Two precision metal parts, Inner Cone and Contact Spring, for a Defense Manufacturer have similar forms as well as features. A detailed inspection process is required throughout production to deliver high-quality parts with zero defects.
- A progressive metal stamping die draws the .0150 thick beryllium copper to the designed form. This material is one of the highest strength copper-based alloys available.
- The parts are washed to ensure they are oil-free.
- Vacuum heat treating removes trapped air and reactive elements to create a cleaner surface and prevent oxidation.
- A detailed AQL inspection is performed by Ultra after heat treating.
- Electroless nickel plating is then completed. This technique applies the coating more uniformly and provides greater corrosion resistance.
- AQL inspection is performed by Ultra technicians after the plating is completed.
- The high-frequency vibrations of the sonic welder melt together a ring and washer onto the inner cone and contact spring. This method creates a more precise and stronger weld.
- Another AQL inspection is then completed by Ultra after the welding process.
- A thin rubber insulating compound is applied to specific surface areas of these two parts to better localize the electricity.
- A final AQL inspection is performed by our technicians before packaging and delivery.
Customer Outcome
- Ultra identified an efficient and cost-effective manufacturing process that met the part’s rigorous quality standards.
- The customer relied on Ultra to properly select certified suppliers.
- Ultra’s project management ensures that stamping, supplier services, and inspections are completed on time to meet delivery dates.
