Application of Laser Welding in Aircraft Engines
(1) Application of Laser Welding in Engine Manufacturing Laser welding technology offers distinct advantages in welding thin-walled, high-precision components for aeroengines due to its superior heat source characteristics, precise deformation control, and broad material compatibility. It holds significant development potential for welding new materials such as aerospace high-temperature alloys, titanium alloys, and titanium-aluminum intermetallic compounds. Overseas countries place high importance on the R&D and application of laser welding technology for aerospace components. The EU Sixth Framework Program project AROSATEC conducted laser welding research targeting compressor stator and blade vane assemblies, high- and low-pressure blade outlet connections to cover plates, and turbine casings.
Pratt & Whitney has achieved automated laser welding for turbine blade components, including secondary turbine rotor blades for the JT9D and FLO engines, as well as turbine blades, guide vanes, casings, and combustion chambers for engines such as the V2500, F100-P, W-220, PW2037, and PW4000. General Electric has successfully laser-welded engine guide vane assemblies, effectively addressing deformation and cracking issues in nickel-based alloy components. The company also employed a 6kW CO₂ laser system to weld jet engine combustion chamber liners. UK-based R&R has automated welding of titanium alloys and high-temperature alloys using solid-state lasers integrated with robotic systems. This ensures weld consistency and process repeatability, minimizes distortion, reduces residual stresses in joints, and significantly cuts post-weld straightening requirements. Japanese JAEC affiliates employed a 6kW CO₂ laser system to weld front and rear sections of the V2500 engine fan casing.
As early as the late 1990s, a company collaborated with Northwestern Polytechnical University to conduct joint research on laser welding processes for Inconel 625 high-temperature alloy front and rear cold air ducts in aeroengines. Utilizing CO₂ laser welding equipment, they developed a complete welding process—from pre-weld cleaning and assembly to post-weld treatment—meeting operational requirements. The Beijing Institute of Aeronautical Manufacturing Engineering has applied laser welding technology to the production of titanium alloy load-bearing components in engines. By replacing plate diffusion bonding with laser welding, the institute pioneered research in China on multi-layer structure manufacturing processes combining titanium alloy superplastic forming and laser welding. Boeing and Washington State University have jointly developed a combined superplastic forming and laser welding process. Laser welding enables more flexible core plate pattern construction, significantly enhancing production efficiency and reducing costs.
(2) Laser Welding Applications in Engine Repair Primary damage forms in engine components include foreign object impacts, wear, cracks, ablation, and manufacturing defects. The diversity of component materials, damage locations, and damage types dictates the complexity of post-damage welding repairs. Laser welding repair technology facilitates near-net-shape forming and reduces crack generation, making it widely applied in aerospace engine component repairs.
Honeywell has successfully applied laser welding technology to repair blades in the LF507 engine for the Avro RJ regional jet series. Canada's Liburdi Group employs automated wire-fed laser welding equipment for blade repairs, achieving successful restoration of high-, medium-, and low-pressure turbine blades for RB211 engines (see Figure 7). In 2001, the company obtained authorization from R&R to specialize in laser welding repairs for RB211 engine blades and other components. Germany's MTU has developed laser welding technology for repairing damaged blades on fan integral blisks, establishing repair specifications encompassing welding, machining, precision polishing, and non-destructive testing.
Drawing on years of technical expertise in laser welding, Top Optics Laser has accumulated extensive experience in aerospace engine manufacturing and maintenance. We can tailor welding solutions to meet diverse requirements. For more details, please call 0510-66663333!