Currently, many such components are machined from solid blocks of material, resulting in relatively poor buy-to-fly ratios. Reduction of material scrap rate is of increasing interest given the continuing rise in material costs world-wide, and the limited availability of many specialist alloys. The use of near net shape parts, produced by LFW and FSW, can provide significant savings in both material cost and production time, for wide range of aerospace components.

Build up of near net shape parts by friction welding processes also provides the opportunity for selection of appropriate materials/alloys in different parts of an aerospace structure. This approach allows the production of tailored components, resulting in both functional and economic benefits. Examples will be shown of the application of this approach to aerospace components, from simple LFW and FSW fabrications in Al and Ti alloys, to more complex components produced by sequential addition of multiple parts.

In summary this presentation will provide an update on recent friction welding development work, aimed at reducing production costs and improving product effectiveness for a wide range of aerospace components.