Fun Fact #13: Did you know that welding can be used to repair airplane engines while they're still running?
Welding in Flight: The Art of Plasma Welding on Live Engines
Plasma welding is one of the most advanced welding techniques, and it’s used in some of the most extreme conditions—including repairing minor damage on airplane engines while they are still running. This type of welding is used to repair small cracks or imperfections in the turbine blades of jet engines, which would otherwise cause significant damage over time. These repairs are done while the engine is operating because shutting down and disassembling the engine for minor repairs would be incredibly time-consuming and expensive.
How Plasma Welding Works
Plasma welding is similar to TIG welding but uses a more focused plasma arc. It allows for extremely precise control of heat, which is why it's preferred in applications requiring minimal heat distortion, such as aerospace.
- Temperatures: Plasma arcs can reach temperatures of 50,000°F (27,760°C), making them hot enough to melt metal instantly and create strong, precise welds.
- Precision: This high degree of precision is critical for in-flight repairs, where even a small amount of distortion or excess heat can damage the surrounding components of the jet engine.
The Benefits of Plasma Welding for In-Flight Repairs
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Minimizes Downtime: Repairing engines in-flight or while they're running saves millions in downtime, making it an attractive option for commercial airlines and military aircraft.
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Extends Engine Life: Regular in-flight maintenance through plasma welding can extend the life of aircraft engines by fixing small cracks before they become catastrophic failures.
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Incredible Precision: Plasma welding offers control that is critical when working on delicate components such as turbine blades. This precision ensures that only the necessary areas are welded, reducing the risk of additional damage to the engine.