How It’s Made Aircraft Wings

Summary

This video delves into the intricate process of crafting aircraft wings, blending traditional techniques with cutting-edge technology. The wings' frame consists of the rear spar, main spar, and ribs made from corrosion-resistant aluminum. Workers use computer-guided machines, hydraulic presses, and pneumatic riveting tools to assemble these components. After attaching the aluminum skin and positioning the fuel tank, the wingtip is added to complete the structure. Despite weighing only 79 kg, the final wing can withstand immense wind pressure, highlighting its strength and precision in design and manufacturing.

Takeaways

• 😀 Aircraft wings are designed to be both light and rigid, balancing traditional methods with modern technology.
• 😀 The wing frame consists of three main components: the rear spar, the main spar, and ribs.
• 😀 Ribs are made from aircraft-grade aluminum, which is corrosion-resistant and has great tensile strength.
• 😀 A computer-guided stamping machine punches holes for rivets and control cables in the aluminum ribs.
• 😀 Hydraulic presses apply up to 150 tons of pressure to form the ribs, which are then smoothed and protected by a plastic film.
• 😀 The main spar is thicker than the ribs and requires 222 tons of pressure to form into shape.
• 😀 Workers manually align the ribs with spring clamps and drill holes for rivets to secure them to the main spar.
• 😀 Pneumatic riveting guns and bucking bars are used to attach the ribs to the spar, with special tools for tight spaces.
• 😀 Aluminum covering, known as the wing skin, is positioned and riveted onto the airframe using spring clamps.
• 😀 The fuel tank is welded into the wing using an argon gas torch to minimize contaminants, then secured and fitted with fuel lines and control cables.
• 😀 The wingtip is made from lightweight fiberglass and plastic composite, and is bolted onto the completed wing assembly.
• 😀 Despite its light weight (79 kg), an aircraft wing can withstand up to 2,500 kg of wind pressure.

Q & A

What are the three main components of an aircraft wing's frame?

The three main components of an aircraft wing's frame are the rear spar, the main spar, and ribs.

Why is aircraft-grade aluminum used for the ribs in the wing structure?

Aircraft-grade aluminum is used for the ribs because it is corrosion-resistant and has great tensile strength, allowing it to withstand extreme wind pressure.

How are holes for rivets and control cables made in the wing's components?

A computer-guided stamping machine is used to punch holes for rivets and control cables in the wing's components.

What process is used to shape the ribs of the wing?

The ribs are shaped using a hydraulic press that applies 150 tons of pressure, stamping the rib to a die shape.

What is the purpose of the grinder in the rib manufacturing process?

The grinder is used to smooth out the sharp edges left by the stamping process.

How is the main spar of the wing constructed?

The main spar is constructed using a similar process as the ribs, but it requires more pressure—222 tonnes—to bend the spars into shape, as the aluminum used is three times thicker.

How are the ribs aligned for riveting to the main spar?

Workers manually push spring clamps into the spar to hold the ribs in position before they are riveted.

What tool is used to rivet the ribs to the main spar?

A pneumatic riveting gun and a bucking bar are used to rivet the ribs to the main spar.

What is the purpose of the wing skin, and how is it attached to the airframe?

The wing skin is an aluminum covering that is positioned onto the airframe using spring clamps, and it is permanently riveted into place.

What is the significance of the argon gas torch in the welding process?

The argon gas torch is used for welding the wing's fuel tank because argon contains fewer contaminants than an acetylene torch, ensuring a cleaner weld.

What is the final step in completing the wing assembly?

The final step in completing the wing assembly is attaching and bolting the lightweight fiberglass and plastic composite wingtip to the wing.

How much wind pressure can the completed wing withstand?

The completed wing can withstand nearly 2,500 kilograms of wind pressure, despite weighing only 79 kilograms.