MANUFACTURING TECHNOLOGY FOR AEROSPACE STRUCTURAL MATERIALSPDF电子书下载

Chapter 1 Introduction 1

1.1 Aluminum 4

1.2 Magnesium and Beryllium 6

1.3 Titanium 7

1.4 High Strength Steels 8

1.5 Superalloys 8

1.6 Composites 9

1.7 Adhesive Bonding and Integrally Cocured Structure 10

1.8 Metal and Ceramic Matrix Composites 11

1.9 Assembly 12

Summary 12

References 13

Chapter 2 Aluminum 15

2.1 Metallurgical Considerations 17

2.2 Aluminum Alloy Designation 23

2.3 Aluminum Alloys 25

2.4 Melting and Primary Fabrication 31

2.4.1 Rolling Plate and Sheet 33

2.4.2 Extrusion 37

2.5 Heat Treating 37

2.5.1 Solution Heat Treating and Aging 37

2.5.2 Annealing 42

2.6 Forging 43

2.7 Forming 46

2.7.1 Blanking and Piercing 47

2.7.2 Brake Forming 48

2.7.3 Deep Drawing 49

2.7.4 Stretch Forming 50

2.7.5 Rubber Pad Forming 51

2.7.6 Superplastic Forming 51

2.8 Casting 57

2.8.1 Sand Casting 60

2.8.2 Plaster and Shell Molding 62

2.8.3 Permanent Mold Casting 63

2.8.4 Die Casting 64

2.8.5 Investment Casting 64

2.8.6 Evaporative Pattern Casting 64

2.8.7 Casting Heat Treatment 65

2.8.8 Casting Properties 65

2.9 Machining 66

2.9.1 High Speed Machining 68

2.9.2 Chemical Milling 76

2.10 Joining 76

2.11 Welding 77

2.11.1 Gas Metal and Gas Tungsten Arc Welding 78

2.11.2 Plasma Arc Welding 80

2.11.3 Laser Welding 81

2.11.4 Resistance Welding 82

2.11.5 Friction Stir Welding 83

2.12 Chemical Finishing 88

Summary 89

Recommended Reading 90

References 90

Chapter 3 Magnesium and Beryllium 93

MAGNESIUM 95

3.1 Magnesium Metallurgical Considerations 95

3.2 Magnesium Alloys 97

3.2.1 Wrought Magnesium Alloys 97

3.2.2 Magnesium Casting Alloys 99

3.3 Magnesium Fabrication 103

3.3.1 Magnesium Forming 103

3.3.2 Magnesium Sand Casting 104

3.3.3 Magnesium Heat Treating 106

3.3.4 Magnesium Machining 107

3.3.5 Magnesium Joining 107

3.4 Magnesium Corrosion Protection 108

BERYLLIUM 109

3.5 Beryllium Metallurgical Considerations 109

3.6 Beryllium Alloys 110

3.7 Beryllium Powder Metallurgy 111

3.8 Beryllium Fabrication 114

3.8.1 Beryllium Forming 114

3.8.2 Beryllium Machining 115

3.8.3 Beryllium Joining 116

3.9 Aluminum-Beryllium Alloys 116

Summary 116

References 118

Chapter 4 Titanium 119

4.1 Metallurgical Considerations 120

4.2 Titanium Alloys 126

4.2.1 Commercially Pure Titanium 126

4.2.2 Alpha and Near-Alpha Alloys 127

4.2.3 Alpha-Beta Alloys 128

4.2.4 Beta Alloys 131

4.3 Melting and Primary Fabrication 132

4.4 Forging 137

4.5 Directed Metal Deposition 140

4.6 Forming 143

4.7 Superplastic Forming 145

4.8 Heat Treating 150

4.8.1 Stress Relief 151

4.8.2 Annealing 152

4.8.3 Solution Treating and Aging 152

4.9 Investment Casting 154

4.10 Machining 158

4.11 Joining 165

4.12 Welding 165

4.13 Brazing 170

Summary 171

Recommended Reading 172

References 173

Chapter 5 High Strength Steels 175

5.1 Metallurgical Considerations 176

5.2 Medium Carbon Low Alloy Steels 182

5.3 Fabrication of Medium Carbon Low Alloy Steels 186

5.4 Heat Treatment of Medium Carbon Low Alloy Steels 191

5.5 High Fracture Toughness Steels 198

5.6 Maraging Steels 200

5.7 Precipitation Hardening Stainless Steels 202

Summary 207

Recommended Reading 207

References 208

Chapter 6 Superalloys 211

6.1 Metallurgical Considerations 213

6.2 Commercial Superalloys 219

6.2.1 Nickel Based Superalloys 221

6.2.2 Iron-Nickel Based Superalloys 224

6.2.3 Cobalt Based Superalloys 225

6.3 Melting and Primary Fabrication 225

6.4 Powder Metallurgy 228

6.4.1 Powder Metallurgy Forged Alloys 228

6.4.2 Mechanical Alloying 230

6.5 Forging 232

6.6 Forming 236

6.7 Investment casting 238

6.7.1 Polycrystalline Casting 239

6.7.2 Directional Solidification (DS) Casting 240

6.7.3 Single Crystal (SC) Casting 242

6.8 Heat Treatment 243

6.8.1 Solution Strengthened Superalloys 243

6.8.2 Precipitation Strengthened Nickel Base Superalloys 244

6.8.3 Precipitation Strengthened Iron-Nickel Base Superalloys 246

6.8.4 Cast Superalloy Heat Treatment 247

6.9 Machining 248

6.9.1 Turning 251

6.9.2 Milling 252

6.9.3 Grinding 254

6.10 Joining 256

6.10.1 Welding 256

6.10.2 Brazing 260

6.10.3 Transient Liquid Phase (TLP) Bonding 263

6.11 Coating Technology 264

6.11.1 Diffusion Coatings 264

6.11.2 Overlay Coatings 265

6.11.3 Thermal Barrier Coatings 266

Summary 266

Recommended Reading 270

References 270

Chapter 7 Polymer Matrix Composites 273

7.1 Materials 276

7.1.1 Fibers 277

7.1.2 Matrices 280

7.1.3 Product Forms 282

7.2 Fabrication Processes 286

7.3 Cure Tooling 286

7.3.1 Tooling Considerations 286

7.4 Ply Collation 291

7.4.1 Manual Lay-up 291

7.4.2 Flat Ply Collation and Vacuum Forming 294

7.5 Automated Tape Laying 295

7.6 Filament Winding 298

7.7 Fiber Placement 304

7.8 Vacuum Bagging 307

7.9 Curing 311

7.9.1 Curing of Epoxy Composites 313

7.9.2 Theory of Void Formation 314

7.9.3 Hydrostatic Resin Pressure 318

7.9.4 Resin and Prepreg Variables 322

7.9.5 Condensation Curing Systems 323

7.9.6 Residual Curing Stresses 324

7.10 Liquid Molding 327

7.11 Preform Technology 328

7.11.1 Fibers 329

7.11.2 Woven Fabrics 330

7.11.3 Multiaxial Warp Knits 331

7.11.4 Stitching 331

7.11.5 Braiding 333

7.11.6 Preform Handling 334

7.12 Resin Injection 336

7.12.1 RTM Curing 338

7.12.2 RTM Tooling 338

7.13 Vacuum Assisted Resin Transfer Molding 339

7.14 Pultrusion 341

7.15 Thermoplastic Composites 343

7.15.1 Thermoplastic Consolidation 345

7.15.2 Thermoforming 351

7.15.3 Thermoplastic Joining 355

7.16 Trimming and Machining Operations 361

Summary 364

Recommended Reading 366

References 366

Chapter 8 Adhesive Bonding and Integrally Cocured Structure 369

8.1 Advantages of Adhesive Bonding 370

8.2 Disadvantages of Adhesive Bonding 371

8.3 Theory of Adhesion 372

8.4 Joint Design 372

8.5 Adhesive Testing 377

8.6 Surface Preparation 378

8.7 Epoxy Adhesives 383

8.7.1 Two-part Room Temperature Curing Epoxy Liquid and Paste Adhesives 384

8.7.2 Epoxy Film Adhesives 385

8.8 Bonding Procedures 385

8.8.1 Prekitting of Adherends 385

8.8.2 Prefit Evaluation 386

8.8.3 Adhesive Application 387

8.8.4 Bond Line Thickness Control 388

8.8.5 Bonding 388

8.9 Sandwich Structures 390

8.9.1 Honeycomb Core 393

8.9.2 Honeycomb Processing 399

8.9.3 Balsa Wood 403

8.9.4 Foam Cores 404

8.9.5 Syntactic Core 406

8.9.6 Inspection 407

8.10 Integrally Cocured Structure 408

Summary 415

Recommended Reading 416

References 417

Chapter 9 Metal Matrix Composites 419

9.1 Discontinuously Reinforced Metal Matrix Composites 424

9.2 Stir Casting 424

9.3 Slurry Casting - Compocasting 427

9.4 Liquid Metal Infiltration (Squeeze Casting) 427

9.5 Pressure Infiltration Casting 430

9.6 Spray Deposition 431

9.7 Powder Metallurgy Methods 432

9.8 Secondary Processing of Discontinuous MMCs 434

9.9 Continuous Fiber Aluminum Metal Matrix Composites 435

9.10 Continuous Fiber Reinforced Titanium Matrix Composites 440

9.11 Secondary Fabrication of Titanium Matrix Composites 447

9.12 Fiber Metal Laminates 452

Summary 455

Recommended Reading 456

References 456

Chapter 10 Ceramic Matrix Composites 459

10.1 Reinforcements 464

10.2 Matrix Materials 467

10.3 Interfacial Coatings 470

10.4 Fiber Architectures 471

10.5 Fabrication Methods 472

10.6 Powder Processing 472

10.7 Slurry Infiltration and Consolidation 474

10.8 Polymer Infiltration and Pyrolysis (PIP) 476

10.9 Chemical Vapor Infiltration (CVI) 482

10.10 Directed Metal Oxidation (DMO) 487

10.11 Liquid Silicon Infiltration (LSI) 488

Summary 490

Recommended Reading 492

References 492

Chapter 11 Structural Assembly 495

11.1 Framing 496

11.2 Shimming 498

11.3 Hole Drilling 499

11.3.1 Manual Drilling 500

11.3.2 Power Feed Drilling 504

11.3.3 Automated Drilling 505

11.3.4 Automated Riveting Equipment 508

11.3.5 Drill Bit Geometries 509

11.3.6 Reaming 514

11.3.7 Countersinking 514

11.4 Fastener Selection and Installation 515

11.4.1 Special Considerations for Composite Joints 518

11.4.2 Solid Rivets 520

11.4.3 Pin and Collar Fasteners 523

11.4.4 Bolts and Nuts 525

11.4.5 Blind Fasteners 527

11.4.6 Fatigue Improvement and Interference Fit Fasteners 528

11.5 Sealing 533

11.6 Painting 534

Summary 535

Recommended Reading 537

References 537

Appendix A Metric Conversions 539

Appendix B A Brief Review of Materials Fundamentals 541

B.l Materials 542

B.2 Metallic Structure 543

B.3 Ceramics 555

B.4 Polymers 556

B.5 Composites 562

Recommended Reading 565

References 566

Appendix C Mechanical and Environmental Properties 567

C.l Static Strength Properties 568

C.2 Failure Modes 570

C.3 Fracture Toughness 572

C.4 Fatigue 576

C.5 Creep and Stress Rupture 581

C.6 Corrosion 582

C.7 Hydrogen Embrittlement 584

C.8 Stress Corrosion Cracking 586

C.9 High Temperature Oxidation and Corrosion 587

C.10 Polymeric Matrix Composite Degradation 587

Recommended Reading 591

References 591

Index 593