Advanced Fabrication (SAM 2 P5)

The current manufacturing process for cold complex structures involves joining cold-formed details by both mechanical and non-mechanical methods and is reliant on tacit skills inherent in skilled labour.

The main aim of this ATI-approved project was to develop novel technology to enhance the manufacture of fabricated components, to produce consistent competitive products. The project concentrated on advancing the understanding and utilisation of automated welding techniques, using robots to weld Outlet Guide Vane (OGV) components during assembly and fabrication. The project also focused on developing novel manufacturing technologies to significantly reduce cost, improved lead-time and enable more complex 3D designs for large static structures. This included the development of new laser welding techniques for joining various configurations of thin-walled aerospace materials and the laser drilling of combustion tiles, enabling the benefits of the early laser technology development to be applied onto critical aerospace components.
Collaboration with the MTC supported the aim of this project which included design, installation and development of an automated Tungsten Inert Gas (TIG) welding cell and a laser welding cell at the MTC.

The project, led by Rolls-Royce, touched a wide range of technologies and operated across different work packages. Technologies specifically addressed were robotic TIG welding, automated laser welding, novel welding fixtures, advanced welding torch designs, Laser and TIG welding predictive models.

Download the Advanced Fabrication (SAM 2 P5) case study
Short Title: SAM 2 P5
Project Number: 110104
Project Cost: £3,782,001
End Date: 31st Dec 2015
Time Horizon: Secure
Lead Partner: Rolls-Royce PLC
Attributes: Cost
ATI Value Stream: Propulsion of the future