While reliable, high-quality welded parts and products are important across industries, this is particularly true in the aerospace sector for equipment fulfilling mission-critical applications. Aerospace welding encompasses any welding technique that a welder performs to join components or assemble a part for intended aerospace applications. Learn more about aerospace welding and the process’ ability to generate strong joints between air- or spacecraft components.

Aerospace Welding Services

Compared to standard practices, aerospace welding processes must comply with additional specific requirements per the National Aerospace and Defense Contractors Accreditation Program (NADCAP). Including contractors, service providers, suppliers, and government representatives, NADCAP is an industry-managed global initiative for developing and overseeing assessment, standardization, and accreditation standards.

Part of receiving and maintaining a NADCAP certification is a company’s adherence to American Welding Society (AWS) standard D17.1. AWS D17.1 outlines requirements for material selection, methodology, and welding processes. Welders must also comply with AS9100D standards, which cover quality management and assurance in the aerospace and defense sectors.

Aerospace Welding Techniques

NADCAP-certified aerospace welders might use any of the following welding methods to create durable products and assemblies:

• Metal Inert Gas (MIG) Welding: Also called Gas Metal Arc Welding (GMAW), MIG welding uses an electric arc between the workpieces and a consumable wire electrode to melt and join components. The welding gun also feeds a shielding gas that safeguards the weld from airborne contaminants.
• Tungsten Inert Gas (TIG) Welding: Another name for Gas Tungsten Arc Welding (GTAW), TIG welding uses a non-consumable tungsten electrode to make an electric arc for heating workpieces. Adding a filler metal to the weld pool as needed allows welders to bond parts successfully while an inert shielding gas protects the weld area from contamination.
• Automated Seam Welding: This technique capitalizes on the speed and precision of automated welding machinery to generate high-quality MIG or TIG welds quickly and efficiently.
• Soldering: Unlike welding, the soldering process doesn’t melt the workpieces themselves, nor does it utilize electric arcs. Instead, it uses heat to melt solder material, and that material fuses workpieces together as it cools and solidifies into a welded joint. Soldering is ideal for delicate applications like electronics.

Applications of Aerospace Welding

Welding is crucial for numerous applications within the aerospace industry, ensuring the durability and performance of critical components.

Aircraft Structures

• Fuselage: The aerospace sector requires components that are both strong and lightweight to facilitate flight and maintain safety. As such, manufacturers utilize various welding techniques to construct the body, or fuselage, of air- and spacecraft. Welding enables them to produce the complex shapes necessary for aerospace applications.
• Wings: With great precision, aerospace welding generates strong bonds between the lightweight frame components of airplane wings. These welds can withstand the stresses of flight loads and maintain wings’ structural integrity.
• Tail Sections: Manufacturers can use welding to create tail sections that deliver reliable stability and control in flight.

Engine Components

• Turbine Engines: To generate dependable joints that can handle extreme pressures and thermal conditions, manufacturers perform aerospace welding to assemble blades, casings, vanes, and other turbine engine components.
• Fuel Systems: For optimal structural integrity, welding can also create permanent, leak-proof bonds between fuel system components like pipes, manifold structures, and fuel tanks.

Other Applications

• Pneumatic and Hydraulic Systems: Aerospace systems require secure, dependable connections between components. Welded pipes and other parts within pneumatic and hydraulic systems help maintain performance and ensure operational safety.
• Heat Exchangers: This equipment regulates the temperature of air- and spacecraft systems. Welding is an effective method for assembling heat exchangers for the aerospace market.
• Landing Gear: Landing gear must absorb the impact of landings and support a craft’s weight during ground operations. Using welding to assemble landing gear promotes safety in taxiing, takeoffs, and landings.

Helander Quality Guarantee

Since 1936, Helander has provided superior metal forming services and high-quality products to companies of all sizes and industries. Our unwavering dedication to excellence is evident in everything we do.

Our industry-compliant aerospace welding capabilities specifically emphasize strength, reliability, and safety. To maintain our NADCAP and AS9100D certifications, we only source materials from NADCAP- and AS9100D-certified suppliers, use top-tier welding equipment, and continually train and evaluate our welders. Our team also performs stringent quality inspections on all of our aerospace welds — classes A, B, and C alike — and facilitates the full-time, on-site presence of a Honeywell Source Certifying Agent for welding.

To learn more about our capabilities and how we support the aerospace market, contact us today.