Ferra produces complex sub systems and sub-assemblies for the aerospace and defense sectors. As part of our advanced manufacturing processes, we apply new technologies and innovative practises to assemble, integrate, test and qualify large aerostructures and electro-mechanical products for our valued partners.
As a full-service partner to the most complex projects, Ferra’s advanced 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 Click bond installation and testing to CBPS206 & CBPS207 plus LMA-PK004A
- Primers, Sealant, Loctite, Silicone and Adhesive sealing to all Aerospace Specifications
Our test capabilities include:
- Balance testing
- Hydraulic and mechanical testing
- Functional testing
- HIPOT testing
- Proprietary acceptance test
Project showcase
Joint Strike Fighter Alternate Mission Equipment (AME) Weapon Adapters
Ferra has been appointed as the sole source supplier of Alternate Mission Equipment (AME) Weapon adapters in support of the JSF F-35 program. This is a 30-year project worth approximately $1.1 billion dollars based on current forecasts.
The adapters secure the weapons to the aircraft. Six different variants of adapters include aluminum and PH 13-8 MO stainless steel versions. The adapters range in size up to 6.0 x 12.0 x 60.0”, and require a detailed manufacturing process consisting of a multi-level route and bill of material including multiple machining operations, heat treatment (to 48 Rockwell), surface treatment (etch, penetrant inspection, passivation, prime and top coat), CMM inspection and final mechanical assembly (bushings, bolts, nuts, bearings, rivets, clamps and clips).
Ferra provides the full test and qualification of the components for vibration and acoustics. Full acceptance and test requirements and SDRLs are also included in this program.
AME Weapon adapters are safety critical items 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 component.
Ferra has displayed world’s best practice on this project including delivery and quality performance in excess of 99%. We have conducted and submitted annual performance readiness reviews on this program and have been maintained as a sole source supplier with our customer.
