The Right Carbide for Superalloys Reduces Tooling Replacement Costs

Meeting Aerospace Manufacturing Challenges

A US-based manufacturer of turbine and jet engine components faced significant challenges in machining components made from Rene 108, a nickel-based superalloy known for its exceptional strength and resistance to extreme conditions. The company was experiencing:

• Frequent Tool Replacements: The tools being used wore out quickly, leading to frequent downtime and lower production efficiency.
• Rising Tooling Expenses: Reliance on externally sourced tools significantly increased costs, impacting overall profitability.

These challenges made it difficult for the manufacturer to balance industry demands for precision and efficiency with the need for sustainable margins.

Transformative Solutions for Better Margins

The manufacturer decided to partner with Hyperion Materials & Technologies to implement two transformative changes to their operations. First, the manufacturer leveraged their existing expertise and equipment to bring tooling production in-house. This allowed them to achieve greater control over costs and enhance operational flexibility.

Second, they upgraded their carbide grade to Hyperion’s H10F tungsten carbide rods, a high-performance substrate engineered for exceptional toughness, wear resistance, and edge retention. This material proved ideal for machining their specific challenging superalloy, Rene 108. Together, these strategic adjustments optimized tooling processes, addressing the critical challenges of durability and cost.

Achieving Outstanding Results

The shift to in-house tooling using Hyperion’s H10F tungsten carbide rods delivered remarkable results. Between others, tool life more than doubled, significantly reducing the need for replacements and minimizing production interruptions. Additionally, the move to in-house production reduced costs per tool by 46%, leading to substantial improvements in profit margins.

This case study highlights how a targeted approach to tooling can transform aerospace manufacturing operations. By combining innovative materials and operational control, the manufacturer achieved both efficiency and profitability gains.

Discover the Details

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