Manufacturing |
Senior Aerospace Metal Bellows provides diverse engineering and manufacturing resources to design and build unique metal bellows assemblies and metal joining solutions. We are vertically integrated with all engineering |
disciplines and manufacturing processes in-house. Sophisticated engineering tools including FEA and 3D Solid modeling are utilized to support challenging applications. |
| Laser welding is performed on our PRC STS 1800 watt Class 4 Laser Welding Station. |   |
| The engineering test lab includes | |
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| The high power electron beam welder is used for large diameter full penetration structural welding. Examples of welding on this machine include full penetration closure welds on accumulators and reservoirs or structural welds on higher level assemblies. |  |
| A metallurgical laboratory is maintained at this facility and is staffed by 2 full time metallurgists as well as a staff of technicians. Weld samples are taken and examined at the beginning of every welding workstation set-up to ensure the integrity of the welds. |  |
| The low power electron beam welder is used for small diameter low penetration sealing and welding requirements. This is ideal for sealing evacuated bellows assemblies. |  |
- 3-D Solid modeling
- Bellows device design & analysis
- Pressure vessel design & analysis
- Finite element structural analysis
- Accumulator and reservoir sizing
- Complex real gas analysis
- Compressible and incompressible fluids analysis
- Development, qualification, and acceptance testing/reports
| Our pump assembly area supports manufacturing for our aircraft potable water system compressors, as well as our industrial bellows compressors and vacuum pumps. | |
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All welders are trained and certified per Senior Operations procedure ES-1025 for special application welds in accordance with AWS D17.1. Certification is by function, material type and thickness. This ensures that only qualified operators perform critical functions and ensures that certified operators maintain proficiency as appropriate. Customers may also specify additional certification programs on an application-by-application basis. Stand-alone certification can be provided for critical functions or processes if needed.
Inside Diameter (ID) WeldingWe operate thirty-eight fully functional ID welding stations. All machines are maintained to standard specifications; this allows us to route work to the optimum work stations as appropriate. Inside diameter welding is achieved on tightly toleranced, semi-automated equipment with part and operation specific tooling. Outside Diameter (OD) WeldingThirty-four OD stations are maintained on a similar basis as the ID machines. These are specialty machines that incorporate precise lathe bed control and Weld Logic power units. Leak DetectionWith 10 helium mass spectrometer leak check machines on site we check all components for compliance to the specified maximum leakage levels with a capability of 1x1010 STD cc He/sec. All bellows capsule welds and assembly welds are checked. |
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| We maintain complete product testing facilities for all aspects of product conformity. Maintaining functional test verification according to required acceptance test criteria consists of mechanical and dimensional verification with electromechanical capabilities designed and maintained for individual applications. We also maintain complete destructive cycle, proof pressure and burst test facilities; certified non-destructive dye penetrate testing capabilities; and an environmental test chamber including digital programming and readout from -73C to +177C. |   |
| Our machine shop includes 9 lathes, 3 milling machines, and 1 turning center. We manufacture and maintain all the precision tooling required to build our products. We also do machining for prototype activities as well as limited production. A large production machining capacity is maintained in a certified vendor base to service long-term production needs. |
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| In house Nadcap certified heat treatment and vacuum furnace brazing capabilities (per MIL-H-6875 and MIL-B-7883) are maintained for use in the manufacture of bellows and related assemblies. We operate a total of 3 vacuum furnaces. We have pyrometric measurement capability per AMS 2750 Rev D. |  |
| Our cleaning room houses two new lines installed in early 2009. This includes two 14-station automated precision cleaning system designed to remove organic and inorganic contamination from metal surfaces. The system uses fully aqueous chemistry and state-of-the-art agitation to produce ultra-clean surfaces. High purity deionized rinse water with a minimum resistivity of 0.5 Mohm•cm and high efficiency dryers assure complete spot free drying. |   |
 Production presses from 25 to 1200 tons of both the mechanical and hydraulic configurations are maintained in an active production press department. Essential to the manufacture of welded metal bellows is specialized forming equipment. Our approach is to utilize a metal on rubber formingprocess that yields precision diaphragms with tightly controlled  geometry. Metal on metal forging processes are also utilized to produce a variety of consumable tools utilized in the manufacturing process. |