Laser Welding
Depending on the model and size of the aeroplane, between 500,000 and over a million rivets are set during the conventional production of commercial aircraft.
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Considerable weight savings and higher manufacturing process rates can be achieved by welding seams using laser beams. The laser welder moves along the component much faster than an automatic riveting machine and at the same time creates a join that is of a quality comparable to a riveted construction. In this way it is possible to lower the production costs per shell unit by up to 20 percent. Furthermore, this method can be smoothly integrated into existing production processes. It is merely the type of join that is changed, not the basic principle of the construction. If necessary, subsequent repairs can be carried out as hitherto using existing methods and tooling. Welded joins have positive side effects. For example, as the welding process produces a positive locking of elements that allows the transmission of energy over the whole length of the join, the design engineers are confronted by both new challenges and also new chances. In addition, a welded construction is less prone to corrosion since on the outer surface the holes that would be needed for the rivets are absent. EADS Military Air Systems makes use of laser welding in the manufacture of structural components for Eurofighter at its Augsburg plant.
