Extrude Hone’s solutions for aerospace at International Paris Air Show 2025
Extrude Hone will attend the International Paris Air Show 2025 to showcase its top-notch finishing and machining solutions to aerospace industry professionals.
Themes of the 2025 Paris Air Show
The Paris-Le Bourget International Paris Air Show, to be held from June 16 to 22, 2025, will showcase the latest technological advances in the aerospace sector. The event is a global reference for professionals in the field, fostering exchanges around the industry’s challenges and innovations.
The 2025 edition will take place over seven days, with a distinction between days reserved for professionals and those open to the general public.
Professional Days (June 16-19, 2025): Reserved for industry players, these days enable companies to conclude contracts, explore innovations, and take part in specialized conferences.
General public days (June 20-22, 2025): These three days enable aviation enthusiasts to explore the exhibits, watch aerial demonstrations, and get up close to iconic aircraft.
We can expect to see some major themes in the spotlight:
- The civil aviation of the future: the focus will be on new generations of aircraft that are lighter, more efficient, and less polluting. Innovations in propulsion (hydrogen, hybrid, electric) and the use of advanced composite materials will be key topics.
- Defense technologies: the show is also a showcase for the latest advances in military aviation, including drones, advanced surveillance systems and new-generation combat aircraft.
- Space exploration: with the rise of NewSpace, space companies and agencies will be presenting their plans for satellites, planetary exploration and manned missions. New business opportunities linked to space tourism and the exploitation of extraterrestrial resources could also be highlighted.
- Sustainable solutions for aeronautics: The ecological transition will be a central topic, with the spotlight on alternative fuels, new low-emission aircraft models, and initiatives to reduce air transport’s carbon footprint.
Technologies to be presented at the International Paris Air Show
The Paris Air Show 2025 will be a unique opportunity to discover cutting-edge innovations in aviation and aerospace. Among the technologies expected to be showcased are
- Green propulsion: Demonstrators of electric and hybrid aircraft will be on display, illustrating manufacturers’ advances to reduce fossil fuel consumption. Hydrogen is also a promising avenue, with several prototype engines under development.
- Supersonic and hypersonic aircraft: a number of industry players could unveil plans for aircraft capable of breaking the sound barrier, using technologies that are more environmentally friendly than previous supersonic aircraft.
- Automation and artificial intelligence: Innovations in autonomous piloting, AI-based air traffic management and route optimization to reduce energy consumption will also be highlighted.
- New-generation satellites and space launchers: The space sector will be well represented, with new models of reusable rockets, satellite constellations for the global Internet, and innovations in lunar and Martian exploration.
Extrude Hone’s solutions for the aerospace industry
Extrude Hone unveils advanced solutions with a focus on surface and flow improvement. Our advanced technologies have gained recognition for their impact on both outer surfaces and inner channels. We will showcase its advanced solutions at our booth, Hall 2b EF 186.
courtesy of Paris Air Show
1. Rocket Pump Housing
- Improvement of laminar flow quality: the volute design and multiple grooves make the pump housing complex in terms of laminar flow quality.
- Stress relief and removal of stress risers: abrasive media polish intricate geometries, enhancing flow performance
Processed on SPECTRUM equipment:
– Pre-AFM: roughness in the range of 900µin+ (23µm+).
– Post-AFM: roughness of 63µin (1.6µm).
2. Rocket Pump Impeller Housing
- Improvement of laminar flow quality redirects impeller flow without creating turbulence.
- Stress relief and removal of stress risers, specifically at the root of the blades.
AFM used for inner passages improves surface and laminar flow quality.
Processed on SPECTRUM equipment
– Pre-AFM: roughness of 63µin (1.6µm).
– Post-AFM: roughness between 8µin (0.2µm) and 4µin (0.1µm).
3. Impeller
- Improvement of laminar flow quality, essential for increasing peak efficiency by at least 10%.
- Stress relief and removal of stress risers at the root of the blades.
- Enhanced impeller performance: AFM improves blade surface, optimizing laminar flow quality.
- Naturally easy to process: shape and tooling create natural restriction, making AFM efficient.
Processed on VECTOR for small ones and SPECTRUM equipment for large ones.
– Pre-AFM: roughness of 63µin (1.6µm).
– Post-AFM: roughness between 8µin (0.2µm) and 4µin (0.1µm).
4. Blisk (Blade Integrated Disk)
- EDM recast layer removal improves laminar flow quality and prepares for thermal barrier coating.
- Stress relief and removal of stress risers at the root of the blades.
- Consistent roughness: AFM adjusts roughness to optimal levels to prevent coating delamination.
Processed on SPECTRUM equipment
– Initial roughness: 120µin (3µm).
– Post-AFM: Up to 11µin (0.3µm) in less than 30 minutes.
5. Outlet Guide Vane and Stator
- EDM recast layer removal enhances laminar flow quality.
- Improvement of laminar flow quality: AFM polishes blades without damaging them, preserving geometry up to the edges.
- Stress relief and removal of stress risers at the root of the blades.
- Enhancement of blade geometry improves airfoil, flow path, and root filet roughness.
AFM processes passages and contours without creating razor edges, polishing, and stress riser removal in a single operation.
6. Turbine Disk
- Smearing removal (after broaching)
- AFM ensures consistent round edges or true radii on different disk geometries.
- EDM recast layer removal produces a flawless surface, eliminating crack risks.
- Stress relief and removal of stress risers improve roundness and edge finish.
AFM, achieving productivity and quality in one operation, radius, smearing removal, and EDM recast layer removal.
Variable radius depending on slot design: achieves 0.2mm radius without pre-machining.
7. EDM recast layer removal
EDM is widely used in industry and has plenty of benefits when creating complex geometries. As a process outcome, EDM users face the recast layer and a heat-affected zone below.
As we know, residual stress in that recast layer and the associated risks are unacceptable in most applications. They can endanger the safety of the workpieces, especially if the component is working under dynamic stress conditions.
AFM can handle all materials, and the process allows for controlling the material removed from the surface.
For a turbine disk with fire tree slots, made of Nickel alloy and with a 400mm (15.7”) outer diameter, the two-way flow AFM process will remove 0.0508mm (0.002”) at the fire tree slot surface in about in 35 minutes, leaving an improved roughness of 0.062µm (2.5 µinc.).
On an Inconel stator with an outer diameter of 310mm (12.2”), the material removal, depending on the location, is between 0.193mm (0.00762”) and 0.386mm (0.01524”) in about 60 minutes. The post-process roughness is between 0.1µm and 0.4µm (4 to 16 µinc.).
Nozzle, components with small channels
Superior solution for flow tuning and surface enhancement.
The internal passage restriction usually comes with demanding geometries that benefit from MICROFLOW, leaving a free of micro-burrs, radiused edges, and polished channel
The Extrude Hone MICROFLOW technology targets ±2% or less of the specified flow rate for the injection nozzle.
MICROFLOW offers refined control of the AFM process to achieve deep spray in the combustion chamber with superior atomization
For the small channels MICROFLOW delivers nice polished surfaces
See this article in the Fluid Power Journal
Aluminum hydraulic manifold
Extrude Hone enables the highest quality hydraulic manifolds.
Hydraulic manifolds are very demanding pieces of engineering and machining that contribute to smooth, precise, and safe flights.
Complex manifolds, such as complex ones with hundreds of areas to finish, benefit from the Extrude Hone Electrochemical Machining (ECM) process, in a single or in multiple steps, and in less than 5 minutes.
Dynamic ECM is the solution to achieve what conventional machining cannot do.
With Dynamic Electrochemical Machining (DECM), you can machine specific designs, such as a hole behind a wall or a ringbone hole in a turbine disk.
In addition, DECM can challenge some EDM applications. If you can relax on the shape tolerance and accept +/—50 µm tolerances, then DECM comes into play. It can reach much higher feed rates, up to 7mm/min, compared to the 0.25 to 0.50mm/min of the EDM process, and still get a great Ra of 1µm.
That’s not all. As there is no thermal stress with DECM operation, no recast layer needs to be removed, as with EDM. That means no secondary post-processing.
Aluminum Manifold
TEM is a good alternative to ECM for aluminum manifolds requiring only deburring. If the geometry is suitable it will deliver the lowest cost per part for an overall deburring.
See the article in the Fluid Power Journal
Spools
Using TEM is the alternative for a 100% burrs removing in this critical component
See this article in the Fluid Power Journal
3D Printing brings in additional challenges to some of the components mentioned above. The roughness is worse compared to casting and it’s not homogeneous. In addition, residual powder can be trapped here and there.
At Extrude Hone, we have designed media specific for Additive Applications.
courtesy of Paris Air Show
courtesy of Paris Air Show
Meet Extrude Hone’s experts at International Paris Air show 2025
Bruno Boutantin, Market & Business Development Director, and Vincent Grimm, Sales Engineer France, look forward to welcoming you to the Extrude Hone booth, Hall 2b EF 186, to discuss your challenges in the aerospace industry.
