A scalable cost modelling architecture for evaluating the production cost-effectiveness of novel joining techniques for aircraft structures

This work introduces a cost modelling architecture in order to determine the cost-effectiveness of the latest joining technology developments. Riveting is the conventional joining method in the aerospace industry, but is a time-consuming, expensive process that adds excessive weight to a structure. As part of the JTI Clean Sky 2 Joint Technology Initiative, the OASIS project (“Optimization of Friction Stir Welding (FSW) and Laser Beam Welding (LBW) for assembly of structural aircraft parts”) aims to demonstrate the feasibility and cost-effectiveness of novel joining technologies. The technologies being investigated are LBW, FSW and Friction Stir Spot Welding (FSSW). Physical demonstrators, simulation studies and access to industry leading technical expertise from OASIS project partners have helped develop detailed production process maps and input accurate process metrics to determine manufacturing costs. To this end, an activity-based cost modelling architecture has been developed to predict the cost-effectiveness of the joining technologies and assess them against both manual and automatic riveted solutions. The model has been designed in a manner that enables integration into current manufacturing eco-systems, has scalability for large aerospace companies and the ability to perform multi-fidelity process cost models that can be integrated with one another as required.