Recent developments in the metallurgical field offer now laser weldable Al-alloys of the 2xxx series such as 2198 (Al-Cu-Li) with high structural efficiency index due to their high strength and low density. In the project, butt and T shape welds from third generation Al-Li aluminium alloys were manufactured with the available in-house laser beam welding facilities. Upon the information gained in the project and in-house experience of the manufacturer (HZG) a large, typical aeronautical structure with stiffeners were manufactured and exploited in this project. A similar structure was manufactured by the Topic Manager with the conventional riveting process.

The projects aimed to document the two processes (LBW and riveting), calculate the manufacturing costs of both structures, perform mechanical tests on the structures and finally compare the two structures in terms of the mechanical performance to manufacturing cost index. Besides cost, the environmental footprint of the two different structures were calculated, as well the extrapolation of the LBW process from Laboratory to Industrial environment.

To this end, the intermediate processes were documented, risk assessment was performed and a manufacturing plan of the typical aircraft structure was constructed. Of course, any industrial repercussion during the implementation of the technology in the manufacturing plant was taken into account during calculation of the implementation plan.