This talk will focus on the use of LFW to produce near net shape parts for aerospace components, and the development of this application towards production. A large number of metallic aerospace parts are currently machined from solid block material, or from oversize forgings, resulting in relatively poor buy-to-fly ratios. The use of near net shape parts produced by LFW can provide significant savings, both in terms of material costs and production time. Build up of parts by LFW also provides the opportunity for selection of appropriate materials/alloys in different areas of a structure, which can provide both functional and economic benefits.

This presentation will summarise recent work at TWI on the LFW of a range of demonstration components in Ti-6Al-4V, which illustrate the potential for applying this technology to the manufacture of aerospace parts. An analysis of the material savings that can be achieved will be included to highlight the benefits of the approach.

Recent developments on LFW equipment will also be presented, including an overview of the capabilities of a new 100 Tonne LFW machine, recently produced by Thompson Friction Welding in Birmingham, UK. This machine is believed to be the largest LFW machine built in the world to date, and is aimed at the fabrication of near net shape aerospace components.