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Laser Joining Processes for Lightweight Aircraft Structures

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Revolutionizing Aircraft Materials and Processes

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Abstract

This chapter deals with laser-based processes for joining light metals and lightweight structures. At the beginning, a short introduction concerning the tool laser beam is given. A subsequent focus will be on laser welding of aluminum, in particular deep penetration laser welding (keyhole welding). A section addresses the specific challenges of this process and the current solution approaches from research and development. Hereby, the increase in the gap bridging ability, the increase in the seam surface quality, the reduction in the susceptibility to hot cracking, the prevention of spatters and pores, and the increase in process reliability are highlighted. Especially, the laser welding of thin sheets up to thicknesses of a few millimeters is covered. Alongside the joining of aluminum alloys, the joining of dissimilar materials in particular plays a key role in aircraft construction in order to transfer the advantages of a targeted eco- and cost-efficient material mix into an efficient multi-material design of lightweight structures. A further subchapter is therefore dedicated to laser-based joining of aluminum and titanium components by deep penetration as well as heat conduction laser processes. The focus here is on the process technology approaches and the strength of the joints achieved. An outlook into the future is given by the consideration of aluminum-titanium-carbon fiber-reinforced plastic (CFRP) transition structures. However, laser irradiation has a high potential not only as a direct joining tool but also for preprocessing or post processing or as a supplementary process. Therefore, laser-based adhesive surface pretreatment processes as well as the production of novel hybrid laminar flow control (HLFC) structures based on the combination of several laser machining processes as an aerodynamic approach to reduce the kerosene consumption are demonstrated.

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Acknowledgments

The author would like to thank his current and former colleagues at the BIAS Institute in Bremen for their many years of cooperation and various support.

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    Peer Woizeschke

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  1. Department of Mechanical Engineering and Aeronautics, University of Patras, Patras, Greece

    Spiros Pantelakis

  2. Department of Mechanical Engineering and Aeronautics, University of Patras, Patras, Greece

    Konstantinos Tserpes

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Woizeschke, P. (2020). Laser Joining Processes for Lightweight Aircraft Structures. In: Pantelakis, S., Tserpes, K. (eds) Revolutionizing Aircraft Materials and Processes. Springer, Cham. https://doi.org/10.1007/978-3-030-35346-9_11

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