Domestic Manufacturing Facility
John Hassall's manufacturing operations are centered around a modern 65,000 square foot facility located in Westbury, New York. John Hassall has earned a worldwide reputation for outstanding quality, achieved through ongoing investments in its people, as well as in the latest manufacturing technology.
Every John Hassall customer is supported by a team of talented hands on professionals, including an account executive, design engineers, manufacturing and quality assurance specialists. This multi-disciplinary team understands and anticipates the inherent complexities of each assignment. Drawing upon extensive experience and know-how, they work directly with customers to determine the most cost effective solution, often making product improvement and cost saving suggestions.
Computer Aided Design (CAD)
John Hassall typically works from customer-supplied prints. We are also capable of providing complete product design solutions utilizing the latest state-of-the-art CAD/CAM systems. All engineering and technical support services are available through the Internet.
Our manufacturing capability features a variety of cold heading machines, including open and solid die headers, reheaders, trimmers and nail presses, as well as multi-station parts formers, capable of producing specialty parts in lengths up to 9" and diameters up to 0.406". In-house tool making allows for exceptionally short lead times, ease in prototyping developmental parts for engineering studies and sustained back up for production runs.Some typical workmanship standards for cold headed parts:
- Diameter tolerance: .0015" total
- Length tolerance: +/- .0025"
- Corner Radii: +/- .003 to .010" for small parts
- Corner Radii: +/- .005 to .015" for large parts
- Surface finish: 32 to 63 RMS
John Hassall's hot forging presses are equipped with digitally controlled induction heaters that produce for the most part high temp/high strength, close tolerance aircraft engine bolts up to 6" in length and shank diameters of 0.625". These bolts are made of such alloys as Inconel 718, Waspaloy, and MP 159* to name a few. A critical area of cut-off blank is heated to a precise temperature in a range of 1,650 to 2,250°F (depending on the material), which allows for heads, shoulders and collars to be formed during the forging process. A great deal of experience, known in the industry as "the black art", as well as metallurgical lab support is required to assure part integrity and conformance to customer specifications throughout the process of fabricating these flight safety critical bolts.
John Hassall's ability to form parts to "near-net" or finished dimensions is directly related to our in-house tool & die making capability. Since the early 60's, our toolmakers were amongst the first to use and perfect the use of carbide in their heading tools. Building on that experience, we can today produce cold headed parts with shank tolerances as close as 0.0007" if necessary, and for all our customers, we can consistently guarantee parts and fasteners of exceptional quality with very short lead times.
When either cold heading or hot forging cannot, by the process alone, create a unique shape or hold a critical tolerance, John Hassall can provide a part to the most demanding specifications by employing a variety of sophisticated secondary operations . . . such as:
- Threading (flat die and tri-roll)
- Multi-axis CNC machining
- Auto-fed CNC centerless grinding
- Specialty surface grinding
- Auto-fed CNC chucking
- Bar-fed Swiss turning
- Vacuum solution heat treatment and aging, induction annealing, as well as atmospheric hardening and tempering
- Milling and Drilling
- Electrical discharge machining (EDM)
- Destructive and non-destructive testing, micro and macro evaluations of materials and parts
- Diameter tolerance: +/- .0001"
- Length tolerance:+/- .001"
- Perpendicularity: .001" total
- Profile: .004" total
- Concentricity: .001" total
- True position: .002" total
- Surface finish: 8 to 16 RMS
NADCAP Certified Heat Treating
Hassall's state-of-the-art heat-treating facility was specifically designed for specialized requirements most commonly called for in military and aerospace applications. John Hassall has vacuum and atmospheric furnace for hardening and tempering, solution & precipitation hardening and annealing; automated induction heaters for selective annealing and hardening; cold treat freeze capability to -120°F.
Complete Metallurgical Laboratory
Equipped to provide both destructive and non-destructive testing, as well as micro/macro evaluations of materials and parts, Hassall's lab operates under the surveillance of Pratt & Whitney's Material Control Laboratory, is registered and approved by Honeywell Aircraft Engines and MTU Aero Engines and conforms to GE Aircraft Engines S-400 guidelines. Testing conducted within this lab includes: X-ray spectrometry, metallography, shear/tensile/yield, hardness and stress rupture (creep), fatigue and non-destructive testing.
Statistical Process Control (SPC)
To ensure adherence to Total Quality Management (TQM), Hassall utilizes Statistical Process Control (SPC) techniques involving networked data collection workstations. Here, we collect historical information on critical product/process variables and attributes. Many of our manufacturing systems are also equipped with computerized process controllers for fail-safe operation.
All products manufactured by John Hassall are 100% traceable as a result of the strict batch control systems. All documentation procedures are developed in accordance with customer guidelines. A complete library of product samples and accompanying paperwork is maintained and readily available for customer inspection.