A formed and welded TC4 bracket provided a structural mounting interface for an aerospace application.
The customer’s challenge
Weld distortion and residual stress made dimensions unstable, while fatigue performance needed improvement.
Material and fabrication route
1.5 mm TC4 titanium.
Process route: Laser cutting → hot forming → TIG welding → pickling → vacuum annealing → nondestructive testing → inspection.
Manufacturing changes
Fixture-controlled welding, post-weld vacuum annealing, shot peening and coordinate measurement addressed the combined requirements.
Engineering analysis
Distortion and residual stress were separate concerns in this welded titanium bracket. A part could match the drawing immediately after welding yet still need the specified post-weld treatment before final dimensional release. The recorded route therefore connects fixture control, annealing, surface treatment and inspection. The fatigue result belongs to the tested bracket configuration, not to all TC4 sheet parts.
Inspection and project results
The project reached weld distortion ≤0.15 mm and the stated fatigue result, with complete X-ray and penetrant inspection.
| Project measurement or production detail | Recorded value |
|---|---|
| Weld distortion | ≤0.15 mm |
| Fatigue test | ≥1,000,000 cycles |
| X-ray and penetrant inspection | 100% |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Bracket drawing and datum scheme.
- Weld and heat-treatment requirements.
- Load case and fatigue acceptance.
- Nondestructive inspection scope.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Aerospace Bracket and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
