Welding and Fabrication for the Aerospace Industry

Our welding team includes CAA approved TIG welders and inspectors, backed by a range of MIG, seam and spot welding equipment. This allows us to handle both structural and pressure applications, in aluminium, stainless steel and specialist alloys.

Core processes include:

• TIG welding for high integrity and thin gauge work
• MIG welding for structural and higher deposition applications
• Seam welding for long, continuous joints on panels and vessels
• Spot welding for localised joining on fine limit sheet metal

This mix of processes means we can select the right method for each joint, balancing strength, distortion control and cosmetic finish depending on the end use.

A key part of our offer is the ability to bring together machined, waterjet cut and formed parts into complete welded assemblies. As a business with strong machining and sheet metal capability, we are used to managing the whole route rather than just one element of it.

Typical welded fabrications include aircraft parts machined and fabricated from titanium, where tight dimensional control and material integrity are essential. We also manufacture pressurised water boilers for aircraft, combining machining, fabrication and welding in house to deliver a fully tested, ready to install unit.

On the heavier side, we produce nuclear plant fire traps using an in house six discipline process, waterjet cutting, fabrication, machining, turning, welding and assembly. This kind of work shows how welding sits within a wider manufacturing package and demonstrates our ability to support high consequence applications.

Whether the job is a compact bracket or a large pressure vessel, the same principles apply, controlled preparation, correct weld procedure and careful inspection.

We routinely weld aluminium alloys, stainless steels and other specialist alloys used in aerospace and nuclear projects. Many parts combine different thicknesses and require a mix of full penetration structural welds and finer cosmetic fillet welds on the same assembly.

Joints range from small, tightly controlled welds on thin gauge sheet metal through to heavier structural welds on plate and section. Because we also control the upstream processes, we can ensure that edges, preps and fit up are suitable for the welding method selected, which reduces rework and improves consistency.

The ability to seam weld and spot weld adds further flexibility for fine limit sheet metal work, where long straight joints and localised spots are often better suited to those processes than manual welding.

Our welding plant is equipped with a range of modern machines to support different processes and applications, including,

• DYNASTY 350 TIG welding plant for high quality TIG work
• REHM Megaplus 400 and Butters AW251 MIG welding plants
• Meritus seam welder and Sureweld spot welder for production sheet metal work
• Weldy 1600 stick / MMA portable welder for on site or hard to access locations
• Nederman and Lincoln portable extraction to maintain a safe working environment

Extraction and fume control are built into the welding bays, supporting both operator safety and a clean environment for aerospace work. Dedicated welding areas within Factory Site 1 sit close to sheet metal, waterjet and machining, which keeps handling distances short and improves flow.

Welded fabrications at GASE benefit from the wider manufacturing capability on site. Factory Site 1 is our centre of excellence for precision fine limit sheet metal, CAA approved welded components, waterjet cutting and 5 axis milling, with additional machining and turning centres of excellence nearby on the same campus.

In practice, that means a typical aerospace fabrication might start as waterjet cut or punched blanks, move through folding and forming on press brakes, then go into a machining cell for critical features, before arriving in welding as a set of accurately prepared components. After welding, the same part can go through bead blasting, straight graining, rumbling and ultrasonic cleaning, with any subcontract finishing managed by us.

For the customer, this integrated route reduces the risk of misalignment between suppliers, shortens lead times and provides a single point of contact for what is often a complex, multi process component.

Welding is controlled within our aerospace focused quality framework. Our quality management system is certified by Bureau Veritas to AS9100 Rev D, supported by AS9102 inspection management using Q Pulse.

Inspection resources include a CRYSTA Apex CNC CMM with scanning, allowing us to verify machined and fabricated features and to inspect to GD and T with profile scanning where required. For certain programmes we carry out microscopic inspection to control foreign object debris and surface condition.

For welded fabrications and pressure vessels, this means we can offer:

• Dimensional checks on pre and post weld components
• Visual and dimensional weld inspection by approved personnel
• Full traceability of materials, welders and procedures
• Inspection reports and documentation aligned to aerospace and nuclear expectations

The combination of CAA approved welders and a robust AS9100 quality system gives customers confidence that weld integrity is backed up by appropriate process control and records.

Although aerospace is a core sector for our welded fabrications, it is not the only one. We also support nuclear, defence, electronics and other high technology industries, drawing on the same mix of fine limit sheet metal, machining and welding disciplines.

Typical applications include:

• Welded aerospace components and aircraft assemblies
• Pressurised water boilers and other aircraft systems
• Nuclear plant fire traps and safety structures
• Electronic and communication enclosures requiring both structural strength and good cosmetic finish
• Assemblies that combine machined frames with sheet metal skins and welded brackets

Each of these draws on slightly different aspects of our capability, but all of them rely on consistent welding carried out within a controlled environment.

GASE is set up to support work ranging from single prototypes through to high volume batch production. Our campus of four factories and a workforce of around 65 skilled people gives us the flexibility to respond to development programmes while still supporting established production contracts.

At the early stages of a project we can work with customers to review designs from a welding and fabrication point of view, suggesting changes that may help with access, distortion control or inspection. Because we also manage the machining and sheet metal aspects, we can consider the whole route rather than just focusing on the weld detail in isolation.

As programmes mature, we can put in place stable weld procedures and jigs to support repeatability, and link these to inspection plans and documentation packs so that ongoing production meets the same standard as the first articles.

Choosing GASE Engineering for welded fabrications and CAA approved welding gives you,

• CAA approved TIG welders and inspectors experienced in aerospace and nuclear work
• A full range of TIG, MIG, seam and spot welding processes, supported by modern plant
• The ability to combine machined and formed components into complete assemblies and pressure vessels
• Integration with fine limit sheet metal, waterjet cutting, CNC machining, turning, finishing and assembly
• An AS9100 Rev D certified quality system with advanced inspection and full traceability
• A single campus in Crayford, Kent managing the full route from raw material to finished, assembled product

If you would like to discuss a welded fabrication or pressure vessel project, or arrange a visit to see our welding facilities, the GASE Engineering team will be happy to help.