AEROSPACE


Laser processing in aerospace manufacturing


www.lasersystemseurope.com/industries/aerospace


Lasers are seeing increasing uptake in aircraft production for applications such as cutting, welding, cleaning, drilling and additive manufacturing


The aerospace sector – which encompasses commercial and military aircraft, satellites, space vehicles, drones, and unmanned aerial vehicles (UAVs) – has undergone some seismic changes in recent years. A proliferation of companies has entered the space race, many of whom require innovative manufacturing techniques for their technologies. By contrast, the impact on commercial aviation of travel restrictions due to the pandemic led to a drop of one third in the rate of civil aircraft manufacturing. In 2019, Europe was one of the


world leaders in civil aeroplane and helicopter production (including various components, parts and aircraft engines), providing around 400,000 jobs and generating €130bn in revenue. While space exploration and defence were largely unaffected by the pandemic, civil aircraft production is still in the recovery stage. In Planning for Uncertainty in Commercial Aerospace, published in February 2023, McKinsey reported a global backlog in orders of 9,400 passenger


aircraft (mostly narrow-body jets) which need building before the end of 2027. But there is uncertainty in the future growth of passenger air travel and in the robustness of supply chains and the workforce. So manufacturers will need to become more productive and nimble to clear the backlog and respond to future changes in demand. The ability of laser processing


to increase productivity and keep costs low could play a crucial role in enabling such a response from the aerospace industry. Laser processing, in the form of cutting, welding, peening and drilling is integral to aerospace manufacturing. Lasers are used to produce flaps for aircraft wings, wing fasteners, parts of jet engines, and parts of seats, for example, as well as being employed to repair turbines, clean or strip paint from components, and prepare surfaces for further processing. Laser additive manufacturing (AM) is also gaining traction in the space flight sector, while there is an increasing requirement for laser marking of aerospace parts for traceability.


Laser cutting and welding Laser cutting is a fast, cost- efficient and, most importantly, precise process that can be used to meet the stringent fabrication requirements of the aerospace sector. Compared with conventional machining, the accuracy of laser cutting results in less material waste, while the process is also faster, cheaper and the equipment needs less servicing. In addition, productivity is maximised because any required changes to


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the machining can be carried out quickly and readily. It can be used in the


production of wing fastener parts, fixture parts, end effector parts, tooling parts, and more. For example, it is equally suitable for small components such as grafoil gaskets and titanium bleed air duct manifolds, as for larger parts such as exhaust cones. It can process a wide range of aerospace materials including aluminium, Hastelloy (nickel that has been alloyed with elements such as molybdenum and chromium), Inconel, nickel alloys, nitinol, stainless steel, tantalum and titanium. Laser welding is also


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used within the aerospace sector, as an alternative to conventional joining methods such as adhesive bonding and mechanical fastening. For example, using lasers to weld lightweight aluminium alloys and carbon fibre-reinforced polymer (CFRP) materials in airframe manufacture is of growing interest, being used to replace riveting wherever possible. Techniques such as laser wobble welding have also seen success in the joining of fuel tanks, where they offer improved joint efficiency, strength, reduced rework and substantial cost savings. Other welding successes in aerospace include joining the cast cores of turbine blades to cover plates, and creating new types of lightweight wing flap that offer increased laminar flow control – thereby minimising drag and optimising fuel efficiency. Overall, laser welding has the


potential to save costs, reduce the weight of components and improve weld quality compared


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