Tolerance Masters completed the construction of a series of exhaust deflectors, employed by the power generation industry to deflect exhaust within a power generation application. A complex series of machining processes was required in order to successfully manufacture each unit. This twenty step process included numerous CNC live tool turning operations, two 5 axis milling operations, and three special finishing processes: heat treating, passivation, and nickel plating per Mil-DTL-26574 specifications.

We constructed each part using a Greek Ascoloy per AMS5616 base material, a substance that is considered a high temperature grade alloy. Due to the critical nature of this material specification, a material test lab report had to be validated against every certified lot. Moreover, due to the close tolerance dimension of this part, custom designed insert tooling had to be applied in order to successfully form the trepan area and undercut face curve geometry from the flange.

Through the application of over twenty complex machining and finishing processes, Tolerance Masters was able to successfully build a series of exhaust deflectors that could be affectively used by the power generation industry.

CNC Machined Greek Ascoloy Exhaust Deflector for the Power Generation Industry

PROJECT HIGHLIGHTS

Product Description
  • This exhaust deflector is used to deflect exhaust within a power generation application.
Capabilities Applied / Processes
  • CNC Machining
  • Heat Treatment
  • Passivation
Equipment Used to Manufacture Part
  • CNC HARDINGE LATHES & VMC MAZAK 5X VARI-AXIS
Overall Part Dimensions
  • 9″ OUTSIDE DIAMETER, 2.5″ THICKNESS
Tightest Tolerances
  • .002″ FLATNESS ON FLANGE SIDE, .030″ MAX RADIUS IN TREPAN & UNDERCUT GROOVE AREAS
Material Used
  • Greek Ascoloy per AMS5616
  • Used for High Temperature Applications
Max Material Finish
  • TBD
Typical Machining Operations
  • CNC Machining:
  • Turning
  • Two 5 Axis Milling Operations
  • Custom Designed Insert Tooling Used for Close Tolerance Trepan
  • Heat Treatment:
  • Any hardness specs? Rc 38 to 40
  • Finishing:
  • Nickel Plating per Mil-DTL-26574
  • Inspection:
  • Inspection operations – CMM used for final inspections
Industry for Use
  • Power Generation
Delivery Location
  • VARIOUS SITES IN CONTINENTAL USA
Standards Met
  • Material Test Lab Report must be Validated for Every Certified Lot
Product Name
  • Exhaust Deflector