TIG Welding and CNC Titanium Machining for Aerospace Assemblies

Background: Aerospace Assembly Requirements

Aerospace assemblies demand extreme precision, structural integrity, and corrosion resistance. Titanium components in these assemblies often combine complex machined features with welded joints. TIG welding titanium is widely used for its precision, low heat input, and ability to maintain material properties.

In this case, the customer was producing aerospace structural assemblies composed of machined titanium components joined via TIG welding. The project required careful integration of CNC titanium machining and TIG welding processes to achieve dimensional accuracy, surface quality, and reliable joints.

Material Selection and Welding Considerations

Titanium alloys used in aerospace applications provide a high strength-to-weight ratio and excellent corrosion resistance. However, welding titanium requires strict control:

• TIG welder titanium processes were used to minimize heat-affected zones

• High-purity shielding gas prevented oxidation and contamination

• Pre-machining was optimized to allow proper weld fit-up

Machinability of titanium alloys was considered alongside weldability to avoid distortion during post-weld finishing.

CNC Titanium Machining of Components

Before welding, components were produced using CNC titanium machining, including:

• Titanium milling for flanges, pockets, and ribs

• Titanium turning for cylindrical alignment features

• Drilling for bolt holes and attachment points

All machined titanium parts were inspected for dimensional accuracy and surface quality before welding.

TIG Welding Titanium for Precision Joints

TIG welding titanium was applied for high-precision, critical joints. Key process considerations included:

• Arc control to prevent overheating

• Gas shielding coverage to avoid oxidation

• Controlled weld bead geometry for uniform strength

Titanium welder parts were fabricated with tight tolerances to allow post-weld CNC machining if required.

Post-Weld Machining and Finishing

After welding, assemblies underwent CNC machining to restore:

• Critical mating surfaces

• Alignment features

• Mounting points

Titanium milling and titanium turning were used as finishing operations, maintaining ±0.01 mm tolerances for aerospace requirements.

Heat Treatment and Stress Relief

Post-weld stress relief and selective heat treatment stabilized the assemblies, reducing residual stresses introduced during welding. Metallographic analysis confirmed no adverse effects on the titanium microstructure.

Inspection and Quality Assurance

Inspection procedures included:

• Visual inspection of welds

• CMM verification of post-weld dimensions

• Gauge checks and functional fit tests

All processes were carried out under ISO9001:2015 and IATF16949 certified systems with complete traceability.

OEM Support and Engineering Collaboration

The project was executed under an OEM model. Engineering support focused on:

• Optimizing CNC machining sequences for weld fit-up

• Selecting TIG welding parameters for different titanium alloys

• Planning post-weld machining and finishing

CAD/CAM tools such as SolidWorks, UG, and CATIA were used. Supported drawing formats included STEP, DWG, DXF, IGS, STL, and PDF. Prototype assemblies were validated prior to production.

Applications in Aerospace

TIG welding titanium combined with CNC machining is widely used in:

• Aerospace structural assemblies

• Turbine components

• Precision aerospace fixtures

This approach ensures strong, corrosion-resistant joints while maintaining tight dimensional tolerances.

Conclusion

This case demonstrates the integration of TIG welding titanium and CNC machining to produce high-precision aerospace assemblies. By controlling welding parameters, machining sequences, and post-weld finishing, manufacturers deliver reliable, structurally sound, and dimensionally accurate titanium components.