Manufacturing and Quality Inspection of an Air Intake Connector used in Missiles

The objective of this work is to manufacture and ensure quality assurance of an air intake connector that is used in missiles. This involved creation of a 3D model and utilizing 3D printing for fabrication, with manufacturing simulation conducted using NX Software. The air intake connector is crucial for air transfer in various systems which is engineered to maintain consistent airflow to the propulsion system, which enhances the aerodynamic stability, minimizes the drag, and improving maneuverability for maximum impact velocity during target or destination approach. The air intake connector is manufactured using manufacturing operations of turning, boring, milling, wire cutting, drilling and tapping by using CNC machines. Inspection and machining of this component in the manufacturing industry are followed by post-processes such as non-destructive testing (NDT) techniques and age hardening. There is huge importance of age hardening in aerospace, automotive, and engineering applications for enhancing material properties and ensuring hardware integrity. Quality control prioritizes defect avoidance or elimination through state-of-the-art NDT techniques like radiographic inspection and dye penetrant testing which are crucial for detecting and addressing defects to prevent potential catastrophic failures during service.