The Challenge: Ajax Precision, a mid-sized contract manufacturer specializing in high-mix, low-volume aerospace components, faced a persistent bottleneck. Machining heat-resistant superalloys like Inconel was grueling on their tooling. They experienced severe notch wear and thermal cracking, leading to tool changes every 45-60 minutes. This not only hurt productivity but also introduced variability in the precision of their critical finishing passes.

“We were walking a tightrope,” says Maria Chen, Lead Process Engineer at Ajax. “We’d dial back parameters to save the tool, but then cycle times suffered. Or we’d push for speed and risk a catastrophic failure that could scrap a valuable part. The inconsistency was our highest cost.”

The Solution: Ajax partnered with Carbide Flats for a targeted trial on their most challenging job: a complex Inconel 718 turbine housing. The Carbide Flats engineering team recommended their CF-718 specific grade, featuring enhanced thermal resistance and a reinforced edge preparation for tough materials.

The Implementation & Results: The results were immediate and measurable.

Tool Life Increased by 220%: The Carbide Flats insert ran for 2 hours and 15 minutes of continuous cut time before reaching wear limits, compared to just 45-50 minutes with their previous supplier.

Surface Finish Improved by 15%: The consistent wear and built-in chip control of the GeoLock™ geometry produced a more uniform surface finish, reducing secondary polishing time.

Confidence to Automate: The predictable, gradual wear pattern allowed Ajax to program proactive tool changes within its CAM system. “For the first time, we felt comfortable running this job lights-out for an entire evening shift,” notes Chen. “That was a transformational shift for us.”

The Bottom Line: By switching to Carbide Flats, Ajax Precision reduced tooling costs per part by over 35%, increased overall machine utilization on their difficult jobs, and gained the process reliability needed to bid on more demanding contracts with confidence.

“Carbide Flats turned a major pain point into a competitive advantage,” concludes Chen. “It wasn’t just a better insert; it was a better solution.”

Could your shop be the next success story? Contact our applications team to schedule a no-obligation trial on your most challenging material.