The largest-ever research project backed by Innovate UK for developing cost-effective titanium alloy structural airframe parts is nearing completion. The three-year TiFab programme has studied more than 170 aircraft components to assess their suitability for an advanced joining process which could offer annual raw material savings of around £9m.
TiFab consortium members CAV Advanced Technologies, KUKA, Ten Solutions and The Welding Institute predict that manufacturers could save over 200 tonnes of titanium a year if they chose linear friction welding to bond parts instead of machining from solid billets.
Linear friction welding was preferred to other welding or deposition techniques because of its speed and ability to achieve near parent material properties, explained project leader Martin Wood.
With the support of several OEMs, the project team has been able to examine a vast number of candidate parts, create design solutions for tailored blanks and establish weld process parameters.
The programme has involved a fitness-for-purpose exercise and the identification of suitable demonstrator parts. The final stages of the project are underway with the demonstrator testing programme almost complete.