"Resistance welding is a technology widely used in the manufacture of aeronautical components"
Testing, validation and technical support services for resistance welding
Our laboratories provide testing, validation and technical support services for resistance welding to help companies meet the requirements set out by the main international standards for aerospace applications: AWS D17.2 “Specification for Resistance Welding for Aerospace Applications” and ISO 16338 “Welding for aerospace applications – Resistance spot and seam welding”.
These standards set out the general requirements for spot and seam welding on aeronautical components, including aspects related to the certification of machines, the qualification of welding procedures, production controls and the acceptance criteria for welded joints.
- Both spot or seam resistance welding is a technology widely used in the manufacture of aerospace components due to its high productivity, repeatability and ability to join materials of reduced thicknesses.
- However, ensuring that these processes meet the aerospace sector’s strict quality and safety requirements calls for appropriately certified equipment, procedures and personnel.
A comprehensive approach to process certification
Compliance with these standards involves much more than simply checking that a welding machine is working properly. The requirements set out in the regulatory documents cover the certification of equipment, the definition and validation of process parameters and the proper preparation and cleaning of materials. They also cover the suitability of the electrodes, tools and test systems used, as well as the training and qualifications of the personnel involved in the various stages of the process.
Furthermore, the standards require production testing and monitoring activities to ensure quality, as well as the assessment of welded joints through mechanical testing, specific inspections and defined acceptance criteria. In this context, having expertise in both materials and manufacturing processes is key in order to shorten development times and maximise the chances of success during the certification stages.
Support in the search for welding parameters
One of the most common challenges facing aerospace manufacturers and suppliers is identifying a robust process window that enables them to fulfil both regulatory requirements and production demands.
As well as carrying out the tests required for certification, TECNALIA supports its clients in the identification and optimisation of the most suitable welding parameters for each combination of material, thickness and joint configuration. This preliminary work enables robust welding procedures to be defined and the number of iterations required during the validation phase to be minimised.
Thanks to our extensive experience in joint technologies and advanced manufacturing, we help companies obtain certification faster, more reliably and in a more reproducible way, whilst reducing the technical risks and costs associated with industrial development.
Testing and assessment capabilities
Our laboratories have the necessary capabilities, equipment and methodologies to carry out the characterisation and validation work required for resistance welding processes used in aerospace applications. These capabilities include the certification of welding machines and procedures, the metallographic assessment of joints to verify their integrity and quality, the performance of mechanical shear tests to determine their structural performance, as well as the inspection and analysis of any discontinuities that may affect the performance or reliability of the joints.
Thanks to this combination of technical resources and specialised expertise, it is possible to take a comprehensive approach to the validation and certification requirements set out in the regulations applicable to the aerospace sector.
Technological partner for the aerospace sector
Increasing demand for lightweight and highly reliable structures is driving the use of advanced joint solutions in the aerospace sector. Against this backdrop, TECNALIA provides manufacturers, Tier 1 suppliers and the aerospace supply chain with access to our laboratory facilities, expertise in joint processes and experience with international standards, to facilitate the certification of their resistance welding processes and accelerate the time-to-market for new products.
Are you developing a new spot or seam welding process for aerospace applications? At TECNALIA, we can help you define, validate and certify your process with guarantees from the initial stages of development.