Complex Manufacturing
From mechanical benchtop assembly and testing and qualification to the integration of electrical system interfaces, it all comes together at Ferra.
As a full-service partner to the most complex projects, Ferra’s assembly process incorporates:
- Bearing installation, bearing swaging, roller swaging, bearing staking, anvil staking, ball staking, proof-loading and testing.
- Bushing installation, sizing, press-fit and shrink fit.
- Lee plug installation.
- Helicoil & Kato inserts, Keensert, Rosan Fittings and threaded fastener installation.
- Riveting (cherry max, cherry lock, blind rivets).
- Mechanical and sub-assemblies (nutplates, huckbolts, lockbolts, clinch nuts, Hi-Lok, Hi-Shear).
- Lanyards and lockwire/safety wire assemblies.
- Fatigue Technologies – Cold work.
- Electrical assembly (crimping, soldering, potting), harness assembly, wire & cable assembly.
- Ground stud installation, torquing and electrical bond testing.
- Cable swaging and pull testing.
- Certified Clickbond installation and testing to CBPS206 & CBPS207 plus LMA-PK004A.
- Primers, Sealant, Loctite, Silicone and Adhesive sealing to all Aerospace Specifications.
Advanced Assembly Project
MH-60 Pylons, Mission Kit, and Gun Mount
Ferra supplies the LH and RH Extended Pylons and Mission Kit in support of the MH-60 Romeo program.
The LHEP and RHEP are attached to the helicopter fuselage and provide stowage for the weapon systems. The Mission Kit is assembled to the forward mount point of the helicopter for location of the FLIR system. There are approximately 1,250 machined parts, sheet-metal detail and sub-assembly parts, electrical harnesses, and standard hardware involved in the production of these complex structural assemblies. These components are brought together into a purpose-built assembly jig for each higher-level assembly that validates no fewer than 15 bank points to less than 0.010” positional tolerance in relation to aircraft locations.
This contract includes the acceptance test and qualification of the final assembly and integrated harnesses for fit and Hi-Pot continuity. Full acceptance and test requirements and SDRLs are included in this program together with source buy-off through delegated DCMA representatives.
The Pylons and Mission Kit assemblies and are subject to full batch traceability, customer approved manufacturing plans and serial number traceability. Serial number traceability is managed through our MRP system (SAP) and involves the use of physical barcodes on each of the LH and RH Extended Pylons
