Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000419
J. Fortain, S. Gadrey
Welded aluminium alloy products are widely used in the construction and packaging sectors: in this context, in order to be competitive, the welding processes must offer valid solutions from both the productivity and quality viewpoints in addition to health-related aspects with regard to welders and operators. In this context, the technological goals of Air Liquide have been focused on improving the quality of welded joints made using the MIG and TIG processes. The approach adopted here is to examine the various gas mixtures from the viewpoint of influence on electrical parameters (voltage), regularity of filler metal transfer, the surface tension of the melt bath and the convection patterns present in the latter.
{"title":"Shielding Gas: Performance Improvement of MIG and TIG Welding of Aluminum Alloys","authors":"J. Fortain, S. Gadrey","doi":"10.1201/9781351045636-140000419","DOIUrl":"https://doi.org/10.1201/9781351045636-140000419","url":null,"abstract":"Welded aluminium alloy products are widely used in the construction and packaging sectors: in this context, in order to be competitive, the welding processes must offer valid solutions from both the productivity and quality viewpoints in addition to health-related aspects with regard to welders and operators. In this context, the technological goals of Air Liquide have been focused on improving the quality of welded joints made using the MIG and TIG processes. The approach adopted here is to examine the various gas mixtures from the viewpoint of influence on electrical parameters (voltage), regularity of filler metal transfer, the surface tension of the melt bath and the convection patterns present in the latter.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124341566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000284
S. Adeosun, E. Akpan, S. A. Balogun
This article discusses the effects of various modifications on the properties of aluminum alloys for structural applications. The effect of reinforcing particles on the mechanical properties of wrought 6063 aluminum alloy arising from our previous works is extensively discussed to identify the most promising reinforcing particles. It also discusses the improvement in mechanical properties of 1200 aluminum alloy using silicon carbide particulates. The effect of micro-alloy additions on the mechanical properties is also outlined in this article based on the results from our previous experimental works. Effect of combining heat treatment and deformation on the mechanical properties of wrought aluminum alloys is also presented. Results presented show that particle reinforcement, deformation, and microelemental additions to aluminum alloy result in significant improvement in mechanical properties of the alloys considered. Addition of reinforcing particles of barite, silicon carbide, iron fillings, and electric arc furnace dust are found to impart improved tensile strength to aluminum alloy. The most outstanding finding is that synergy between particle addition, deformation, and heat treatment has a good prospect in the production of improved aluminum alloy materials for automotive applications.
{"title":"Wrought Aluminum Alloy: Reinforcement, Alloy Addition, and Deformation Effects on Mechanical Responses","authors":"S. Adeosun, E. Akpan, S. A. Balogun","doi":"10.1201/9781351045636-140000284","DOIUrl":"https://doi.org/10.1201/9781351045636-140000284","url":null,"abstract":"This article discusses the effects of various modifications on the properties of aluminum alloys for structural applications. The effect of reinforcing particles on the mechanical properties of wrought 6063 aluminum alloy arising from our previous works is extensively discussed to identify the most promising reinforcing particles. It also discusses the improvement in mechanical properties of 1200 aluminum alloy using silicon carbide particulates. The effect of micro-alloy additions on the mechanical properties is also outlined in this article based on the results from our previous experimental works. Effect of combining heat treatment and deformation on the mechanical properties of wrought aluminum alloys is also presented. Results presented show that particle reinforcement, deformation, and microelemental additions to aluminum alloy result in significant improvement in mechanical properties of the alloys considered. Addition of reinforcing particles of barite, silicon carbide, iron fillings, and electric arc furnace dust are found to impart improved tensile strength to aluminum alloy. The most outstanding finding is that synergy between particle addition, deformation, and heat treatment has a good prospect in the production of improved aluminum alloy materials for automotive applications.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"291 ","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120871080","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000309
G. Melhem, P. Munroe, C. Sorrell, Alsten Clyde Livingstone
The present work reports findings for the application of specialized aerospace aluminum rivets, manufactured from Al 7075 (Al-Zn-Mg-Cu) T6 alloy stem/mandrel, with an Al 5056 (Al-Mg) shank or sleeve, which were used for construction rectification of an outdoor louver façade on a high-rise building. These specialized rivets were used to replace failed conventional construction rivets, which consisted of sleeve and mandrel comprised of either all-steel, all-aluminum, or aluminum-steel. The building is in close vicinity to the ocean and exposed to extremely high wind loading, making the rivets susceptible to failure by corrosion and fatigue. The focus of the present work is to report the examination of the specialized replacement rivets following an in-service lifetime of 12 years. The examination revealed that the replacement rivets (mandrel and sleeve) remained intact and uncontaminated, essentially free of corrosion. It is likely that sunlight exposure and the composite nature of the rivets enhanced the performance through age hardening. Analysis of the rivets included visual inspection, optical microscopy, Vickers microhardness testing, and transmission electron microscopy. The aim of the analysis was to correlate microstructures with microhardnesses, using these data to evaluate the ultimate tensile strength (UTS), yield strength (YS), and the potential for further age hardening. The Vickers microhardnesses were observed to have increased by ~8% over the service lifetime of 12 years, which equates to increases in YS (34.8–46.8 MPa) and UTS (23.8–45.6 MPa). Although the results show that there is a large increase in the strength values when comparing the unused rivets to the 12-year-old rivets, this increase in hardness may not necessarily be due purely to natural aging kinetics such as exposure from the sun and outdoor temperature. However, there appears to be some insignificant alteration of the microstructure and mechanical properties as a result of this exposure.
{"title":"Field Trials of Aerospace Fasteners in Mechanical and Structural Applications","authors":"G. Melhem, P. Munroe, C. Sorrell, Alsten Clyde Livingstone","doi":"10.1201/9781351045636-140000309","DOIUrl":"https://doi.org/10.1201/9781351045636-140000309","url":null,"abstract":"The present work reports findings for the application of specialized aerospace aluminum rivets, manufactured from Al 7075 (Al-Zn-Mg-Cu) T6 alloy stem/mandrel, with an Al 5056 (Al-Mg) shank or sleeve, which were used for construction rectification of an outdoor louver façade on a high-rise building. These specialized rivets were used to replace failed conventional construction rivets, which consisted of sleeve and mandrel comprised of either all-steel, all-aluminum, or aluminum-steel. The building is in close vicinity to the ocean and exposed to extremely high wind loading, making the rivets susceptible to failure by corrosion and fatigue. The focus of the present work is to report the examination of the specialized replacement rivets following an in-service lifetime of 12 years. The examination revealed that the replacement rivets (mandrel and sleeve) remained intact and uncontaminated, essentially free of corrosion. It is likely that sunlight exposure and the composite nature of the rivets enhanced the performance through age hardening. Analysis of the rivets included visual inspection, optical microscopy, Vickers microhardness testing, and transmission electron microscopy. The aim of the analysis was to correlate microstructures with microhardnesses, using these data to evaluate the ultimate tensile strength (UTS), yield strength (YS), and the potential for further age hardening. The Vickers microhardnesses were observed to have increased by ~8% over the service lifetime of 12 years, which equates to increases in YS (34.8–46.8 MPa) and UTS (23.8–45.6 MPa). Although the results show that there is a large increase in the strength values when comparing the unused rivets to the 12-year-old rivets, this increase in hardness may not necessarily be due purely to natural aging kinetics such as exposure from the sun and outdoor temperature. However, there appears to be some insignificant alteration of the microstructure and mechanical properties as a result of this exposure.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115326111","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000388
S. Jahanian
A numerical method is presented for evaluating the residual stress distribution in a long aluminum solid cylinder subjected to rapid cooling. An analytical model is developed for the temperature distribution. For the boundary conditions, experimental data for the outer surface of the cylinder are used, and a reasonable agreement between the predicted temperature distribution at the center of the cylinder and the experimental data is observed. For the numerical analysis, a quasi-static, uncoupled thermoelastoplastic analysis, based on a hyperbolic sine law, is presented. The numerical results are presented for the temperature distribution as well as the thermoelastoplastic stress distribution in a solid cylinder with temperature-dependent properties. The residual stress distribution is compared with the results of other investigators who used the Finite Element Method, and a reasonable agreement between our results and previous results is observed. The conclusion is reached that the temperature dependency of the yield stresses and the problem of post-yielding are two important factors to be considered when developing a model for predicting the residual stresses in quenched bodies.
{"title":"Quenching of Aluminum Solid Cylinder: Numerical Study","authors":"S. Jahanian","doi":"10.1201/9781351045636-140000388","DOIUrl":"https://doi.org/10.1201/9781351045636-140000388","url":null,"abstract":"A numerical method is presented for evaluating the residual stress distribution in a long aluminum solid cylinder subjected to rapid cooling. An analytical model is developed for the temperature distribution. For the boundary conditions, experimental data for the outer surface of the cylinder are used, and a reasonable agreement between the predicted temperature distribution at the center of the cylinder and the experimental data is observed. For the numerical analysis, a quasi-static, uncoupled thermoelastoplastic analysis, based on a hyperbolic sine law, is presented. The numerical results are presented for the temperature distribution as well as the thermoelastoplastic stress distribution in a solid cylinder with temperature-dependent properties. The residual stress distribution is compared with the results of other investigators who used the Finite Element Method, and a reasonable agreement between our results and previous results is observed. The conclusion is reached that the temperature dependency of the yield stresses and the problem of post-yielding are two important factors to be considered when developing a model for predicting the residual stresses in quenched bodies.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"33 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132331249","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000447
A. Suslov
Because of their high specific strength and satisfactory corrosion resistance, aluminum alloys belong to the group of fundamental structural materials in modern engineering. Their wide use has been made possible as a result of developing advanced methods of processing and producing permanent joints by welding or brazing. However, the application of brazing aluminum alloys is limited because of the problems in removing the strong and chemically resistant oxide film. These problems can be overcome by using metallic coatings which themselves do not oxidize during heating in vacuum and, when deposited, the oxide film is broken up and can be removed from the surface of the parent material. The most promising method is to use metallic coatings in the form of individual components of the brazing alloy which forms in contact melting of the deposited coatings with aluminum in heating for brazing. This brazing method is referred to as contact-reactive brazing and is used widely for brazing aluminum alloys. This article provides an overview of the contact-reactive brazing process.
{"title":"Metallic Coatings for Brazing Aluminum Alloys","authors":"A. Suslov","doi":"10.1201/9781351045636-140000447","DOIUrl":"https://doi.org/10.1201/9781351045636-140000447","url":null,"abstract":"Because of their high specific strength and satisfactory corrosion resistance, aluminum alloys belong to the group of fundamental structural materials in modern engineering. Their wide use has been made possible as a result of developing advanced methods of processing and producing permanent joints by welding or brazing. However, the application of brazing aluminum alloys is limited because of the problems in removing the strong and chemically resistant oxide film. These problems can be overcome by using metallic coatings which themselves do not oxidize during heating in vacuum and, when deposited, the oxide film is broken up and can be removed from the surface of the parent material. The most promising method is to use metallic coatings in the form of individual components of the brazing alloy which forms in contact melting of the deposited coatings with aluminum in heating for brazing. This brazing method is referred to as contact-reactive brazing and is used widely for brazing aluminum alloys. This article provides an overview of the contact-reactive brazing process.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"13 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131010216","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000277
Kavian Omar Cooke, T. Khan
Aluminum metal matrix composites are materials frequently used in the automotive and aerospace industries due to their high strength-to-weight ratio, formability, corrosion resistance, and long-term durability. However, despite the unique properties of these materials, the lack of a reliable joining method has restricted their full potential in engineering applications. This article explores the effect of bonding time on transient liquid phase diffusion bonding of Al6061 containing 15 vol.% alumina particles using a 5 μm electrodeposited Ni-coating containing nano-sized alumina particles as the interlayer. Joint formation was attributed to the solid-state diffusion of Ni into the Al6061 alloy followed by eutectic formation and isothermal solidification at the joint interface. Examination of the joint region using scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction showed the formation of eutectic phases such as Al3Ni, Al9FeNi, and Ni3Si within the joint zone. The results indicate that the addition of nano-size reinforcements into the interlayer can be used to improve joint strength. The joint strength recorded was 136 MPa at a bonding time of 10 min with a marginal increase in the shear strength when the bonding time is increased to 30 min.
{"title":"Nanostructured Ni/Al2O3 Interlayer: Transient Liquid Phase Diffusion Bonding of Al6061-MMC","authors":"Kavian Omar Cooke, T. Khan","doi":"10.1201/9781351045636-140000277","DOIUrl":"https://doi.org/10.1201/9781351045636-140000277","url":null,"abstract":"Aluminum metal matrix composites are materials frequently used in the automotive and aerospace industries due to their high strength-to-weight ratio, formability, corrosion resistance, and long-term durability. However, despite the unique properties of these materials, the lack of a reliable joining method has restricted their full potential in engineering applications. This article explores the effect of bonding time on transient liquid phase diffusion bonding of Al6061 containing 15 vol.% alumina particles using a 5 μm electrodeposited Ni-coating containing nano-sized alumina particles as the interlayer. Joint formation was attributed to the solid-state diffusion of Ni into the Al6061 alloy followed by eutectic formation and isothermal solidification at the joint interface. Examination of the joint region using scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction showed the formation of eutectic phases such as Al3Ni, Al9FeNi, and Ni3Si within the joint zone. The results indicate that the addition of nano-size reinforcements into the interlayer can be used to improve joint strength. The joint strength recorded was 136 MPa at a bonding time of 10 min with a marginal increase in the shear strength when the bonding time is increased to 30 min.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128343520","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000201
M. N. Rao, G. Dhineshbabu, Prateek Sibal
Cast aluminum alloys find widespread application in the automotive and aircraft industries on account of their good castability, corrosion resistance, and high strength to weight ratio. Use of quality indices to rank cast aluminum alloys in terms of their quality has been in vogue since 1980s. Quality indices enable design engineers to select appropriate alloy condition by comparing the changes in quality with the changes in processing parameters like aging temperature and aging time. They also enable design engineers to select an appropriate alloy by way of comparing the quality obtainable with different alloy compositions. The present article highlights the effect of hot isostatic pressing (Hipping) on the quality of cast aluminum alloy 354 by using quality indices Q0, Q, and QC put forth in published literature. It has been observed that material in Hipped condition has higher value of these indices as compared to non-Hipped condition. This behavior is consistent across different aging conditions of the alloy. It is concluded that improvement accruing through Hipping of cast aluminum alloy 354 can be satisfactorily rated by using these quality indices.
{"title":"Hipping Evaluation in Cast Aluminum Alloys: Quality Index-Based Approach","authors":"M. N. Rao, G. Dhineshbabu, Prateek Sibal","doi":"10.1201/9781351045636-140000201","DOIUrl":"https://doi.org/10.1201/9781351045636-140000201","url":null,"abstract":"Cast aluminum alloys find widespread application in the automotive and aircraft industries on account of their good castability, corrosion resistance, and high strength to weight ratio. Use of quality indices to rank cast aluminum alloys in terms of their quality has been in vogue since 1980s. Quality indices enable design engineers to select appropriate alloy condition by comparing the changes in quality with the changes in processing parameters like aging temperature and aging time. They also enable design engineers to select an appropriate alloy by way of comparing the quality obtainable with different alloy compositions. The present article highlights the effect of hot isostatic pressing (Hipping) on the quality of cast aluminum alloy 354 by using quality indices Q0, Q, and QC put forth in published literature. It has been observed that material in Hipped condition has higher value of these indices as compared to non-Hipped condition. This behavior is consistent across different aging conditions of the alloy. It is concluded that improvement accruing through Hipping of cast aluminum alloy 354 can be satisfactorily rated by using these quality indices.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131735964","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000436
K. Karhausen, A. Korhonen
Because of its lightweight and strength, aluminum alloys are used are being used increasing for the production of lightweight construction. In addition to applications in the expanding transportation market, aluminum sheet and foil materials are traditionally used for food and medical packaging, thin foil, and fin stock for air conditioners and heat exchangers, decorative panels and lithographic sheet. Rolling is a process used for the production of strip or sheet. In this article, rolling processing of aluminum and aluminum alloys is discussed in detail and specific processes include: hot-rolling, cold-rolling, and rolling of aluminum foils.
{"title":"Rolling of Aluminum","authors":"K. Karhausen, A. Korhonen","doi":"10.1201/9781351045636-140000436","DOIUrl":"https://doi.org/10.1201/9781351045636-140000436","url":null,"abstract":"Because of its lightweight and strength, aluminum alloys are used are being used increasing for the production of lightweight construction. In addition to applications in the expanding transportation market, aluminum sheet and foil materials are traditionally used for food and medical packaging, thin foil, and fin stock for air conditioners and heat exchangers, decorative panels and lithographic sheet. Rolling is a process used for the production of strip or sheet. In this article, rolling processing of aluminum and aluminum alloys is discussed in detail and specific processes include: hot-rolling, cold-rolling, and rolling of aluminum foils.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"46 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131305607","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000305
Amauri Garcia, P. Goulart, F. Bertelli, J. Spinelli, N. Cheung
A careful technique of dissolution of the Al-rich phase is conducted in hypoeutectic Al–Fe alloys samples, which were solidified under a wide range of cooling rates envisaging deeper investigations on the skeletal arrangement of either Al6Fe intermetallic fibers or Al3Fe plates, and their dependence on solidification thermal parameters. The experiments were carried out with hypoeutectic Al–Fe alloys, subjected to equilibrium solidification from the melt, steady-state solidification (Bridgman growth), transient directional solidification in water-cooled and air-cooled molds and rapid solidification (laser remelting), thus permitting a significant range of microstructural scales to be examined. It is shown that Al6Fe prevails for cooling rates >1.5 K/s, and that a short zone of coexistence of Al3Fe and Al6Fe phases exists for cooling rates <1.5 K/s, which is rapidly replaced with the prevalence of Al3Fe intermetallics with further decrease in cooling rate. In contrast, even with high values of cooling rate, typical of the laser remelting process, the Al–Al3Fe eutectic is shown to prevail.
{"title":"Hypoeutectic Al–Fe Alloys: Formation and Characterization of Intermetallics by Dissolution of the Al Matrix","authors":"Amauri Garcia, P. Goulart, F. Bertelli, J. Spinelli, N. Cheung","doi":"10.1201/9781351045636-140000305","DOIUrl":"https://doi.org/10.1201/9781351045636-140000305","url":null,"abstract":"A careful technique of dissolution of the Al-rich phase is conducted in hypoeutectic Al–Fe alloys samples, which were solidified under a wide range of cooling rates envisaging deeper investigations on the skeletal arrangement of either Al6Fe intermetallic fibers or Al3Fe plates, and their dependence on solidification thermal parameters. The experiments were carried out with hypoeutectic Al–Fe alloys, subjected to equilibrium solidification from the melt, steady-state solidification (Bridgman growth), transient directional solidification in water-cooled and air-cooled molds and rapid solidification (laser remelting), thus permitting a significant range of microstructural scales to be examined. It is shown that Al6Fe prevails for cooling rates >1.5 K/s, and that a short zone of coexistence of Al3Fe and Al6Fe phases exists for cooling rates <1.5 K/s, which is rapidly replaced with the prevalence of Al3Fe intermetallics with further decrease in cooling rate. In contrast, even with high values of cooling rate, typical of the laser remelting process, the Al–Al3Fe eutectic is shown to prevail.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"21 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125686873","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-16DOI: 10.1201/9781351045636-140000279
D. L. Majid, N. H. Manan, Yee Ling Chok
A honeycomb composite structure is usually composed of a lightweight hexagonal core sandwiched between two thin face sheets that are adhesively joined. Both the core and the face sheets can be combinations of many types of materials depending on the application. In this article, an overview of the design and manufacturing process of aluminum honeycomb composite structures particularly for aerospace application is presented. Aluminum honeycomb composite structures are lightweight constructions with high specific strength and stiffness that are applied mainly in the aerospace industry. An aluminum honeycomb panel is typically made up of the secondary structural components and interiors of an aircraft such as the wing skin, trailing edge, control surface, flooring, partitions, aircraft galleys, and overhead bins, to name a few. Other applications are in the spacecraft, helicopter, missile, and satellite. Owing to its honeycomb design peculiar to the hexagonal beehives, it can reach more than 30 times higher in stiffness and 10 times higher in flexural strength compared to its solid counterpart of the same weight. The mechanical properties of the honeycomb composite structure hinge on the materials of the core and face sheets, the core geometries, and the thickness of the face sheets. Designed for superior flexural and shear loading, the selection of the optimal honeycomb design will depend on the application requirements. The principal design criterion of a sandwich structure in aerospace applications is weight saving, and there is a trade-off between performance and cost. In terms of manufacturing of the honeycomb composite sandwich structure, the two main processes are the expansion process commonly used for low-density cores and the corrugation process for higher density cores.
{"title":"Honeycomb Composite Structures of Aluminum: Aerospace Applications","authors":"D. L. Majid, N. H. Manan, Yee Ling Chok","doi":"10.1201/9781351045636-140000279","DOIUrl":"https://doi.org/10.1201/9781351045636-140000279","url":null,"abstract":"A honeycomb composite structure is usually composed of a lightweight hexagonal core sandwiched between two thin face sheets that are adhesively joined. Both the core and the face sheets can be combinations of many types of materials depending on the application. In this article, an overview of the design and manufacturing process of aluminum honeycomb composite structures particularly for aerospace application is presented. Aluminum honeycomb composite structures are lightweight constructions with high specific strength and stiffness that are applied mainly in the aerospace industry. An aluminum honeycomb panel is typically made up of the secondary structural components and interiors of an aircraft such as the wing skin, trailing edge, control surface, flooring, partitions, aircraft galleys, and overhead bins, to name a few. Other applications are in the spacecraft, helicopter, missile, and satellite. Owing to its honeycomb design peculiar to the hexagonal beehives, it can reach more than 30 times higher in stiffness and 10 times higher in flexural strength compared to its solid counterpart of the same weight. The mechanical properties of the honeycomb composite structure hinge on the materials of the core and face sheets, the core geometries, and the thickness of the face sheets. Designed for superior flexural and shear loading, the selection of the optimal honeycomb design will depend on the application requirements. The principal design criterion of a sandwich structure in aerospace applications is weight saving, and there is a trade-off between performance and cost. In terms of manufacturing of the honeycomb composite sandwich structure, the two main processes are the expansion process commonly used for low-density cores and the corrugation process for higher density cores.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"167 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128157388","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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