TextureJet publishes new research on the repeatability of its edge treatments

TextureJet has completed an extensive research project into the repeatability of edge break treatments on nickel superalloy using its electrochemical jet machining technology.

TextureJet’s Stat technology was already proven to achieve higher quality edge finishing in a White Paper published in 2024. This result was achieved through increased repeatability and precision compared to the current methods utilised in edge finishing of aerospace components.

The new research shows that compared to manual brush deburring, TextureJet achieves four times more precision and, compared to automated brush deburring, it achieves nearly two times more precision.

For precision component manufacturers this means better control for the edge profile created, which will improve the quality of the products processed.

The research demonstrates how TextureJet’s electrochemical jet machining technology offers distinct advantages in terms of safety, sustainability and repeatability compared to current methods in edge finishing.

The results show that TextureJet’s Stat process, utilising an automated delivery system, consistently achieves edge break results well within aerospace specifications and demonstrates the scalability of creating a wide range of different radii to suit exacting part specification.

The technology can lead to significant savings due to reduction in both reprocessing and scrappage experienced with current methods.

Edge finishing for metal components can include edge rounding and edge breaking, which are techniques that can be used to make the edges of metal sheets look attractive, as well as being safe and functional as burrs and sharp edges are removed.

However, this definition understates its vital importance, in particular for components used in safety critical applications. Components under stress with untreated sharp edges can induce high stress concentrations which cause stress cracking in service and lead to complete product failure.

There are also the risks of sharp edges creating a hazard in handling and difficulties in part mating where effective clearance is required.

Edge finishing processes need to be carried out with minimal effect on component geometry or integrity with the highest repeatability.

On complex high precision parts with multiple features, edge finishing can constitute up to 30% of part costs, create bottlenecks and be significantly impactful on yield given that by the point that edge break is required, a considerable amount of “value-add” has been invested in the part. As such, scrappage can be costly, with up to 5% of manufacturing costs in German automotive and tooling industries being attributed to rejects and reworks based on edge finishing.

Edge finishing is a crucial step in manufacturing and the results of the work conducted clearly demonstrated that TextureJet’s Stat platform technology can controllably and repeatably generate edge break features in an automated fashion, with the ability to scale the size of the radius and the affected zone as required by the design intent and operational needs.

All the results presented were achieved with pH neutral saline based electrolytes using automated delivery methods, offering distinct advantages in terms of safety, sustainability and repeatability, compared to currently utilised methods which can include the use of harsh acids, creation of airborne contaminants or a high level of manual processing.

With global expansion plans, it is an exciting time for the growing company. Jonathan Mitchell-Smith, CEO and founder of TextureJet says, “We are proud to have developed the next generation of targeted and sustainable surface processing technology. Our innovative, globally patented technology can not only edge finish but also deburr, roughen, polish, pattern, part mark or remove coatings from almost any metal surface with precision and control. This attractive alternative to existing technologies results in reductions in factory and toxic footprint, as well as process and operational costs. The process is flexible, easily automated, scalable, and cost-effective, making it an excellent choice for all high value manufacturing industries”.