Laser welding of titanium fairings
Project challenges
To produce a production-ready laser welding process to replace an existing resistance welding method for the production of titanium fairings.
Business challenge
Process Innovation
Sector
Aerospace
Technology or capability
Laser Based Manufacturing
Automation & Robotics
The MTC works with Rolls-Royce to develop a laser welding process for titanium fairings, resulting in an automated, consistent process that eliminates reliance on tacit knowledge.
We worked with the MTC to build on earlier mathematical modelling to develop a robust process we can now deploy in Rolls-Royce.
Clive Grafton-Reed, Global Process Owner - Laser Processes, Rolls-Royce
The Challenge
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.
MTC's Solution
- Design and manufacture of assembly tooling with integral argon shielding
- Process trials on full scale parts to produce engine test parts
The MTC personnel blended into the integrated project team seamlessly, working tirelessly to deliver customer needs to a very high standard.
Mark Saint, Laser Welding IPT Lead, Rolls-Royce Samulet 2
The Outcome
- 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
