At our workshops, every step is designed for optimal efficiency and accuracy.  We recently completed buckets, which are a consumable, for a large aluminum pot tending machine.  We’d like to share the behind the scenes processes of these jobs with you.

🔹 Ordering & QA/QC: All parts were ordered and tracked within our integrated ERP system.  QA/QC was conducted on incoming goods in accordance with ISO9001 requirements.

🔹 Material Preparation:  Components were laser/flame cut by our trusted supplier and delivered to AI&S where they were carefully sorted and positioned in work areas for efficient machining.

🔹 CNC Machining Prep:

• • Several factors are considered before machining, including tooling, work holding, machine capacity, programming, material properties, and coolant needs.
  • To enhance accuracy and save time in the fabrication process, all weld preps were machined in our CNC mill, streamlining the bucket fabrication process.

🔹Fabrication:

• • Once all items were machined, they were tack weld.  Items were tack welded to ensure that we were able to check the fabrication of the parts before welding.
  • After approval, welding of checked assemblies occurred.

• • After welding, QA/QC of welding were conducted.  This included dimensional checks to ensure all tolerances were within an acceptable level.
  • Once all welds and dimension checks passed, we then proceeded to post processing, such as cleaning of all spatter, dressing welds and ensuring the removal of all sharp edges.

• • The last step on fabrication was a final 100% visual examination of each item.

🔹 Fabrication to Final Machining–  After fabrication, the buckets return to the machine shop for their final touches:

• • Line Boring: With the extended boring head on our Doosan VCF 850, which allows for 180-degree spindle rotation, we ensured precise line bore tolerances on the lower and upper pin ears.
  • Final Lip Machining: The bucket’s lip was machined with pinpoint accuracy, using an angled face plate, blocks, packers, and multiple reference points to achieve the exact lip angle required.

From start to finish, every detail was focused on delivering quality and precision in a systematic way.  We provide engineered buckets across a variety of industries. Please contact our Sales team if we can help your organisation with their engineering requirements.

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