Resolving Weld Failures Impacting Fleet Flight Safety
The Challenge
The existing weld process used by a sub-tier supplier lacked proper qualification, repeatability, and documented inspection controls. Without a validated process or defined acceptance criteria, weld integrity varied from batch to batch resulting in structural failures under operational loads.
Impact
- Flight-safety risk across the entire propulsion fleet
- Unplanned downtime and field repairs
- Loss of confidence in supplier capability
- No qualified weld procedure or inspection plan
- High potential for recurring failures without intervention
Solution
The project centered on a full root-cause investigation and collaborative process development with the sub-tier supplier. Key actions included establishing a qualified weld procedure, defining process parameters, and developing inspection plans tailored to propulsion-system requirements. The qualification effort ensured the weld process met structural, thermal, and operational load conditions.
Outcome
The new weld process eliminated field failures and restored fleet safety. The qualified procedure and inspection plans provided repeatable weld quality, improved supplier performance, and ensured long-term reliability of propulsion systems across all operating environments.
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Our Approach
The Results
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