The Danger of Low-Cost Aerospace Welding

The following is a fictional scenario based on real industry risks to illustrate the importance of choosing a certified, experienced welding partner.

It begins with an emergency landing.

A commercial aircraft diverts mid-flight after cockpit alarms indicate a critical failure. The root cause? A failed clamp assembly on the jet engine. Specifically, a resistance spot weld on a V-band clamp securing an air bypass duct. The duct, meant to channel compressed air through sensors and back into the engine, allowed pressure to escape when the clamp failed—forcing an emergency response and grounding the aircraft.

It’s a dramatic—but entirely plausible—example of what can go wrong when quality welding is overlooked.

What Went Wrong?

In this imagined case, investigators traced the issue to multiple undersized spot welds, lacking the proper fused zone required for high-reliability applications. The clamp manufacturer had outsourced the welding to a low-cost shop promising quick turnarounds. But when auditors made an unannounced visit, they uncovered a lack of documentation, nonexistent weld testing, and no adherence to the Class A aerospace welding standards—which require radiographic (X-ray) inspection.

Though the weld shop performed the defective work, the primary manufacturer bore the consequences: legal liability, massive financial losses, and ultimately bankruptcy. A devastating outcome, all because a few corners were cut.

Image of the V-band clamp with failed spot welds

 

This Could Happen—If You Choose the Wrong Vendor

While this story is hypothetical, it reflects the real-world risks that can occur when quality and certification aren’t prioritized. Unfortunately, some welding shops may pass basic audits but still lack the processes, personnel, and accountability needed to meet aerospace standards. And by the time an issue is discovered, it’s often too late.

The lesson? The cheapest option today could become the most expensive mistake tomorrow.

 

Why Lynn Welding Is Different

At Lynn Welding, we’ve built our reputation on doing things right the first time. We maintain the certifications, experience, and infrastructure required to support complex, critical applications—especially in aerospace, defense, and medical industries.

Our certifications include:
✔ NADCAP Accreditation
✔ AS9100 Certification
✔ AWS D17.1 & AWS D17.2 Compliance
✔ Independent Quality & Inspection Departments
✔ Decades of Aerospace Welding Experience

We don’t just weld parts—we protect programs, reputations, and lives.

 

Know What to Ask Before You Partner

When selecting a welding vendor, we encourage you to dig deeper than price or lead time. Ask:

• What is your NADCAP audit history? Can you share your most recent findings and how they were addressed
• How experienced is your team in aerospace welding?
• Is your quality department independent of company ownership?
• What testing and process controls are in place to prevent quality escapes?
• Is your quality manual available for review?
• How is accountability handled within your organization?

A weld failure at 30,000 feet may be fictional here—but the consequences of working with an uncertified or unqualified welding shop are very real. Every weld you outsource is a decision that affects safety, compliance, and long-term success.

 

At Lynn Welding, we take that responsibility seriously. That’s why we’ve invested in the certifications, training, and procedures needed to consistently deliver reliable, audit-ready results—on every part, every time.