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Developed by engineers at MetLase in Rotherham, the ‘gas shield’ controls argon delivery within shielded welding, preventing the age-old problem of oxygen or water vapour affecting the quality of the weld.
Using precision laser cutting technology and patented joining methodology, MetLase identified an engineering grade metallic foam that dissipates the argon gas in a precise manner, providing an almost perfect inert atmosphere for the process.
It also developed a digital enhancement, which has the ability to provide constant information and alerts prior to the welding taking place.
“This was a significant challenge for our team but one we relished, as it also gave us the opportunity to ‘prove-out’ some new joining techniques we had developed, whilst integrating digital technologies into the mix that deliver a game-changing solution to the welding process,” said Jon Ham, lead engineer on the project.
“The aerospace industry has stringent quality standards to meet and we had to find an answer that would produce welding performance better than 10 parts per million and could be used across numerous civil engine variants.”
He added: “Innovation and pushing the boundaries of engineering is what we do best, and I’m delighted to report that our gas shield provides a significant reduction in welding rework, which saves considerable time and cost.”
MetLase, which is a joint venture between Unipart and Rolls-Royce, is now looking at ways to customise the solution for other aerospace customers, with the firm’s standardised manufacturing process meaning it could take just two weeks to provide a bespoke ‘shield solution’.
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Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers.