Revolutionising TIG welding for aerospace manufacturing

Electrical switching & drive systems & components

First Quarter 2025 Electrical switching & drive systems & components

Yaskawa Southern Africa has partnered with Aerosud Aviation, a leading aerospace manufacturer, to implement a cutting-edge robotic TIG welding solution tailored to the exacting demands of aerospace production. The collaboration, highlighting both companies’ commitment to innovation, precision and efficiency, is poised to strengthen Aerosud’s production capabilities and ensure compliance with stringent original equipment manufacturer (OEM) standards.

The project, spearheaded by Yaskawa’s national project manager, Devon Prinsloo, and Aerosud’s welding engineer, Nico du Toit, demonstrates the potential of automation and robotics to transform aerospace manufacturing.

Meeting aerospace challenges with advanced automation

Aerosud’s need to scale up the production of aluminium track cans for Airbus A320 aircraft was a key driver for the project. “Airbus is ramping up production on its Single Aisle aircraft, requiring us, as a single-source supplier, to increase throughput,” explains Du Toit. “This welding robot solution allows us to repeatedly produce uniform welds on 1,4 to 1,6 mm aluminium while meeting OEM specifications with the highest efficiency.”

The TIG welding process, chosen for its superior quality and precision, delivers clean, consistent welds with minimal distortion, and is essential for aerospace components. The solution integrates Yaskawa’s high-precision robotic arms, Fronius TIG welding systems and a SERVO-ROBOT Micro-Trac camera system, ensuring accurate seam tracking and filler wire positioning. “The camera scans the weld seam before welding, enabling precise alignment,” says Prinsloo. “This approach not only ensures repeatability, but also reduces waste by minimising errors. Automation in TIG welding enhances safety, precision and efficiency, all of which are critical in aerospace manufacturing.”

Seamless integration and tangible benefits

Yaskawa’s expertise in robotics and software was instrumental in overcoming the complexities of aerospace welding. Using MotoSim simulation software, the welding process was meticulously planned, reducing programming errors and setup time. Additionally, Yaskawa’s custom solutions addressed challenges such as variable component geometries, and maintaining consistency across diverse materials.

The impact on Aerosud’s operations has been significant. “This technology improves workflow efficiency by reducing rework and increasing yield,” notes Du Toit. “Automation allows us to maintain consistent quality, while scaling up production. This positions Aerosud as a competitive, innovative supplier in the global aerospace market.”

A commitment to innovation

The success of this project underscores Yaskawa’s mission to push the boundaries of automation technology. “This collaboration reflects our dedication to developing solutions that address the most complex manufacturing demands,” says Prinsloo. “Aerospace manufacturing requires precision and reliability, and Yaskawa is proud to contribute to Aerosud’s growth and innovation.”

Looking ahead, the partnership between Yaskawa and Aerosud is set to explore new advancements, including adaptive welding technologies. By leveraging their combined expertise, the two companies are paving the way for further innovation in aerospace robotics and manufacturing.

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Electrical switching & drive systems & components

Revolutionising TIG welding for aerospace manufacturing

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