Robot-based Continuous Ultrasonic Welding for Automated Production of Aerospace Structures

Abstract

Thermoplastic composite materials for structural aircraft components offer advantages in terms of performance and efficient production. In this context, ultrasonic welding is a promising joining technique that could replace the classical mechanical fastening by riveting and bolting which requires extensive drilling and sealing. At the Center for Lightweight Production Technology (ZLP) in Augsburg a robot-based continuous ultrasonic welding system has been developed. It consists of an end-effector mounted on a standard industrial robot, which allows the flexible joining of large flat and double-curved structures. The functional efficiency has already been proven on various components such as a stiffened fuselage panel or a rear pressure bulkhead. In order to benefit from the high welding speed this fusion bonding process is currently being matured to further improve robustness. A parameter study was carried out to identify optimized processing parameters.