A leading German aircraft OEM faced stringent requirements for landing gear components—demanding exceptional strength-to-weight ratio, thermal stability above 650°C, and resistance to stress corrosion cracking in high-cycle fatigue environments. To meet these aerospace-grade specifications, the OEM sought a qualified Tier-2 supplier capable of delivering precision near-net-shape forgings in nickel-based superalloys. Our forging facility in Shandong Province was selected following rigorous AS9100 Rev D audit and material traceability validation. The project involved annual supply of 42–68 kg unit-weight Inconel 718 forgings across three critical landing gear subassemblies, with total program volume exceeding 12 tons per year.
The primary technical challenges centered on metallurgical integrity and dimensional fidelity. Inconel 718’s high work-hardening rate and narrow hot-working temperature window (950–1050°C) made conventional open-die forging prone to surface cracking and inconsistent grain flow. Additionally, the component geometry featured thin-walled sections (as low as 8.2 mm), deep internal cavities, and tight ±0.15 mm tolerances on critical bearing surfaces—requirements far exceeding standard ISO 8062 Class CT4 allowances. Thermal distortion during solution heat treatment further threatened final part conformity. Supply chain resilience was also critical: the OEM mandated dual-source capability, full batch-level PMI (Positive Material Identification), and real-time NDT reporting via EN 462-2 compliant radiography and ultrasonic testing.
We deployed a vertically integrated process combining closed-die isothermal forging, controlled-cooling post-forging heat treatment, and CNC finish-machining with in-process metrology. A custom-designed Ni-based die material (H13 + 5% Mo coating) enabled stable tool life over 1,200 cycles while maintaining die cavity accuracy. Forging was performed at 985°C ±5°C under 12,500-ton hydraulic press with real-time strain-rate monitoring to suppress dynamic recrystallization anomalies. Each billet underwent triple-melt VIM-ESR-VAR processing to ensure ultra-low sulfur (<0.002%) and hydrogen (<1.5 ppm) content. Post-forging, parts underwent vacuum solution annealing at 980°C followed by rapid water quenching and double aging (720°C/8h + 620°C/8h) to optimize γ' precipitate distribution. All forgings were certified to AMS 5662 and EN 10269 standards, with full traceability from ingot heat number to final inspection report.
Project execution followed a phased APQP framework: Phase 1 included FEA simulation of die fill and thermal stress mapping using DEFORM-3D; Phase 2 involved pilot runs with 100% 100% UT scanning and metallographic cross-sectioning to validate grain orientation (ASTM E112). Phase 3 scaled to full production with automated optical CMM verification of 28 GD&T features per part. We implemented an ERP-integrated quality module enabling real-time SPC charting of hardness (32–36 HRC), tensile strength (≥1300 MPa), and elongation (≥12%). Logistics were synchronized with the OEM’s JIT schedule via EDI 856 ASN, with climate-controlled air freight packaging meeting IATA Packing Instruction 950.
The partnership delivered measurable performance gains: first-pass yield improved from 71% to 96.4% within six months; average lead time reduced from 14 to 8.5 weeks; and scrap rate dropped below 0.8%, well under the OEM’s 2.5% contractual threshold. Most critically, all 1,842 delivered forgings passed 100% non-destructive evaluation with zero field failures over 36 months of service on A320neo and A350 XWB platforms. The customer reported a 17% reduction in downstream machining time due to superior near-net geometry, contributing directly to their landing gear assembly line efficiency. This success established our facility as a qualified supplier for Rolls-Royce and Safran under the European Aerospace Qualification System (EAQS).
‘Their mastery of Inconel 718 thermomechanical processing—combined with uncompromising documentation discipline—made them the only non-EU supplier we approved for safety-critical landing gear forgings,’ stated the OEM’s Head of Supplier Technical Development. Beyond immediate delivery, this project catalyzed long-term collaboration on next-generation GH4169 variants for hypersonic vehicle applications. It also validated our capability to serve the European aviation market under strict EASA Part 21G and EU Regulation (EU) 2018/1139 compliance frameworks—solidifying our position as a trusted nickel alloy forging partner for aerospace Tier-1s across Germany, France, and the UK.
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