How to Reduce Maintenance Schedules for Aerospace Thermocouples

Reducing Maintenance Schedules for Aerospace Thermocouples  

The aerospace composites market, which relies on autoclaves to manufacture aircraft components, is soaring upwards, according to various research studies. One projection has this market set to grow from USD $31 billion in 2021 to USD $54 billion by 2030, for a compound annual growth rate (CAGR) of more than 7.5%.

These composites, reinforced with carbon, ceramic or glass-based fibers are gaining traction due to beneficial properties such as low density and robust mechanical characteristics. Notably, North America holds a dominant position in the composites market, accounting for nearly 45% of the global aerospace composites revenue. However, countries like France, Germany and the United Kingdom are also leading producers of aircraft components.  

This booming market relates to a corresponding demand for manufacturing equipment and tools—including autoclaves and reliable and accurate monitoring systems, like thermocouples, to help verify the integrity and enhance the safety of the aerospace components produced.  

However, a significant number of aerospace manufacturers still opt to fabricate thermocouples in-house. Yet the benefits of outsourcing this task to established, experienced manufacturers such as TE Wire, a recognized specialist in the manufacturing of high-temperature thermocouples, are tangible. In addition to the labor expenditure, companies could realize a significant increase in standardization, reliability and quality by sourcing thermocouples from an experienced outside source.   

The Importance of Aerospace Autoclaves 

Aerospace autoclaves perform an integral function when processing composite materials to create aerospace components. Specifically, composite materials are known for their high strength-to-weight ratio. Autoclaves control temperature and pressure to cure composites, fortifying the bond between fibers. Built to stringent regulatory standards, autoclaves feature robust design elements like thick walls and emergency valves to protect both safety and product quality.  

Through their role in the curing process, particularly the ability to minimize resin voids, autoclaves help attain the ideal resin-to-fiber balance in aircraft parts for greater quality and reliability. Given this critical role, the demand for precise monitoring tools to help gauge temperature for example, it becomes imperative to have <a href=” https://tewire.com/aerospace-composites/ “>efficient and reliable thermocouples within the aerospace autoclave</a>.  

Labor Savings: Redirecting Talent 

Manufacturing thermocouples in-house requires skilled labor, dedicated hours and specialized equipment. By outsourcing, aerospace firms can redirect their talented workforce to more mission-critical tasks. As industry evolves and output demands increase, every minute saved can be utilized for tasks that more directly contribute to production and profitability.  

Standardization and Consistency 

Maintaining a consistent standard with in-house fabrication can prove challenging. There is no aspect of aerospace manufacturing that shouldn’t be guided by precision requirements, with thermocouples no exception to this rule. Outsourcing their manufacture to a company that specializes in thermocouple design, engineering and manufacturing helps customers receive standardized products that have been quality checked and produced with the benefit of years of experience. This reduces variability, increases reliability and supplies a component that will operate within a tolerance range that will supply more precise measurements.  

Quality Improvement

Specialized thermocouple manufacturers build their reputations on years of industry service, scientific study and application, engineered design features and by implementing the latest industrial innovations. Leveraging this expertise supplies customers with thermocouples that are not only reliable, but also durable.  

High-quality, durable products translate to fewer system failures. This reduces the risks and costs associated with unscheduled downtime from thermocouple failure or product waste due to imprecise autoclave readings—significant pain points for any industry segment, with aerospace no exception. Other associated failures can lead to corrective action reports or reports to a regulatory body.  

Long-term Cost Benefits 

While in-house thermocouple fabrication might appear to be a cost-effective option, the long-term view paints a different picture. Considering labor costs, equipment maintenance, potential downtime due to component failure, the valuable floor space dedicated to its manufacture, and risks associated with inconsistent quality, outsourcing emerges as a financially sound option.  

Moreover, many advanced technologies available in today’s market make thermocouple assembly in a dedicated plant faster and more reliable. This helps supply a reduced Total Cost of Ownership (TCO) over the component’s lifecycle.  

Traceability and Accountability 

One of the last benefits could be one of the most important as more companies require complete traceability for all parts and components. Working with an established manufacturer supplies component traceability.  

This degree of transparency lends accountability to every process and allows companies to identify errors, diagnose the core issue and formulate plans to prevent them from recurring.  Full traceability also aids in ensuring compliance with rigorous aerospace industry standards and regulations.  

Benefits of Outsourcing Thermocouples Used in Aerospace Autoclaves 

It is time to reevaluate the outdated practice of thermocouple fabrication in the back room of the manufacturing facility. Outsourcing the manufacture of this critical element for autoclave success offers clear advantages in terms of labor allocation, product consistency, quality assurance and traceability, in addition to savings for total cost of ownership through greater reliability, durability and accuracy to avoid waste.  

Overall, the advantages of using a professionally fabricated and engineered autoclave include:  

• Thermocouples are pre calibrated (easy to pass NADCAP) 
• No reverse polarity 
• Eliminates need to strip insulation 
• Easy to install and achieve vacuum seal (avoid leaks) 
• Cuts labor costs/time/space devoted to in-house assembly 
• Eliminate risk of foreign object debris (FOD)  

The newest product from TE Wire, PEEKSense™ Thermocouple Sensors represent the next generation of temperature sensing products designed for use in the manufacturing of advanced thermoplastic composites. The traditional method of manufacturing a high-temperature thermocouple calls for stripping the wire, then insulating it. However, the manufacturing method of composites using PEEKSense enables assemblies without stripping any wire, for faster, more cost-effective installation and more reliable composite curing because the wire remains whole and unaffected, to eliminate the likelihood of failures or composite defects .  

PEEKSense does not melt and is rated up to 400 C (752 F). It does not leak under pressure (up to 200psi) and will not unravel like typical polyimide films. It also offers complete traceability to its calibration data and manufacturing history.   

Outsourcing emerges clearly as the optimal path forward. Looking for a partner to supply reliable high-temperature thermocouples utilized in hundreds of autoclaves within the aerospace sector? Call TE Wire today.