Laser Welding Optimization for High-Performance Nickel Superalloy Aerostructures & Propulsion Systems

Nickel-based superalloys, such as Inconel 625 and IN792 DS, are essential for aerospace, propulsion, and hypersonic applications due to their high-temperature strength and oxidation resistance. However, traditional welding methods, such as Electron Beam Welding (EBW) and Gas Tungsten Arc Welding (GTAW), face challenges in precision, defect formation, and scalability, particularly for thick-section components (>0.25 inches). The Templar-Weld Approach leverages advanced laser welding to optimize deep-penetration welds, reducing heat-affected zones (HAZ), distortion, and residual stress while improving joint integrity and repeatability. This Phase I effort will develop and refine laser welding process parameters for cast, wrought, and additively manufactured (AM) Nickel-based superalloys, conduct metallurgical and mechanical testing, benchmark laser welding against EBW, and assess commercial robotic laser welding systems for scalability and Air Force integration. The outcome will provide a validated, cost-effective, and high-precision welding process for next-generation aerospace and defense components.