Welding is an essential part of most industries. Almost every object around us — from furniture to automobiles to window railings — was built on the expertise of welders.

The same can be said for the aerospace industry.

Also called structural welding, aerospace welding involves fusing together metallic components to provide structural support in aircraft and spacecraft. Some of the most common welding processes seen in the aerospace industry include: 

• Gas welding 
• Gas Tungsten Arc welding 
• Resistance welding 
• Electron Beam welding 

The key differences between structural welding and other welding processes, however, are that the welds here must be clean, heated to high temperatures, and cooled faster. Considering how crucial the process is, aerospace welding also involves taking a few extra precautions. 

Welding has been used in the construction of some of the first few commercial aircraft and has continued to be relevant as technology has evolved.  

Let’s take a closer look at some of its major contributions. 

Plugging Leaks 

Welding processes are crucial to increasing the efficiency of aircraft.

Regular maintenance of engines, for instance, has been proven to have a direct impact on fuel consumption and costs. On the other hand, even a small leak in an aircraft’s fuel tank can cause major disruptions, and in the worst case, lead to an aircraft running out of fuel mid-air.

By employing the right welding processes and leaning on the KnowHow of experts, the industry can go a long way in countering any accidents caused by negligence. 

Smoother Flights 

We’ve all been on shaky and unstable flights at some point in our lives. This can be uncomfortable at best and scary at worst. Here too, welding processes play a big part. 

Provided the aerospace welders use the right processes and ensure that the cuts are clean and that all components are in place, flights will be a lot smoother.

This not only enables passengers to have a more comfortable flight but that pilots can do their jobs more efficiently. In some cases, even the smallest of errors in welding can lead to much bigger issues, such as cracks developing along the plane. 

Modernizing Components 

Aerospace welders are also responsible for innovation — experimenting with newer materials and processes to ensure faster and more efficient flights.

As engineers figure out ways to create lighter aircrafts that use less fuel, the contribution of aerospace welding experts cannot be understated. 

Preventing Accidents 

Faulty welding processes can prevent devastating incidents such as fire outbreaks or carbon monoxide filling up in the cabin.

While the former can be prevented by implementing welding processes to fix leaks in the fuel tanks, the latter can be avoided by fixing cracks and leaks in the exhaust system. 

In both cases, it’s crucial that the aerospace welder relies on the latest technologies and makes no errors.

Forge Forward with nexAir  

Aerospace welding is a lucrative profession that takes time, effort, and long hours of training to master. nexAir, the leading supplier of welding equipment and technological KnowHow since the 1940s, understands this all too well. 

This is why we’re committed to exploring the latest innovations in the welding industry and helping welders Forge Forward with the right tools and training to minimize error. With our support, structural welders can focus on what truly matters — furthering the future of aerospace innovation.