Aluminium Honeycomb Panel with Aluminium Extrusion Welding

[KVARM]

Hello,

I am seeking a welding expert to assist with a project involving an Aluminium honeycomb panel with Aluminium extrusion.

Specification:

• Honeycomb Panel Dimensions: 45 mm Height, core bonded with glue
• Top and Bottom Skin Thickness: 1 mm
• Extrusion Type: C-Type
• Extrusion Thickness: 3 mm
• Welding Requirement: Four-side edge welding of extrusion to honeycomb panel

Welding Method:

I am considering several welding methods for this application:

• Laser Beam Welding (LBW)
• Electron Beam Welding (EBW)
• Friction Stir Welding (FSW)
• TIG/MIG Welding

I would appreciate your expert guidance on the most suitable welding technique for our specific requirements, taking into account factors such as heat input, joint quality, and potential damage to the honeycomb core.

Thank you for your time and consideration. I look forward to your valuable input.

 

[SWComposites]

You better be certain that the welding heat does not destroy the core to facesheet bond.

Also, show a sketch of your part.

 

[kingnero]

I've got extensive experience with fabrication of train panels (floor, roof, side wall, partitions, ...). Similar, but not the same. Certainly not glue bonded, they're exclusively extruded honeycomb panels.
All longitudinal joints there are welded by FSW. Double-sided simultaneously, if possible (depends on the machines that are available at the manufacturer).
Close collaboration is necessary with the extruder. Fabrication/extrusion parameters are paramount, both in dimensions/straightness as the structure of the aluminium (be aware that a lot of alloys can be made using the same designation, eg. EN-AW 6005, in both fibrous and recristallyzed structure, each with their own specific properties that impact weldability.

All other joints are made using MIG and TIG. There are no transverse welds ever made using FSW that I am aware of.
Also, quite some longitudinal joints are welded using automated MIG, but then there are backing strips extruded into the panel. But also for FSW, the joints are optimised and extruded in order to accomodate the welding process and geometry.

That being said, good luck welding 1 mm plate to a 3 mm extrusion. Not impossible, not easy either.

 

[KVARM]

Please find attached a photo of the Aluminium honeycomb panel welding. This joint was achieved through Laser Beam Welding (LBW). I would appreciate your expertise in suggesting alternative welding methods or optimizing the existing LBW process.

 

[kingnero]

Laser welding could possibly be a good solution. Joint looks cold from the picture. You need to optimise your parameters and perform macrographic sections in order to be able to correctly assess the weld quality.