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Résultats exploitables
The development of welded structures has been identified by airframe manufacturers as potentially leading to lighter airframes and low-cost manufacturing. Weight and cost efficiency can be obtained on the 'integral structure' or 'rivet-free' aluminum (Al)-alloy airframes through the use of advanced welding technologies, such as laser beam (LBW) and friction stir welding (FSW), and the introduction of new aluminum alloys with improved performances.
A318 and A380 aircraft are already flying having had their fuselage panels manufactured with large distance LBW skin-stringer joints. Now, there is a need to extend the current level of technology to 'more critical and difficult-to-join' sections of metallic airframes with the replacement of conventional riveted sub-sections with a short distance welded integral structure, which exhibits light-weight and damage-tolerant features.
Within this context, the main scientific and technological objectives of the Wel-air project were:
- to optimise and validate the most suitable short distance laser beam welding process parameters for various Al-alloy combinations for the joining of stiffener/clip-skin connections of airframes by understanding and controlling the basic mechanisms of hot tearing, crack initiation and crack growth at the run-in/out location;
- to develop a short distance friction stir welding process for suitable joints and non-laser weldable alloys and gain knowledge about these new applications;
- to develop repair schemes of short distance welds and define allowable damages to minimise the maintenance and operational costs;
- to conduct systematic damage tolerance analysis on short distance welded coupons to establish the mechanisms of initiation and spread of the damage at or around the run-outs;
- to establish structural safety provisions for the case of ageing and corrosion damage (long-term behaviour/durability) by understanding the micro-mechanism/metallurgy of the damage at the short distance welds.
The Wel-air project developed:
- a complete database, which is related to the manufacture and performance of innovative and improved welding concepts for stiffener-clip-skin connection including new joint design, laser beam welding and friction stir welding procedures and a selection of new high performance light alloys for both stiffeners and skin;
- run-in/out control and repair procedures for both laser beam welding and friction stir welding;
- recommendations on optimum material conditions (temper and surface) prior to welding to optimise the post-welding behaviour;
- damage tolerance data and fundamental rules for the integration of new welding on aircraft sections that are more critical.
The technical approach of the project followed a 'develop, test, check, make recommendations, validate on components' pattern, split into five technical Work Packages. The first three Work Packages dealt with the establishment of databases relative to potential techniques for improving the fatigue and damage tolerance behaviour of short distance welds, using both friction stir welding and laser beam welding for stiffener-skin connections.
Key results of the Wel-air project include:
- short distance welding procedures for stiffener-skin connections using LBW and FSW;
- fatigue and damage tolerance behaviour of run-in/out;
- new high performance alloys combinations: Alcan Al-alloys;
- Behaviour analysis from basic specimen to technological components.
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