Laser Welding for Titanium Fairings

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.

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 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