What quality control measures are used to inspect brake system accessories made from superalloys?

Material Verification and Chemical Analysis

Quality control begins with confirming alloy composition. Advanced material testing and analysis ensures that elements such as Ni, Co, Cr, Mo, and W meet specification ranges. This prevents performance deviation in high-stress braking environments. For powder metallurgy alloys such as FGH97, particle size distribution and oxygen content are carefully monitored to guarantee fatigue performance.

Dimensional Inspection and Tolerance Validation

Superalloy brake accessories require strict dimensional accuracy to ensure sealing, alignment, and mechanical fit during high-load braking. CMM measurements, laser scanning, and functional gauging are commonly used. Final shaping is achieved through precision superalloy CNC machining, ensuring assembly compatibility in aerospace and automotive applications.

Defect Detection and Structural Soundness

Internal porosity and microcracks can significantly reduce braking reliability. Post-casting or AM components are inspected using X-ray scanning, ultrasonic testing, and penetrant inspection. If necessary, consolidation methods like hot isostatic pressing (HIP) are applied to close defects and improve fatigue strength, especially in rotating or high-stress elements.

Surface and Wear Resistance Evaluation

Components subjected to sliding friction or high surface pressure must be tested for wear and corrosion resistance. Hardness testing, tribology evaluation, and salt spray testing are used to simulate real service conditions. For extreme heat zones, protective layers such as thermal barrier coating (TBC) are checked for adhesion, thickness, and uniform coverage.

Regulatory and Industry Validation

Brake components used in aerospace, marine, and defense applications must meet strict regulations. Full certification procedures are implemented to comply with standards within the aerospace and aviation and military and defense industries. Non-destructive evaluation, fatigue testing, and traceability documentation ensure safe and repeatable performance across all batches.