equipment includes:
Vacuum furnaces
Tempering furnaces
Salt bath furnaces
The processes in question have been designed to support a range of aerospace metallic materials, which are utilised in the machining of various components of tubing systems.
Welding processes are predominantly employed in the fabrication of tubing assemblies and aerospace fluid system components.
Available welding processes include:
Gas tungsten arc welding (GTAW / TIG welding)
CO₂ gas shielded welding
Flame brazing
These processes facilitate the reliable integration of tubing structures and fluid system hardware employed in aerospace applications.
Non-destructive testing is a method of assessing the structural integrity of aerospace components that does not affect their functionality.
Available inspection methods include:
Fluorescent penetrant inspection (FPI)
Magnetic particle inspection (MPI)
These inspection methods are employed in two distinct capacities: firstly, as a means of internal production verification, and secondly, in the provision of external inspection services when such is required.
Special processes are overseen within a regulated manufacturing environment, supported by aerospace quality systems and certification programmes.
Current process capabilities include several NADCAP-accredited operations, and additional certifications are being actively pursued.
Ongoing development plans include the expansion of:
Welding process qualifications
Additional surface treatment technologies
Expanded non-destructive testing capabilities
These developments are conducive to the long-term objective of establishing fully integrated aerospace manufacturing capabilities.
