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2017 | Book

Processing of Aerospace Metals and Alloys: Part 1—Special Melting Technologies Read chapter Read first chapter

Aerospace Materials and Material Technologies

Volume 2: Aerospace Material Technologies

Editors: N. Eswara Prasad, R.J.H. Wanhill

Publisher: Springer Singapore

Book Series : Indian Institute of Metals Series

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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About this book

This book serves as a comprehensive resource on various traditional, advanced and futuristic material technologies for aerospace applications encompassing nearly 20 major areas. Each of the chapters addresses scientific principles behind processing and production, production details, equipment and facilities for industrial production, and finally aerospace application areas of these material technologies. The chapters are authored by pioneers of industrial aerospace material technologies. This book has a well-planned layout in 4 parts. The first part deals with primary metal and material processing, including nano manufacturing. The second part deals with materials characterization and testing methodologies and technologies. The third part addresses structural design. Finally, several advanced material technologies are covered in the fourth part. Some key advanced topics such as “Structural Design by ASIP”, “Damage Mechanics-Based Life Prediction and Extension” and “Principles of Structural Health Monitoring” are dealt with at equal length as the traditional aerospace materials technology topics. This book will be useful to students, researchers and professionals working in the domain of aerospace materials.

Table of Contents

Frontmatter
Erratum to: Failure Analysis and Prevention
K. P. Balan, A. Venugopal Reddy

Processing Technologies

Frontmatter
Chapter 1. Processing of Aerospace Metals and Alloys: Part 1—Special Melting Technologies
Abstract
This chapter discusses in detail the special melting technologies adopted for worldwide commercial scale manufacture of aerospace metals and alloys. Some case studies have been included to illustrate the role of these melting technologies in the production of premium-quality products for critical aerospace applications.
M. Chatterjee, A. Patra, R. R. Babu, M. Narayana Rao
Chapter 2. Processing of Aerospace Metals and Alloys: Part 2—Secondary Processing
Abstract
The basics of different techniques of secondary processing of metals and alloys are presented and discussed. This chapter will also provide details of the processing of superalloys (nickel- and cobalt-based) and steels.
S. Narahari Prasad, P. Rambabu, N. Eswara Prasad
Chapter 3. Superplastic Forming of Aerospace Materials
Abstract
This chapter discusses the phenomenon of superplasticity, as seen in different materials such as metals/alloys, intermetallics, ceramics, bulk metallic glasses and composites. The phenomenon of low temperature/high strain rate superplasticity is also briefly discussed. The various forming operations and the recent developments in forming processes like superplastic forming-diffusion bonding, friction stir processing, roll forming, and incremental forming have also been reviewed. Finally, some applications of superplastic forming in the manufacture of aerospace components are presented.
K. A. Padmanabhan, S. Balasivanandha Prabu, S. Madhavan
Chapter 4. Welding Technologies in Aerospace Applications
Abstract
This chapter reviews the joining of aerospace metals. The joining processes that are covered include gas tungsten arc, plasma arc and gas metal arc welding; resistance-based welding processes; flash butt welding; and high energy density processes such as electron beam welding, largely employed to weld titanium and nickel-base alloys. For enhanced strength and to weld dissimilar metals that are not weldable by fusion welding, solid-state welding processes such as friction welding and friction stir welding are employed. Brazing and diffusion bonding are largely used to join metal matrix composites and ceramics as well as ceramics to metals, and also nickel-base and titanium-base alloys. Magnetic pulse welding is a futuristic solid-phase welding process that may replace some of the current solid-state processes. The materials covered include aluminium, titanium and nickel-base alloys, steels, metal matrix composites, intermetallics and dissimilar metal combinations such as aluminium to stainless steel and maraging steel to low-alloy steel. Other aspects also discussed are online weld monitoring and fixturing during welding, and post-weld heat treatment to control distortion.
T. Mohandas
Chapter 5. Nanomanufacturing for Aerospace Applications
Abstract
In this chapter synthesis of nanomaterials by various nanomanufacturing (top-down and bottom-up) processes, synthesis and properties of aerogel, and advanced electrodeposited coatings and their properties, are reviewed. Further, the potential applications of nanomaterials, aerogels, and electrodeposited coatings in the aerospace industry are concisely surveyed.
S. Anandan, Neha Hebalkar, B. V. Sarada, Tata N. Rao

Characterisation and Testing

Frontmatter
Chapter 6. Microstructure: An Introduction
Abstract
This chapter gives a brief account of the different microscopic techniques to observe and interpret the microstructures of metals and alloys. The whole range of techniques from optical, scanning electron and transmission electron to field ion microscopy techniques is covered. The basic principles of the different microscopes, the advantages and limitations of the variety of techniques, and interpretation of microstructural features are described. Since it would be difficult to include the details of all the techniques, the list of references contains important resources for additional details of all of the techniques described in this chapter.
C. Suryanarayana
Chapter 7. Texture Effects in Important Aerospace Materials
Abstract
This chapter summarizes the effects of processing-induced crystallographic texture on the properties of three important classes of aerospace metallic materials, namely aluminium alloys, titanium alloys and nickel-base superalloys.
R J H Wanhill
Chapter 8. Physical Property Significances for Aerospace Structural Materials
Abstract
This chapter summarises the significances of material density, elastic modulus, thermal expansion coefficient and thermal conductivity for the selection and use of some aerospace structural materials. The summary focusses on airframe materials, but thermal barrier coatings (TBCs) are also considered.
R J H Wanhill
Chapter 9. Structural Alloy Testing: Part 1—Ambient Temperature Properties
Abstract
Standard data on ambient temperature mechanical and environmental properties, including yield and tensile strengths, fatigue and fatigue crack growth, fracture toughness, corrosion and stress corrosion, are essential—indeed mandatory—for the qualification and certification of aerospace structural materials and the design of actual structures and components. This chapter discusses the determination of important ambient temperature mechanical and environmental properties of aerospace alloys at the basic level of specimen and coupon testing.
R J H Wanhill
Chapter 10. Structural Alloy Testing: Part 2—Creep Deformation and Other High-Temperature Properties
Abstract
Information on mechanical properties such as yield strength, tensile strength, fracture toughness and fatigue strength of materials is important in designing structures and components used at ambient temperatures (see Chap. 9 in this Volume of the Source Books). However, for high-temperature applications such as in power plants, petrochemical industries and aeroengines, data on the mechanical behaviour of materials at elevated temperatures are required. This chapter discusses creep deformation and fracture mechanisms of alloys, experimental determination of creep and stress rupture properties and various methods for the prediction of these properties. In addition, other aspects of high-temperature mechanical behaviour are briefly considered, namely creep–fatigue interactions; thermal and thermomechanical fatigue; dwell cracking; and creep crack growth.
R. J. H. Wanhill, D. V. V. Satyanarayana, N Eswara Prasad
Chapter 11. Non-destructive Testing and Damage Detection
Abstract
This chapter briefly describes various techniques used for non-destructive inspection (NDT) of aerospace components for detecting defects, cracks, corrosion, and other degradation features, as part of quality assurance and in-service inspection. The capabilities and applications of widely used NDT techniques for examining metallic as well as composite aerospace structures are discussed. Recent advances in NDT techniques for automated, fast and cost-effective in-service and in situ monitoring of aircraft are highlighted, as well as future directions.
B. Purna Chandra Rao

Structural Design

Frontmatter
Chapter 12. Design of Aircraft Structures: An Overview
Abstract
This chapter presents some of the important aspects in the design and analysis of aircraft structures. These important aspects are related to material selection, structural configuration, loads evaluation, static strength and deflection estimation, static stability evaluation, fatigue and fracture effects, aeroelastic considerations, and influence of dynamic loadings. The key aspects in specific areas are combined to provide an overall perspective of aircraft structural design and analysis. It must be noted that manufacturing and ground and flight testing are integral parts of the whole process of design, but these aspects are not addressed here.
S. Kamle, R. Kitey, P. M. Mohite, C. S. Upadhyay, C. Venkatesan, D. Yadav
Chapter 13. Aircraft Mechanical Systems
Abstract
The design process of any aerospace vehicle can be broadly classified into three categories, i.e. structural design, system design and avionics design. This chapter presents the various mechanical systems and sub-systems involved in aerospace platforms with their principles of operation and functional applications in generic form. The major components/equipments involved in each of the systems are mentioned in brief. Finally, the various types of materials, properties, processes and their testing in aerospace mechanical systems design are briefly discussed.
R. V. Huliraj, H. L. Janardhana
Chapter 14. Design and Structures of Aircraft Engines
Abstract
Structural integrity and optimal weight configuration of aerospace structures continue to be a challenging task. In the case of aircraft engines, the task poses further complexities relating to rotating components, thermal environment and fatigue considerations. This chapter outlines the engine operating environment, structural design practices, failure modes and some aspects of reliability as applicable to military aircraft engines. A few important structural design methodologies are discussed in detail including the testing and validation aspects. The current design trends and technical challenges involved are also addressed.
Rajaram Nagappa, Sankarkumar Jeyaraman, C. Kishore Kumar
Chapter 15. Missile Propulsion Systems
Abstract
This chapter provides a general description of propulsion systems suitable for missiles. These systems are solid- and liquid-fuelled rockets, liquid-fuelled ramjets, solid fuel ducted rockets (ramrockets), and scramjets. Concise summaries about testing are also given, and mention is made of a scramjet test facility developed by the Defence Research and Development Laboratory (DRDL) in Hyderabad, India. This facility is part of the DRDL hypersonic programme entitled ‘Hypersonic Technology Demonstrator Vehicle’ (HSTDV).
P Satyaprasad, M Pandu Ranga Sharma, Abhishek Richarya, A Rolex Ranjit, B S Subhash Chandran
Chapter 16. Fatigue Requirements for Aircraft Structures
Abstract
This chapter first summarizes the evolution of fatigue design requirements for aircraft structures. For metallic (mainly aluminium alloy) structures these requirements have developed since the 1950s. Composite materials (notably carbon fibre reinforced plastics) present a relatively new challenge. There follows a concise discussion of the several possible methods for assessing the fatigue lives of aircraft structures. The emphasis is on requirements, but design and operational issues are also addressed.
R. J. H. Wanhill
Chapter 17. Full-Scale Fatigue Testing
Abstract
Full-scale fatigue testing (FSFT) forms an integral part of the aircraft development and certification prior to induction into service. The five historical stages of evolution of FSFT are described with a detailed description of present-day requirements including composite structures. The technology used in the FSFT process is explained in detail.
R. Sunder
Chapter 18. Residual Strength Requirements for Aircraft Structures
Abstract
This chapter is an adjunct to Chap. 16. The present chapter first summarizes the evolution of residual strength design requirements for metallic aircraft structures. There follows a concise discussion of the methods for assessing the residual strengths of aircraft structures, with the emphasis on testing and data requirements.
R. J. H. Wanhill
Chapter 19. Stress Corrosion Cracking in Aircraft Structures
Abstract
Stress corrosion cracking (SCC) occurs, or can occur, in all major alloy systems used in aircraft structures. The consequences of stress corrosion failures may be serious, even leading to loss of an aircraft. This chapter first surveys the types of structures and materials used in aircraft and the environments encountered by them. Case histories from a wide variety of aircraft are used to illustrate the problems caused by SCC in service. Guidelines are given for preventing and alleviating these problems.
R. J. H. Wanhill, R. T. Byrnes

Special Technologies

Frontmatter
Chapter 20. Aero Stores (Materials) Inspection and Quality Assurance
Abstract
Quality assurance (QA) encompassing inspection, testing, evaluation and certification of an aero store provides the guarantee for reliable performance during its operational usage. QA agencies shoulder the prime responsibility for flight safety. Military aircraft are often required to operate in harsher environments than their civilian counterparts. Hence the quality requirements for military aero stores are stringent. In the development phase the primary role of QA is to detect design deficiencies during qualification testing as part of the airworthiness certification. Further, this Chapter discusses (i) the importance of process control during manufacturing of aero stores and (ii) the critical inspection stages and important check points, spot/surprise checks and quality audits for various materials (aluminium, titanium, nickel-based alloys, special steels and composites).
K. K. Mehta, S. Chawla
Chapter 21. Fatigue Life Enhancement for Metallic Airframe Materials
Abstract
This chapter briefly summarises some of the life enhancement and repair techniques available to locally increase the fatigue lives of metallic airframe structures. The chapter concentrates on a broad review of those methods as applied to aluminium alloy aircraft structures, for which most of the techniques have been developed. Although aimed at aluminium alloys, most of these methods are equally applicable to the other metallic airframe structural materials, i.e. steels and titanium alloys. To round out the descriptions of each of the methods, the pros and cons are also briefly discussed based on the experience of the authors in maintaining the structural integrity of several aircraft types.
L. Molent, S. A. Barter
Chapter 22. Structural Health Monitoring
Abstract
This chapter describes and discusses the evolution of structural health monitoring (SHM) technologies for aircraft. The introduction gives the importance of SHM, its application potential and the principal constituents. This is followed first by a description of strain monitoring systems and HUMS and then of damage monitoring systems. Two major classes of techniques—namely acoustic waves and fibre optics—are described and reviewed. A few applications are also highlighted. Issues and strategies for implementation of SHM are discussed, indicating the path forward.
Prakash D. Mangalgiri, Kota Harinarayana
Chapter 23. Failure Analysis and Prevention
Abstract
This chapter first reviews the fracture and fractography of metals and alloys, with examples of typical fractographs. Then the tools and techniques used in failure investigations are briefly described. The second main part of the chapter is devoted to three case studies on aeronautical component failures. Each case study is described with background information, followed by experimental results consisting mainly of visual examination, fractographic examination, metallographic examination, hardness measurements, and chemical analysis. The results are then discussed and conclusions are drawn. Wherever possible, suitable remedial measures are suggested.
K. P. Balan, A. Venugopal Reddy
Chapter 24. Airworthiness Certification of Metallic and Non-metallic Materials: The Indian Approach and Methodologies
Abstract
The Indian scenario of airworthiness certification and philosophy of certification of metallic and non-metallic materials and approach, the classification of materials based on their criticality of application and agencies involved in certification activity, and their roles and responsibilities are briefly described in this chapter. Appropriate examples and case studies for each class of materials are also discussed.
M Sai Krishna Rao, P Rambabu, Ch. V. S. Murthy, B Jana, B Saha, N Eswara Prasad, P Jayapal, K Tamilmani
Chapter 25. Lightweight Ballistic Armours for Aero-Vehicle Protection
Abstract
This chapter surveys the materials and technologies involved in the development of armour for aircraft, especially helicopters. The materials suitable for these applications are a mixed family of armour-grade ceramics and polymer matrix composites, and transparent armour laminates. These materials are tailored to specific requirements based on mission profiles and threat assessments, which are discussed first. Some examples of armour in helicopters are given to illustrate the applications. Finally, the qualification test requirements are summarised. The following books are important and useful reference sources: (1) Bhatnagar, A. (Ed.), 2006, ‘Lightweight Ballistic Composites’, Woodhead Publishing Limited, Abington, Cambridge, UK. (2) Hazell, P.J., 2016, ‘Armour: Materials, Theory and Design’, CRC Press, Taylor & Francis Group, Boca Raton, FL 33487-2742, USA.
Arun Kumar Singh, R. J. H. Wanhill, N. Eswara Prasad
Metadata
Title
Aerospace Materials and Material Technologies
Editors
N. Eswara Prasad
R.J.H. Wanhill
Copyright Year
2017
Publisher
Springer Singapore
Electronic ISBN
978-981-10-2143-5
Print ISBN
978-981-10-2142-8
DOI
https://doi.org/10.1007/978-981-10-2143-5

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