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Assembly of Weldment for the Industrial Strength Networking Industry

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Assembly of Weldment for the Industrial Strength Networking Industry
Assembly of Weldment for the Industrial Strength Networking Industry
When the United States military approached McAlpin Industries about designing and building a rugged aluminum weldment capable of housing an industrial-strength network application, we knew we were a company that was fit, willing, and able to accomplish the task at hand. After consulting the customer-supplied prints as well as our own 3D math models, we got swiftly to work for Uncle Sam.

Our integrated DFM (design for manufacturing) process involved four essential phases: machining, metal fabrication, welding, and assembly. Using an 11” extrusion press, we quickly formed basic internals of the aluminum (both 6061-T6 and 6061-T4). Next, we got going with a CNC turret laser to minutely fabricate the interior details of the main structure. After tack welding, MIG welding using a custom-fabricated feature, TIG welding, and grinding, we were ready to get down to the nitty-grit: actual assembly of the weldment.

Using automated hardware insertion systems to apply silicone sealant (as per the customer spec), as well as instilling the necessary threads with LocTite, riveting, and PEM insertion, we came up with a final weldment with overall dimensions of 29.375” length, 22.500” width, and 18.875” height. Tightest tolerances were honed to a pinpoint accuracy of ±.0015”. After a finishing process that included black anodizing, black powder coating, matte black painting, and silkscreening, we were ready to turn out the 30 units as requested with maximum efficiency and excellent turnaround time.

Project Highlights

Product Description This Weldment was assembled for use within an Industrial Strength Military Network application
Capabilities Applied/Processes Integrated DFM (Design for Manufacturing)
  • Machining of Extrusions in Vertical CNC Machining Centers
Metal Fabrication
  • Turret/Laser internal Details
  • Tack Welding
  • MIG Welding Using Custom Fabricated Fixture
  • TIG Welding
  • Grind
  • Assemble Using Mechanical Fasteners
  • Apply Silicone Sealant As Per Print
  • Apply LocTite to Necessary Threads
  • Press Fit Bushings
  • Riveting
  • PEM Insertion
Equipment Used to Manufacture Part 11” Extrusion Press
CNC Machining Centers
CNC Combination Turret Laser
GTAW (TIG) and GMAW (MIG) Welding Systems
Automated Hardware Insertion Systems
Automated Powder Coat Line
Overall Part Dimensions Length: 29.375”
Width: 22.500”
Height: 18.875”
Material Used Aluminum (6061-T6 and 6061-T4)
Tightest Tolerances ±.0015”
Finish Black Anodize
Black Powder Coating
Matte Black Paint
Inspection Performed In Process Inspection
1st Article Inspection
Industry for Use Industrial Computer Network
Quantity 30
Standards Met Customer supplied prints, 3D Math Models
Product Name Rugged Enclosure