Welding is the process of joining metal parts by melting the surface of the connecting points on each piece, using a blow torch or flame. This is followed by hammering or pressing to bind the parts together. The concept of welding has existed since the prehistoric Bronze age. However, today's type of welding process was introduced in the 19th century, which ensued with acetylene discovery. It is one of the remarkable findings of mechanics that has yielded innumerable benefits.
Likewise, this technology revolutionized the aerospace industry allowing the successful manufacturing of commercial aircraft in the early 20th century, composed of a ‘welded steel tube frame.’ Therein, welding and advanced aircraft manufacturing has prevailed in coordination. This technology became a gateway for the engineering and development of lightweight aircraft made from lighter metals like aluminum, titanium, and magnesium. Therefore, welding is a critical process in the aircraft industry.
Here, we have compiled the types of welding techniques that are generally employed in the aircraft industry. Further, we will shed light on the new methods introduced to be used in the future.
Gas Welding
Gas welding consists of an oxy-acetylene flame produced in a torch by burning acetylene in pure oxygen. The subsequent flame has a temperature as high as 6,300 Fahrenheit (F), which can easily melt metal. The melted metal surfaces are then bonded together to yield a joint. Thus, gas welding is used in the aircraft industry to manufacture and repair aircraft.
The leading equipment involved in this type of welding are two cylinders to hold oxygen and acetylene; cylinder gauges to regulate the pressure; mixing head, colored hoses, and a spark lighter. Additional precautionary equipment is needed to ensure procedure safety, including welding goggles with the right colored lenses, a specific wrench for acetylene tank valves, any leakage, and a functional fire extinguisher.
Electric Arc Welding
Electric arc welding is the most common welding technique because it can be used on all weldable metals. In the aircraft industry, this welding technique is extensively used for manufacturing and repair.
There are three categories of electric arc welding. Each differs in their equipment and the procedure employed. However, they follow the same underlying function: forming an electric arc to concentrate the heat produced, melt, and then join metals.
The three categories of Electric arc welding are Shielded Metal Arc Welding, Gas Metal Arc welding, and Gas Tungsten Arc Welding.
Electric Resistance Welding
Electric Resistance Welding, also known as spot or seam welding, is used to join thin metal sheets. This technique is majorly employed in the development and manufacturing process of an aircraft. Electric resistance welding machines consist of two copper electrode jaws that hold the thin metals to be welded. Pressure and an electric current are applied and concentrated at a single point, which yields a resistance greater than those of the copper electrodes. This results in molten spots held in place by the jaws to unite and solidify the metal parts.
Plasma Arc Welding
Plasma Arc Welding is a new technique introduced in the late 20th century to make welding processes more accurate and manageable. It is employed in precision and miniature applications as it is performed through automated machinery. In this welding technique, a plasma torch is initiated within a tungsten electrode containing a fine copper nozzle. The torch forms a constricted plasma arc that concentrates the heat at a single point producing high-quality, exceptional welds. This high precision technique makes it an ideal welding process to be used in the aircraft industry’s future.
At Acorn Welding, we specialize in the mechanics of aircraft welding procedures. We ensure our staff is equipped with all the advanced skills and equipment to provide you with the best aircraft services. If you wish to get in touch with us, click here.
