Aerospace welding is not a luxury, it’s a necessity for both legacy and modern aircraft. Metal fatigue, vibration-induced cracking, and corrosion are common problems in aircraft components, especially in high-heat and high-stress areas like exhausts, firewall structures, and engine mounts.

Instead of replacing entire assemblies, certified aviation welders can repair and restore these components, extending their life while meeting exacting regulatory standards. Welding in this context is not just about joining metal; it's about restoring functionality, maintaining safety, and preserving compliance.

According to the FAA Advisory Circular 43.13-1B, all welding repairs on aircraft components must be completed by certified personnel using approved processes, tools, and techniques. This makes choosing the right aerospace welding service crucial.

Aerospace Welding Requires More Than Just Technical Skill

Not all welders are equally good, especially in aviation. Performing welds on aircraft parts requires specialized training, certification, and a deeper understanding of materials, tolerances, and structural dynamics.

The difference between a general welder and a certified aerospace welding technician comes down to experience and regulation. In aviation, there is no margin for error. Improper heat control, incorrect filler materials, or welds that deviate even slightly from specifications can compromise the structural integrity of the entire aircraft.

Welders in aerospace applications are typically certified by agencies like Transport Canada, the FAA, or EASA. Their work must be documented, traceable, and repeatable. Welding procedures are not improvised; they are precisely followed under controlled conditions to ensure reliability and compliance.

What Makes An Aerospace Welding Service Truly Specialized

Aerospace welding facilities are a world apart from typical machine shops. These facilities invest in specialized equipment, work with aviation-grade materials, and maintain detailed records for every weld completed.

Let’s break down the three defining elements of a true aerospace welding service.

Certified Technicians And Approved Welding Procedures

All welding technicians must be certified to perform aviation welding tasks. Certification is not a one-time achievement, it requires ongoing training, periodic testing, and adherence to strict procedural standards.

Welding procedures are outlined by approved documentation such as WPS (Welding Procedure Specifications) and must be followed exactly. These documents dictate everything from amperage settings and electrode type to shielding gas composition and post-weld inspection methods.

Material-Specific Knowledge And Welding Expertise

Aircraft parts are made from complex materials such as titanium, Inconel, stainless steel, and 4130 chromoly. Each of these materials behaves differently under heat, and incorrect technique can easily lead to distortion, cracking, or premature failure.

Aerospace welding technicians understand how to manage thermal expansion, control heat-affected zones, and apply correct filler metals. This expertise is critical in parts like engine mounts and exhaust manifolds, where vibration and thermal cycling are constant.

Advanced Equipment And Inspection Capabilities

Leading aerospace welding services use industry-specific equipment such as precision TIG welders, back-purging systems for exhaust welding, and CNC-machined jigs to hold parts in perfect alignment.

Post-weld inspections are also highly technical, involving both visual inspection and non-destructive testing (NDT) like dye penetrant or magnetic particle inspection. These inspections ensure structural soundness and regulatory compliance.

Aircraft Parts That Commonly Require Aerospace Welding

Welding is used across various aircraft systems, but some components are particularly prone to damage due to their stress exposure and location. These parts require specialized handling and welding expertise to remain airworthy.

Engine Mounts

Engine mounts absorb the vibration, thrust, and weight of the engine. Over time, fatigue cracks or corrosion can appear at welded joints or mounting points. These must be repaired using certified techniques to ensure alignment and strength are maintained.

Exhaust Systems

Aircraft exhaust systems endure extreme heat and must be leak-free to prevent performance loss or carbon monoxide intrusion. Welding in this area must be precise and pressure-tested.

Carburetor Air Boxes

These components are integral to engine breathing and must maintain their structural integrity. Any distortion or leakage can result in performance loss.

Firewall Components And Brackets

The firewall protects the cabin from heat and fire. Any component welded in this area must meet high thermal resistance and structural durability standards.

Why Certification And Compliance Are Non-Negotiable

Every repair or fabricated part in aviation must be traceable and approved by regulatory bodies. This is not just a best practice, it’s the law.

Aerospace welding services must be able to provide:

• Certificates of conformance
  
• Transport Canada or FAA approval tags
  
• Repair log entries
  
• Material traceability reports
  
• Inspection documentation (including NDT results)
  

Lack of proper documentation can lead to inspection failure, fines, or even grounding of the aircraft.

What To Ask Your Aerospace Welding Provider

Choosing the right welding service is critical. Before committing, ask the following:

• Are your technicians certified under FAA or Transport Canada standards?
  
• Do you follow written welding procedures for each material and part?
  
• Can you provide documentation and traceability for each job?
  
• Are you experienced with legacy or modified aircraft parts?
  
• Do you conduct non-destructive testing and quality assurance inspections?
  

A quality aerospace welding provider will have clear answers to all of these questions and should be willing to provide documentation and references.

Long-Term Value Of Certified Aerospace Welding Services

Investing in professional welding services may cost more upfront, but it pays dividends in the long run. Certified repairs:

• Ensure continued airworthiness and compliance
  
• Reduce the risk of unexpected failures or grounding
  
• Extend the lifespan of critical components
  
• Preserve the resale value of your aircraft
  
• Offer peace of mind through inspection-ready documentation
  

In aviation, the cheapest solution is rarely the safest. Choosing a certified aerospace welding service is an investment in safety, reliability, and long-term performance.

About Us

Acorn Welding is North America’s leading provider of aircraft welding and component manufacturing services. Specializing in certified repairs and fabrication of aircraft components, our facility is approved by Transport Canada and trusted by aviation professionals worldwide. 

With a reputation built on precision, compliance, and deep aviation expertise, Acorn Welding supports a wide range of aircraft models, from legacy taildraggers to modern bush planes. To request a quote or speak with a certified technician, contact us today.