7 Methods For Welding Aeronautical Components
Flight safety is the most important aspect to consider for any plane. Certain strategies can be used to maximize safety, such as maintaining the aircraft engine exhaust system in optimum conditions.
Professional aviation welders are capable of performing different types of welding procedures to ensure the flight safety, performance, and efficiency of your aircraft. Let’s discuss the various types of welding in detail so you can get familiar with their significance in welding aircraft parts such as an aircraft exhaust system.
Flash welding involves using pressure to weld a short arc. FW ensures that the end product is as strong as the base material. A significant benefit of using FW is its wide-ranging applications.
FW can be used to weld various types of aluminum and temperature-resistant alloys. Welders don’t have to spend too much time preparing the surface. Instead, they can get started with welding the aircraft engine exhaust system and components quickly.
However, it is important to have substantial welding experience and training to perform FW. Otherwise, it can be highly dangerous for inexperienced individuals.
Friction welding involves bringing mechanical changes to the components. The metals are typically joined after deformation. However, the metals are not fully melted to ensure their particular characteristics remain intact.
As a result, an end-product made through FRW is expected to have all the major components of the metals used during the welding process. It is a useful feature in the welding of aircraft engine exhaust systems because an aircraft requires many different metal components with varying attributes that are possible to achieve with FRW.
Moreover, the joint metal also has high strength, as high as the base material of the other components. Most welders use FRW to join components with a circular cross-section, such as in the turbine shaft. Some professional welders can also use FRW to merge aluminum landing gear components.
Unlike friction welding, FSW involves using a specialized tool to deform the metals and combine them slowly. FSW is not suitable for all types of metals as the original qualities of the components can get lost in FSW.
Generally, professional aviation welders use FSW when dealing with aluminum alloys like the 2xxx and 7xxx series. With the introduction of modern welding tools and techniques, it has become possible to weld such alloys now, but it was not possible before. Research shows that FSW is better than conventional welding methods because it offers 40% to 50% greater strength.
As the name suggests, RSW depends on resistance for welding purposes. This resistance is generated by heat to merge the sheets of metal. The metal sheets pressing against each other have a flow of current from electrodes that creates heat and resistance.
RSW is a highly popular welding method used in the automotive industry. It allows welders to automate the welding procedures at a cost-effective rate. With time, the adoption of the RSW in the aeronautic industry is also increasing.
TIG welding is one of the most popular types of welding in the aerospace industry. It is known for its impressive versatility in meeting the requirements of repairing and maintaining aircraft. Most welders prefer TIG as the go-to welding method.
A major reason behind the popularity of TIG is that no other welding method is capable of welding as many metals and alloys as TIG. Therefore, welders experienced in TIG do not have to constantly change the welding techniques and can produce the best results with TIG.
The flexibility and cost-effectiveness of GMAW make it one of the most popular types of welding in the world. It is used in many different industries because it is capable of fulfilling numerous requirements.
However, it is important to note that using GMAW to weld aeronautical components is not affordable due to the large size of the heat source required. Moreover, it can affect the traits of the base metals involved, causing an adverse impact on flight safety and performance.
Most welders use electron beam welding and laser beam welding simultaneously to get the best results. It is known for providing great benefits such as greater performance, better accuracy, and high quality. Generally, LBW is used to weld and drill the components of smaller aircraft and jet engines that have heat-resistant alloys.
The bottom line is that there are many different types of welding used to fulfill varying welding requirements. Welding practices have greatly evolved as humans have been dealing with metals for a long time, but modern techniques and technology have streamlined the welding procedures.
Professional aviation welders, such as Acorn Welding, also use different types of welding methods to deal with specific issues, such as fixing the aircraft engine exhaust system. Ultimately, professionals have the best knowledge and skills to apply suitable welding techniques.