Achieving a significant improvement in the workpiece surface finish as well as a longer-lasting bur.
A leading industrial gas turbine MRO service provider in South East Asia contacted ATA for help in recommending an alternative bur solution to improve productivity and reduce their consumption of burs.
There is a high cost associated with the repair of the turbine blades so improvements to the process to lessen this cost was imperative for the company to remain competitive.
The specific application involved the repair of large nickel alloy turbine blades and the removal of weld from the component which required heavy stock removal but needed to have a fine surface finish.
Deburring inside air foil cooling blades during the post laser clad machining process.
The specific application involved the repair of and removal of weld on large nickel alloy turbine blades, which required heavy stock removal but needed to have a fine surface finish.
The company had been using a range of Single Cut burs provided from their region for many years but were experiencing very fast wear on the burs and a lot of clogging in the teeth. This meant that the finishing time on the components was slow and operators were experiencing a lot of downtime from changing burs.
ATA worked closely with the company, trialing a number of bur cuts to ensure the optimum solution was found.
Following conclusive results, ATA recommended a combination of our aggressive ATA Cut 5 (Foundry Cut) bur which is designed for heavy deburring to remove non-ferrous metals, along with our high-quality ATA Single Cut (Cut 2) bur to achieve a fine finish.
Using the Cut 5 to remove material and clean a large turbine blade.
When implemented into their operating process, the customer reported that the ATA Cut 5 removed the material much faster and improved their overall speed, quality, and productivity thanks to the efficiency delivered by the aggressive geometry design and reduced clogging of the teeth.
By replacing their problematic Cut 2 bur with the higher quality ATA Cut 2, the customer reported a significant improvement in the workpiece surface finish as well as a longer-lasting bur which had the additional benefit of reducing the overall quantity of burs used.
Photos showing the chipping and wear that the customer experienced with the competitors Cut 2 bur, compared to the undamaged ATA Cut 2 after testing.