Welding jigs ready for demonstrator assembly

Abstract

This report focuses on the opportunities and challenges of applying the static resistance welding process to a full scale upper shell fuselage demonstrator. The importance considering the assembly technologies during design phase is underlined in order to exploit the potential of the respective welding technology. Resistance welding of thermoplastic composites is highlighted as baseline technology for integrating frames into the upper shell of the Multifunctional Fuselage Demonstrator enabling high quality welds independent from part thickness. A customized welding jig for frame to skin welding is described focussing an increased degree of process automation with de-risked welding process execution.