Periodic Reporting for period 1 - WELDER (Welding Equipment for optimised, fast and accurate LongituDinal barrEl joint closuRe)
Reporting period: 2021-01-01 to 2022-06-30
The manufacturing large-scale parts/components is a complex and challenging process that requires the implementation of an integrated approach capable of ensuring the manufacturability, quality and high-precision of the large-parts from the engineering stages –i.e. design, simulation/modelling and production planning—. Europe is leading the manufacturing of complex large-scale components with worldwide and top-class manufacturing companies (e.g. AIRBUS, FOKKER). This demanding manufacturing of large parts is the foundation for the
competitiveness of the EU aeronautic strategic value chain. The welding operations of the airplane fuselage (i.e. manufacturing of large-scale components) demand the implementation of a holistic data management and a comprehensive automation methodology to achieve the desired levels of productivity, efficiency and quality based on the development and implementation of modular and flexible equipment (Plug-and-Produce concept).
The main objective of the WELDER project is to design, develop and deploy at TL´s facilities two robot-based and fully operative welding solutions (namely, ultrasonic welding end-effectors and resistance welding end-effectors), including all the needed tooling and auxiliaries for the longitudinal barrel joint of the 8m long fuselage demonstrator. Moreover, WELDER will be focused on implementing an online monitoring and control system based on an endto-end digital manufacturing solution, enabling a bidirectional dataflow to feed the whole lifecycle management digital twin and, thus, optimising the process and product performance and while enabling new approval/acceptance procedures. Therefore, the successful execution of the WELDER project will become the spearhead of the aerospace
industry thermoplastic adoption strategy through the provision and demonstration of the airplane fuselage welding replacing conventional joining systems relying on fastening, riveting and adhesives, thus highly improving the environmental and economic performance of the aerospace sector, according to CS2 objectives.
competitiveness of the EU aeronautic strategic value chain. The welding operations of the airplane fuselage (i.e. manufacturing of large-scale components) demand the implementation of a holistic data management and a comprehensive automation methodology to achieve the desired levels of productivity, efficiency and quality based on the development and implementation of modular and flexible equipment (Plug-and-Produce concept).
The main objective of the WELDER project is to design, develop and deploy at TL´s facilities two robot-based and fully operative welding solutions (namely, ultrasonic welding end-effectors and resistance welding end-effectors), including all the needed tooling and auxiliaries for the longitudinal barrel joint of the 8m long fuselage demonstrator. Moreover, WELDER will be focused on implementing an online monitoring and control system based on an endto-end digital manufacturing solution, enabling a bidirectional dataflow to feed the whole lifecycle management digital twin and, thus, optimising the process and product performance and while enabling new approval/acceptance procedures. Therefore, the successful execution of the WELDER project will become the spearhead of the aerospace
industry thermoplastic adoption strategy through the provision and demonstration of the airplane fuselage welding replacing conventional joining systems relying on fastening, riveting and adhesives, thus highly improving the environmental and economic performance of the aerospace sector, according to CS2 objectives.
WELDER project began on January of 2021 in a Kick-off meeting participated by the partners, CT Ingenieros, AIMEN, AITIIP and Dukane jointly the topic leader, Airbus. Dukane own the responsability started with the design of the ultrasonic welding head and AITIIP with the design of the resistance welding head.
Dukane proposed their innovative sonotrode solution, the rotary sonotrode and was tested with the thermoplastic. However the results wasn't good enough to be confidence that the welding head will works in a proper way. WELDER consortium decided to use the conventional sonotrode. The welding head is already manufactured and delivered pending of the integration.
AITIIP has designed and manufactured the resistance welding and is completly functional. The first trials with the welding head have started at AITIIP facilities in Zaragoza. The resistance welding head is still pending to be integrated in MULTIFAL project and is expected to accomplish by the end of the year. AITIIP is responsible for the manufacturing of Frame Couplings, the parts which will join the frames of the Upper and Lower Shell and will be welded by resistance welding with their own welding head.
Supporting the design activities, AIMEN was performing welding trials in their laboratories, derisking and feeding the designs. WELDER with the support from CT Ingenieros has performed Finite Elements simulations jointly with AIMEN welding trials for a better understanding on the welding strategies, parameters and properties.
Dukane proposed their innovative sonotrode solution, the rotary sonotrode and was tested with the thermoplastic. However the results wasn't good enough to be confidence that the welding head will works in a proper way. WELDER consortium decided to use the conventional sonotrode. The welding head is already manufactured and delivered pending of the integration.
AITIIP has designed and manufactured the resistance welding and is completly functional. The first trials with the welding head have started at AITIIP facilities in Zaragoza. The resistance welding head is still pending to be integrated in MULTIFAL project and is expected to accomplish by the end of the year. AITIIP is responsible for the manufacturing of Frame Couplings, the parts which will join the frames of the Upper and Lower Shell and will be welded by resistance welding with their own welding head.
Supporting the design activities, AIMEN was performing welding trials in their laboratories, derisking and feeding the designs. WELDER with the support from CT Ingenieros has performed Finite Elements simulations jointly with AIMEN welding trials for a better understanding on the welding strategies, parameters and properties.
Nowadays, composites used in aerospace have mainly been thermoset composites (TSCs). Currently the trend has changed towards the use of thermoplastic composites (TPCs). They require higher temperatures and pressures during manufacturing but they can be remelted, promising benefits in repair and end-of-life recyclability.
The first results obtained in the laboratories are promising for both techcnologies . We believe the utrasonic and resistance welding have a great future in the reduction of weight and reducing the time manufacturing of the future airframes. Focus on reducing airframes weight, turn into less fuel consumption and less CO2 emmisions helping to reverse the climate change.
The first results obtained in the laboratories are promising for both techcnologies . We believe the utrasonic and resistance welding have a great future in the reduction of weight and reducing the time manufacturing of the future airframes. Focus on reducing airframes weight, turn into less fuel consumption and less CO2 emmisions helping to reverse the climate change.