CNC Machining of Aerospace-Grade Alloys

Future of CNC Machining in Aerospace

• Digital Twin Integration: Simulating machining processes before production.

• AI-Driven Optimization: Predictive maintenance and real-time feed adjustments.

• Hybrid Manufacturing: Combining 3D printing and CNC in a single workflow.

sasaalloy is at the forefront of these innovations, delivering high-performance components for aerospace manufacturers worldwide.

Conclusion

CNC machining plays a critical role in producing reliable, lightweight, and high-strength aerospace components from cutting-edge alloys. While the process can be challenging due to material hardness and tight tolerances, modern CNC technology—when paired with expert knowledge—enables efficient and precise manufacturing.

At sasaalloy, we specialize in CNC machining of titanium, aluminum, Inconel, and specialty alloys for demanding aerospace applications. With certified processes, state-of-the-art equipment, and a commitment to excellence, we help clients achieve the perfect balance of strength, performance, and compliance.

Contact sasaalloy today to discuss your CNC machining project, and let our technical team help you bring your aerospace components to life with unmatched precision.

In the aerospace industry, precision, strength, and reliability are not just desirable—they’re essential. Components must perform flawlessly in extreme environments, under high loads, and with minimal weight. That’s why aerospace-grade alloys, including titanium, aluminum, nickel-based superalloys, and specialty steels, are the materials of choice. But working with these advanced materials requires cutting-edge manufacturing methods, and that’s where CNC machining comes in.

In this article presented by sasaalloy, we explore the significance of CNC machining in the aerospace industry, the challenges of machining aerospace-grade alloys, key best practices, and how to achieve optimal performance with tight tolerances and complex geometries.

What Are Aerospace-Grade Alloys?

Aerospace-grade alloys are engineered materials designed to meet the rigorous requirements of flight and space travel. These alloys offer:

• High strength-to-weight ratio

• Excellent fatigue resistance

• Corrosion and heat resistance

• Tight dimensional stability

Common Aerospace Alloys:

• Titanium alloys (e.g., Ti-6Al-4V)

• Aluminum alloys (e.g., 7075, 2024)

• Nickel-based superalloys (e.g., Inconel 718, Hastelloy X)

• Stainless steels (e.g., 17-4PH, 15-5PH)

• Cobalt-chromium alloys

These materials are widely used in airframes, engine components, landing gear, structural assemblies, and even interior cabin systems.

Why CNC Machining Is Crucial for Aerospace

CNC (Computer Numerical Control) machining offers the precision, repeatability, and flexibility needed to turn high-strength alloys into flight-critical parts. The aerospace sector demands:

• Tight tolerances (often within ±0.001 mm)

• Complex 3D geometries

• High surface finish

• Batch-to-batch consistency

CNC machines—especially 5-axis and multi-tasking centers—enable the creation of intricate aerospace parts such as turbine blades, brackets, housings, fasteners, and structural fittings.

Challenges in CNC Machining Aerospace Alloys

1. Material Hardness and Toughness

Titanium and Inconel are notoriously difficult to machine due to their:

• Low thermal conductivity

• High strength at elevated temperatures

• Work-hardening properties

Solution: Use sharp, coated carbide tools and minimize tool dwell time.

2. Heat Generation

Excessive heat during cutting can degrade tool life and part integrity.

Solution: Apply flood coolant or high-pressure coolant systems. For heat-sensitive alloys, consider cryogenic machining.

3. Tool Wear

High alloy content causes rapid tool abrasion.

Solution: Use wear-resistant coatings like TiAlN or diamond-like carbon (DLC), and schedule frequent tool changes.

4. Chatter and Vibration

Vibrations can affect surface finish and dimensional accuracy, especially with thin-wall aerospace components.

Solution: Implement rigid workholding, minimize overhang, and optimize spindle speed and feed rates.

CNC Machining Processes for Aerospace Alloys

● Milling

Ideal for creating slots, pockets, and complex contours in wing sections and engine casings.

● Turning

Used for shafts, rods, and fasteners in landing gear and control mechanisms.

● Drilling and Boring

Creates accurate holes for fasteners, rivets, or passageways in fluid systems.

● EDM (Electrical Discharge Machining)

Best for extremely hard materials and precise internal features.

● 5-Axis Machining

Allows simultaneous movement across five axes, enabling production of complex 3D shapes in fewer setups.

CNC Machining Standards in Aerospace

CNC machining for aerospace is governed by strict quality and documentation standards, including:

• AS9100 / ISO 9001 – Quality management systems for aerospace

• NADCAP – Certification for special aerospace processes

• FAA, EASA, and DoD – Industry-specific regulations and documentation

At sasaalloy, all CNC machined aerospace components are manufactured under certified processes to ensure traceability, quality control, and compliance with international standards.

Best Practices for CNC Machining Aerospace Alloys

1. Use Optimized Tool Paths

Advanced CAM software helps reduce air cutting, improve tool engagement, and prevent collisions in 5-axis operations.

2. Select the Right Tooling

Use high-performance tooling designed specifically for titanium or nickel alloys, with proper geometry and chip evacuation design.

3. Maintain Stable Workholding

Use custom fixtures, vacuum chucks, or hydraulic clamps to minimize vibration and ensure part accuracy.

4. Apply Coolant Intelligently

High-pressure or cryogenic cooling extends tool life and improves surface finish on heat-resistant alloys.

5. Inspect and Measure Continuously

Use in-process probing and coordinate measuring machines (CMMs) for dimensional validation.

CNC Machining vs Additive Manufacturing in Aerospace

While 3D printing (additive manufacturing) is gaining popularity, CNC machining still offers: