Manufacturing
The leading manufacturer of sheet metal aerospace components. Completing forming, machining, laser, and welding operations.
Process Engineering
Danville Metal's engineering staff is highly experienced in process development, metal forming, machining, welding, along with a variety of process improvement techniques. Utilizing Siemens Unigraphics NX® CAD software to design tools and working in cooperation with our team of skilled programmers, who provide multi-axis CNC programs, we have a solid reputation for development of a variety of details, sub-assemblies, and assemblies. Our experienced engineering staff is continuously working toward ideas to develop and improve each production process.
Forming
Danville Metal leads the aerospace industry in its abilities to form exotic alloys, such as Hastelloy, Inconel, and Waspaloy. With both conventional and hydroforming capabilities, Danville Metal produces some of the most difficult shapes in the metal forming industry. We stand ready to meet your manufacturing challenges.
Danville Metals skilled technicians use a variety of conventional tools to form material. We design and manufacture most of our dies, allowing for shorter development times and lower costs without sacrificing quality and consistency.
Conventional Machining
CNC multi-axis milling and turning machinery is at the heart of our manufacturing processes. We offer 2 through 5-axis machining, allowing us the ability to hold close tolerances on a wide variety of configurations, material types and sizes. Our current systems will handle turning of up to 50" diameters and 34" lengths; horizontal milling of materials 39" x 31.5" x 31"; and vertical milling of 49" x 26" x 30"
Laser
Danville Metal Stamping uses state-of-the-art CNC lasers with up to 6-axis motion. Machining capabilities include cutting, hole drilling, both trepanning and percussion with C02 or Fiber lasers. Our Laser Department can machine material thicknesses from .005 to .285. Hole diameters can be machined as small as .008", using either Trepan or Percussion drilling.
Nonconventional Machining
Electrical-Discharge Machining (EDM) - We employ three (3) different methods of EDM, depending on our customer's need.
RAM is the most conventional method, generally used for simultaneously drilling hundreds of small cooling holes in multiple, flat blanks for turbine vanes. While our systems are capable of cutting hole diameters of up to 2 inches, most of our work requires hole diameters of less than 0.015 inch.
CNC Wire-cut EDM, which is one of the most versatile methods for cutting complex profiles in multiple axis.
Fast Hole EDM, which employs the use of robotics to rapidly drill small holes (.098" max.) in a single piece.
Welding
Danville Metal offers a wide variety of joining processes, all of which are Nadcap certified.
Danville Metal meets and exceeds the most stringent welding requirements in the aerospace industry. We are approved by all major gas turbine engine builders and the U.S. military to perform Laser, T.I.G., and Resistance spot and seam welding processes. Give us an opportunity to satisfy your most difficult welding requirements.
Heat Treating
The Thermal Processing Department at Danville Metal specializes in furnace brazing with nickel, copper and precious metal braze alloys. Heat treating services are performed in a vacuum, hydrogen and inert gas atmospheres. Typical heat-treating processes include stress relieving, normalizing, solution treating, precipitation age hardening and tempering of exotic alloys.The expertise in the heat treating industry awaits your heat treating and brazing needs.
Brazing
Danville Metal Thermal Processing Department (formerly Thermo Techniques), utilizes vacuum technology to heat treat and braze stainless steels and super alloy materials. Heat treat cycles include stress relief, thermal sizing, solution, and precipitation hardening. Our furnaces are calibrated, controlled, and monitored per the pyrometric requirements of AMS2750, and are equipped with technically advanced, automated controls to achieve process uniformity, repeatability, and data collection. Braze alloys used are nickel and copper. NADCAP and OEM Customer Approved.
Associated Manual Operations
When the job calls for special attention, Danville Metal relies on our team of skilled Sheet Metal experts.From sheet metal layout to manual drilling, sandblasting, edge-finishing, and many other operations which require manual skills that only trained professionals can provide, we have your needs covered. Skill, workmanship and personal attention to detail will never be outdated at Danville Metal.
Tool Making/Maintenance and Repair/Storage
Our fully equipped tool room is staffed with experienced toolmakers and CNC machinists dedicated to tooling development and maintenance. Our engineering and tooling capabilities have been a valuable resource in meeting our customers needs for over 75 years.