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Wednesday, June 10, 2009 - 2:00 PM
WDJ1.2

The Latest Advances in Welding and Joining for Aerospace

I. D. Harris, EWI, Columbus, OH

Welding and joining has a longstanding place in the Metallics M&P arena for a wide range of products and materials including predominantly stainless steels, aluminum alloys, nickel alloys and titanium alloys.  These processes, such as GTAW, PAW, and EBW are well characterized and used daily, especially within the tier supplier base.  Particular advancements, especially in Yb-Fiber lasers, and other proceses such as CSC/CMT GMAW, laser weld-bonding, and novel additive manufacturing processes such as very high power ultrasonic additive manufacturing (VHP UAM) or titanium and nickel alloys offer particular advantages to cut cost and increase performance in airframe, substructure and subsystem fabrication.  These novel processes will be highlighted as they impact metallic and composite structure and composite to metallic joining technologies in transition to manufacturing.  The TRL and MRL positions of these technologies will be discussed and application examples will be presented.  Examples range from additive manufacturing using lasers and arc welding to cut buy to fly costs on titanium forgings, to upscaling UAM capabilities from 1.5 kW to 9 kW on a 5 axis CNC workstation to produce VHP UAM capabilities.  Laser weld-bonding of aircraft structure to replace fasteners and promote laminar flow in skin structure for regional jet and bizjet applications will be highlighted, and examples given of structure fabricated to date.

Summary: Welding and joining, while always a part of the Metallics M&P agenda, is receiving increasing attention because of ever increasing competitive cost and performance metrics. Interest and use of Friction Stir Welding has led to a hightened interest and awareness of the possibilities to reduce buy-to-fly ratios and cut cost using welding and joining. This paper highlights some of the latest techniques and processes available to achieve these ends, ranging from composites joining to high speed laser welding of metallics.