Rösler UK modernizes shot blasting system at Pratt and Whitney for optimized process control

Rösler UK has worked closely with leading aerospace OEM Pratt and Whitney to replace an outdated shot blasting system with a more agile solution. The new system, installed at Christchurch Engine Centre, an aerospace maintenance, repair and overhaul facility, provides optimized process control and leads to more consistent results in coating finish and adhesion.

Shot blasting technologies are essential in the aerospace industry to clean, strengthen or polish metal surfaces. Shot blasting abrasive materials at high speed removes contaminants and creates a uniform, textured surface. This is crucial for the adhesion of coatings as well as for resistance to wear, heat and corrosion, which are of great importance in aviation.

Tony Pugh, Aerospace Projects Manager at Rösler UK says, “When looking to replace the old robot shot blasting system at the Christchurch Engine Centre, an aviation maintenance, repair, and overhaul centre, Pratt and Whitney were interested primarily in a system that would give them better process control and which would ultimately lead to consistent results in respect of surface texture and therefore coating adhesion. Our shot blasting concept optimises process control as it is a closed loop system which measures and allows for adjustment of key process variables (KPVs) and requires less input from operators, meaning greater efficiency and cost savings.”

A closed-loop system not only enables accurate measurement and adjustment of KPVs, but also minimizes waste and environmental impact by continuously circulating the abrasive through the system. It also incorporates mechanisms to clean and condition the abrasive, ensuring consistent effectiveness for consistent surface treatment results. These systems are highly efficient and sustainable and are ideal for operations that require stringent cleanliness and surface preparation standards, as is the case with Pratt and Whitney and other aerospace OEMs.

Tony Pugh continues, “The KPVs Rölser’s shot blasting system measures and adjusts for Pratt and Whitney’s solution include blast media flow, air pressure, air volume, blast nozzle distance and angle to workpiece, blast grit size, all backed up with predictive maintenance messages and prompts. All of this control, together with machine and process status, is presented to the operators and management via our unique PC Supervisor, Windows-10- based system, which also stores all process data per part number and easily interfaces with Manufacturing Execution Systems.”

The Shot Blasting System developed for Pratt and Whitney is primarily intended for the treatment of rotating aerospace components, which often have complex geometries and tight tolerances. This complexity makes surface treatment particularly challenging, as all surfaces must be achieved evenly without damaging the precise contours or compromising the dimensional accuracy of the components. In collaboration with Pratt and Whitney, Rösler has developed a solution that meets these requirements while utilizing the company’s many years of expertise in industrial surface treatment.

In addition, Rösler has integrated ABB robots into the shot blasting solution for Pratt and Whitney, which is particularly beneficial for complex rotating components and difficult approach angles due to the flexibility of RobotStudio and offline programming. The overall system offers optimized ergonomics for operators as well as safe and easy access for maintenance, which is essential in any industrial environment.