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A client in a cutting-edge technology sector approached us with an exceptionally demanding project: machining a set of critical components (BasePlate, ConcavePlate, CoverPlate, and Internal Frame) from a rare and expensive exotic alloy – 1J22.
This project not only involves high-value materials but also demands exceptional precision and reliability, presenting a significant challenge for manufacturing team. Let’s explore how Xmake rose to the occasion and delivered this critical project flawlessly.
1J22 is a high-performance iron-cobalt alloy with nearly half cobalt content. It offers extremely high magnetic induction and stable performance under strong magnetic fields, making it widely used in aerospace motors, generators, and precision electromagnetic devices. Due to its rare composition and processing difficulty, its price is often five to ten times higher than ordinary steel.
High Risk, Zero Margin for Error
When we took on this project, the risks were clear from the very beginning. The raw material—1J22—costs more than 20 times that of standard aluminum alloys. On top of that, its unique physical properties made machining far more demanding than conventional alloys.
In such conditions, there is no margin for error. A single scrapped part could mean not only substantial financial losses but also critical delays in the customer’s R&D progress.
Faced with the client’s strict zero-defect requirement, our engineering team rose to the challenge, swiftly providing machining solutions and maintaining close communication to drive part production forward.
Leveraging Rare Expertise to Mitigate Risk
While many machine shops would hesitate, our prior experience with 1J22 gave us the confidence to accept the challenge. We leveraged our hard-won knowledge to deploy a meticulous, risk-averse strategy:
Targeted Cutting Strategy: We selected specialized cutting tools and optimized feeds, speeds, and cooling strategies specifically for 1J22’s properties to ensure clean cuts and avoid work hardening.
Enhanced Quality Inspection: We implemented additional in-process inspection checkpoints after every critical machining step to immediately identify and correct any potential deviation.
Resourceful Material Management: Our CNC programmers optimized the nesting and toolpaths to maximize material yield from every expensive blank, minimizing waste.
Flawless Execution Fosters Strategic Partnership
Through disciplined execution and our specialized expertise, we successfully machined all components to exact specifications without a single scrap part. We delivered the complete set of high-value parts on time, enabling our client’s project to move forward without costly delays or setbacks.
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