Weber Metals

CAPABILITIES

The aerospace industry turns to us for mission critical, high performance aluminum forgings

ALUMINUM

Weber’s Aluminum Capabilities

• Closed die forgings range up to 3,500 sq in. depending on the geometry

• Cold compression stress relieve to tempers T7452, T7352, and T7454, including incremental stress relieve capabilities

• Utilizing highly advanced, digitally-controlled presses, our capabilities range from 1,500 to 60,000 tons

Aluminum Product Types

Structural / Slab / Blocks / Fittings / Frames / Bulkheads / Beams / Disks / Custom Shapes

FEATURED PRODUCTS

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Monolithic Window Frame

7050
Contoured in two directions
Stress Relieved

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Landing Gear Shock Strut

Alloy 7075
650 lbs

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Inboard Wheel

Tempered 2000 and 7000 Series

Transforming titanium ingots into highly-engineering products

TITANIUM

Weber Controls All Aspects of the Process

Our automated, computer-controlled operations reduce variability, shorten lead times and deliver maximum flexibility.

Titanium Product Types

Structural / Slab / Blocks / Fittings / Frames / Bulkheads / Beams / Disks

How We Benefit Our Customers

Low Start-Up Costs

Maximum Flexibility for Change

Reduced Waste

Part Conforming Grain Structure

Increased Throughput

Improved Cycle Time

FEATURED PRODUCTS

hand-forged-blocks

Cut-to-size Hand Forged Blocks

Up to 180” in Length

cockpit

Cockpit Window Frame

6-4 Beta-Annealed
36” W x 60” L
500 lbs

shaper-stapped

Shaped and Stepped Forgings

Open-And Closed-Die Solutions

bulkhead

Bulkhead

6-4 Annealed
136” L
500 lbs

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Aeroturbine

6-4 and 6-2-4-2 Disks
Manufactured up to 44” Diameter

HIGHly SKILLED & HIGH QUALITY

Our Process

Weber tailors its processes to satisfy customer requirements and is able to manage a large supply base to assist in performing these activities.

Special processing or machining may be incorporated into our process depending on customer needs.

Forging

Various grades of aluminum and titanium alloys

OPEN DIE

Open die forging/forming to create unique preform shapes for closed-die forgings and engineered hand forgings.

  • Up to 11,000 lbs
  • ST > 4″
  • LT > 11″ < 38″
  • LG < 22 ft

CLOSED DIE

Closed die forging to create complex forging shapes, concurrently engineered with our customers for ease of manufacture and machinability.

  • Up to 4000 lbs
  • Aluminum compression stress relieving
  • Incremental forging capabilities for large forgings
bulkhead-1

Weber's stress relieved aluminium close die forgings are shown in their assembled locations for a large business jet cockpit.

ENGINEERED HAND FORGINGS

  • Up to 7x less material compared to plate
  • Low residual stress in EHF parts
  • Multi directional bend capable
  • Maximum weight 8,000lbs

LARGE MONOLITHIC FORGINGS

  • We have the ability to produce and stress relieve large monolithic forgings reducing final part weight
  • Our large presses allow for us to design and replace multiple parts with a single forged piece.

ROTATING PARTS

We currently produce engine disks ranging from 16” – 48” diameter:

  • Forge from Ti 6-4. Ti 6–2–4–2, and Inconel 718
  • Producing disks weighing up to 1000lbs
  • Each disk must have material and physical properties of the highest grade to function in the latest generation of commercial & jet engines
Weber Metals_24
Penetrant

Quality Assurance

Our quality assurance department has full-dimensional inspection capabilities, state-of-the-art coordinate measuring machines, and laser-scanning equipment that map and compare to customer models.

In-House Testing

Our in-house destructive testing facility offers mechanical testing, micro and macro-structural examinations (including grain flow), and chemical composition verification in accordance with the most recent industry and customer specifications.

Non-destructive testing to verify surface and internal material integrity, including:

  • State-of-the-art fluorescent penetrant inspection lines for small and large forgings
  • Four ultrasonic inspection tanks allowing inspection of open and closed die forgings

Heat Treatment

  • Perform low temperature annealing/aging of titanium forgings
  • 10,000 lb drop-bottom electric furnace for solution treatment of aluminum
  • 50,000 lb gas-fired age furnace for aluminum
  • Two 12,000 lb salt bath age furnaces for aluminum
  • High-temperature solution treatment and engineered cooling solutions for titanium forgings

Metallurgy

Our Metallurgists participate on various industry committees related to materials and processing such as the Aluminum Association, SAE, MMPDS, FIA & Nadcap.

They are supported by a highly-skilled group of technicians who closely monitor and control forging and heat-treating operations to assure the highest quality product is delivered.

  • In-house test material removal / machining
  • Macro/microstructural prep / etch / evaluation
  • Grain flow evaluation
  • In-house wet lab
  • Tensile testing

Secondary processing

  • Water jet / torch cutting
  • Conventional contour cutting
  • Hand and large-scale grinding equipment to remove surface burrs and imperfections

The Largest Press in North America

60,000 ton press

The 60,000 Ton press is capable of producing some of the largest monolithic structures in the world. Use of this press reduces piece weight, eliminates the need for more unique part numbers, and optimizes assembly by decreasing the amount of connection points for fasteners.

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Weber’s Large Monolithic Forgings Capabilities

  • We have the ability to produce and stress relieve large monolithic forgings reducing final part weight
  • Our large presses allow for us to design and replace multiple parts with a single forged piece.

Weber’s Engineered Hand Forging Capabilities

  • Up to 7x less material compared to plate
  • Low residual stress in EHF parts
  • Multi directional bend capable

Maximum weight 8,000lbs