Aerospace manufacturer solves weld root penetration problem with ID weld profiling machine

Tri Tool designed and developed a custom precision tube squaring machine to remove difficult-to-reach weld root penetration.

Situation

Like the arteries, veins, and capillaries of the human body, extensive piping and tubing systems deliver essential gases and liquids to critical equipment and systems within space- and aircraft, as well as to critical infrastructure such as launch pads.

Welding of these pipes and tubes is a delicate process, and the work often is performed in confined spaces such as tube racks or the wings of an airplane. In these difficult-to-reach areas, weld root penetration becomes a concern.

When fabricating a small, two-part diffuser nozzle weldment at its California facility, a private aerospace manufacturer noticed a small weld root penetration inside the nozzle chamber caused by the arc welding process. If not removed, the weld root penetration would disrupt the flow of fluid and compromise the nozzle’s performance.

The manufacturer’s previous attempts using off-the-shelf hand-held tooling to remove the root penetration resulted in inconsistent surface finishes that hampered subsequent nondestructive tests on the weld. To avoid having to redo the entire fabrication process, the company needed a tool that could reach inside the nozzle and machine the weld root to be flush.

Resolution

For the project, Tri Tool engineers were given minimal drawings of the nozzle parameters and tasked with designing an ID weld profiling system that could access the nozzle chamber through a 1-in. tube inside of the nozzle throat. The machine system had to travel 4 in. to reach the weld root and had to trim the weld root down by 0.15 in.

Tri Tool modified its existing model 302 ID weld profiling system, changing the size configurations and capabilities to meet the aerospace manufacturer’s specifications. The company also created an adjustable T-shaped handle jig to help ensure accurate, repeatable machining results.

The customized machine was able to access the weld root and smooth the interior profile of the nozzle without cost or schedule delays. The manufacturer continues to use the tool at its California facility as a critical component of its advanced manufacturing process.