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To produce a production-ready laser welding process to replace an existing resistance welding method for the production of titanium fairings.
The aim was to develop a process and tooling which would reduce or eliminate the need for post welding part sizing or forming.
This would improve the product consistency, reduce the manual input and decrease the cycle time.
Design and manufacture of assembly tooling with integral argon shielding
Process trials on full scale parts to produce engine test parts
Delivered fatigue test coupons used to generate stress data for process approval
Delivered parts to production geometry for static engine test running
Delivered a fully documented, transferable process for customer deployment
Generated process & lifing data applicable to future applications
Achieved significant reductions in part distortion on full scale components
BENEFITS TO THE CLIENT
A fully defined, stable, repeatable process to deliver more consistent products
Access to a world class laser facility for process development avoided the need for capital investment until a robust production process was developed
Access to industrially experienced process experts halved the time to develop a production solution
Existing production was not disrupted by development activity during the project
Proof of Concept related to Process development and optimization in the context of Aerospace (Aeronautics)