铝制飞机紧固件孔结构修复的非熔化添加剂方法

IF 4.2 Q2 ENGINEERING, MANUFACTURING Additive manufacturing letters Pub Date : 2024-10-23 DOI:10.1016/j.addlet.2024.100249
R. Joey Griffiths , David Garcia , Greg D. Hahn , Jim Lua , Nam Phan , Hang Z. Yu
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引用次数: 0

摘要

航空航天铝结构中紧固件孔的损坏对飞机的耐久性提出了重大挑战,而用于修复过大孔的传统衬套方法往往因缺乏冶金结合和有限的边缘距离而无法达到预期效果。本研究调查了添加剂搅拌摩擦沉积(一种非熔化添加剂工艺),将其作为航空航天紧固件孔结构修复的可行替代方法。该修复工艺在 AA7050(Al-Zn-Mg-Cu-Zr)孔结构上进行了演示,包括用新材料填充过大的孔并进行加工以恢复孔的原始尺寸。修复后的孔洞试样无缺陷,在完全反向拉伸-压缩加载(R = -1)条件下表现出良好的疲劳性能。在 123.5 兆帕的额定应力幅值下,未修复基线试样的平均失效循环次数为 12,666 次,有效修复试样的平均失效循环次数为 17,372 次。在航空航天应用中,很难在不影响疲劳性能的情况下修复复杂的几何结构;这项研究首次证明了添加剂修复的效果始终优于未修复的基线试样。值得注意的是,这一成果是通过低能耗、高成本效益的解决方案实现的,无需进行修复后热处理。除少数异常值外,修复后的疲劳性能总体上仍低于未损坏的原始试样,这可能是由于添加剂搅拌摩擦沉积的热机械加工性质导致 AA7050 中的沉淀演变。与适当老化的 AA7050-T7451 基体材料相比,这种演变削弱了修复区域和邻近基体材料的强度,导致裂纹的产生和增长速度加快。
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A non-melting additive approach to structural repair of aluminum aircraft fastener holes
The damage to fastener holes in aerospace aluminum structures presents significant challenges for aircraft durability, and conventional bushing methods for repairing oversized holes often fall short due to the lack of metallurgical bonding and limited edge distance availability. This study investigates additive friction stir deposition, a non-melting additive process, as a viable alternative for the structural repair of aerospace fastener holes. The repair process, demonstrated on AA7050 (Al-Zn-Mg-Cu-Zr) hole structures, involves filling oversized holes with new material and machining to restore the original hole size. The repaired hole coupons are defect-free and exhibit good fatigue performance under fully reversed tension-compression loading (R = -1). At a nominal stress amplitude of 123.5 MPa, the average number of cycles to failure is 12,666 for unrepaired baseline coupons and 17,372 for effectively repaired coupons. Restoring complex geometries without compromising fatigue performance has been difficult in aerospace applications; this study marks the first demonstration of additive repair that consistently outperforms the unrepaired baseline coupons. Notably, the result is achieved through a low-energy, cost-effective solution without the need for post-repair heat treatment. Except for a few outliers, the post-repair fatigue performance generally remains inferior to that of undamaged, pristine coupons, likely due to precipitate evolution in AA7050 caused by the thermomechanical processing nature of additive friction stir deposition. This evolution weakens the repair region and the adjacent base material, leading to faster crack initiation and growth compared to the properly aged base material, AA7050-T7451.
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来源期刊
Additive manufacturing letters
Additive manufacturing letters Materials Science (General), Industrial and Manufacturing Engineering, Mechanics of Materials
CiteScore
3.70
自引率
0.00%
发文量
0
审稿时长
37 days
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