Laser Automation and Design Development for Future Engine Requirement
Business challenge
Process Innovation
Growth & Scaling
Sector
Aerospace
Technology or capability
Laser Processing
Optimising laser welding for aerospace applications
Throughout LADDER the MTC aims to design, develop and test several fixturing and shielding solutions for a variety of features identified by ITP Aero as common across their range of complex sheet metal fabrications. In addition to this, several state-of-the-art equipment and techniques such as in-process monitoring, laser beam manipulation, and gas shield particle image velocimetry are being trialled to identify their respective advantages and limitations for application to the welding of aerospace panel components. The MTC will also identify suitable parameter windows for a few materials and geometries through a number of sensor instrumented DOEs, the data from which will feed into a predictive model being developed by the University of Nottingham.
The Challenge
Laser welding has a significant potential for application within the aerospace manufacturing industry, particularly for the joining of complex and heat sensitive components.
The development of knowledge, parameters, and processes that will allow ITP Aero to move away from their current more traditional manufacturing processes would be a significant step towards allowing them to truly take advantage of the potential laser technologies have to offer.
High level project goals for ITP Aero (project lead) include improvement of RFT 60-90%, reducing tooling costs 50%, and reducing cycle time by 50%.
MTC's Solution
- To design and develop potential fixturing and shielding solutions for features and components identified by ITP Aero.
- To identify, down-select, and practically trial several state-of-the-art laser processes and laser equipment, to identify their application to the case study materials and weld geometries identified by ITP Aero. In particular to identify their relevance to helping ITP Aero achieve their project goals.
- To develop processing windows for a number of selected materials and weld geometries identified by ITP Aero. Including the generation of weld data required for predictive model being developed by the University of Nottingham.
Developing laser welding capability will unlock new opportunities for ITP Aero, helping us meet the needs of future aviation products.
Christopher Brown, Associate Director - Technology & Industrial Engineering, ITP Aero UK
The Outcome
To provide a library of solutions and suggestions for the fixturing and shielding of various common features across ITP Aero’s product portfolio.
To provide the advantages and disadvantages of the trialled technologies and techniques when applied to ITP Aero’s case studies applications. Allowing for sound future capital investments.
To provide processing windows for ITP Aero across identified applications. And to provide data for Nottingham Universities predictive model.
To help ITP Aero increase right first time from 60% to 90%, reduce tooling costs and cycle time by 50%.
Benefits to the Client
Enhance productivity and efficiency of ITP Aero in their production.
Improve ITP Aero sustainability credential by reducing waste from manufacturing production through improvement of right first-time manufacturing.
Enable ITP Aero to potentially branch into new markets and improve sales in the aerospace sector through production and quality enhancement.
With the knowledge that MTC has gained on gas shielding, process monitoring and beam oscillation, the MTC can support more of the aerospace supply chain to adopt processes like laser-beam welding, demonstrating the business case for this investment in the UK. Crucially this learning can also be applied to a variety of other sectors to support the UKs manufacturing strategy, such as electrification and defence.
Bethan Smith, Technology Manger - MTC