Design of a Lower Wing Skin Panel

New welding technology to make lighter aircraft

Laser beam welding (SRL) is entering complex
areas of large-scale application thanks to
advanced laser technologies, which allow for
process flexibility and performance
improvement. A group of researchers funded by
the European Union demonstrated their
competence by replacing conventional riveting
with laser welding in the process of producing
light structures that support heavy loads.

The use of mechanical connection technologies is
deeply rooted in the aeronautical industry, as
evidenced by the fact that around fifty thousand
rivets are used to join integral structures to the
surfaces of a typical fuselage. Laser welding is an
instrumental technology that, in addition to
being able to replace riveting in aircraft
structures, is decisive in reducing the weight of
the aircraft fuselage thanks to a greater use of
aluminum.

Within the EXTRA-LASER (Extrapolation and
technical and economic study of a laser beam
welding technology (extra-laser)) project, a
research team compared SRL and mechanical
joints, focusing on aspects related to
environmental impact, safety , the efficiency of
the process and the manufacturing costs of
aeronautical structures. The work activities were
based on the use of a representative structure of
a Clean Sky technological demonstrator: a flat
panel with four stringers.

Taking into account that most of the fatigue
failures originate in the holes of the rivet fixings,
laser welding contributes to improving the
general safety of the structure. Laser welded
structures have improved damage tolerance
thanks to better material properties and greater
process flexibility. Proper process conditions
help ensure good microstructure of the metal
alloys, which significantly influences the
formation of porosity, corrosion resistance and
susceptibility to hot cracking.
Using innovative lithium-aluminum alloys for the
demonstration panel, the team reduced the
weight of its structure by 20% without
modifying the structural design while, compared
to the rivet-bonded structure, the processing
time of the laser welded structure was 50%
lower.

The energy demand during the manufacturing
phase of the new process seems to be higher
than that of the riveting structure, although it is
also true that a lower weight will result in a
decrease in the fuel consumption of the aircraft.
In the case of SRL structures, manufacturing
costs are considerably higher due to the high
price of aluminum and lithium.

The results of the project can consolidate the use
of laser welding as a cleaner manufacturing
process with less polluting emissions.
Furthermore, the increasing use of SRL for
integral structures eliminates the need for
riveting, noisy and monotonous activity, which
reverts to a more pleasant working environment.