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Open Access
Article
Publication date: 19 March 2024

Zhenlong Peng, Aowei Han, Chenlin Wang, Hongru Jin and Xiangyu Zhang

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC…

Abstract

Purpose

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

Design/methodology/approach

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

Findings

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

Originality/value

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2633-6596

Keywords

Article
Publication date: 21 August 2023

Dinesh Kumar, Surjit Angra and Satnam Singh

This research outlines the development and characterization of advanced composite materials and their potential applications in the aerospace industry for interior applications…

Abstract

Purpose

This research outlines the development and characterization of advanced composite materials and their potential applications in the aerospace industry for interior applications. Advanced composites, such as carbon-fiber-reinforced polymers and ceramic matrix composites, offer significant advantages over traditional metallic materials in terms of weight reduction, stiffness and strength. These materials have been used in various aerospace applications, including aircraft, engines and thermal protection systems.

Design/methodology/approach

The development of design of experiment–based hybrid aluminum composites using the stir-casting technique has further enhanced the performance and cost-effectiveness of these materials. The design of the experiment was followed to fabricate hybrid composites with nano cerium oxide (nCeO2) and graphene nanoplatelets (GNPs) as reinforcements in the Al-6061 matrix.

Findings

The Al6061 + 3% nCeO2 + 3% GNPs exhibited a high hardness of 119.6 VHN. The ultimate tensile strength and yield strength are 113.666 MPa and 73.08 MPa, respectively. A uniform distribution of reinforcement particulates was achieved with 3 Wt.% of each reinforcement in the matrix material, which is analyzed using scanning electron microscopy. Fractography revealed that brittle and ductile fractures caused the failure of the fractured specimens in the tensile test.

Practical implications

The manufactured aluminum composite can be applied in a range of exterior and interior structural parts like wings, wing boxes, motors, gears, engines, antennas, floor beams, etc. The fan case material of the GEnx engine (currently using carbon-fiber reinforcement plastic) for the Boeing 7E7 can be another replacement with manufactured hybrid aluminum composite, which predicts weight savings per engine of close to 120 kg.

Originality/value

The development of hybrid reinforcements, where two or more types of reinforcements are used in combination, is also a novel approach to improving the properties of these composites. Advanced composite materials are known for their high strength-to-weight ratio. If the newly developed composite material demonstrates superior properties, it can potentially be used to replace traditional materials in aircraft manufacturing. By reducing the weight of aircraft structures, fuel efficiency can be improved, leading to reduced operating costs and environmental impact. This allows for a more customized solution for specific application requirements and can lead to further advancements in materials science and technology.

Details

Aircraft Engineering and Aerospace Technology, vol. 95 no. 10
Type: Research Article
ISSN: 1748-8842

Keywords

Article
Publication date: 17 April 2023

Kawaljit Singh Randhawa

The purpose of this study is to prepare a state-of-the-art review on advanced ceramic materials including their fabrication techniques, characteristics, applications and…

Abstract

Purpose

The purpose of this study is to prepare a state-of-the-art review on advanced ceramic materials including their fabrication techniques, characteristics, applications and wettability.

Design/methodology/approach

This review paper presents the various types of advanced ceramic materials according to their compounding elements, fabrication techniques of advanced ceramic powders as well as their consolidation, their characteristics, applications and wetting properties. Hydrophobic/hydrophilic properties of advanced ceramic materials are described in the paper with their state-of-the-art application areas. Optical properties of fine ceramics with their intrinsic characteristics are also presented within. Special focus is given to the brief description of application-based manipulation of wetting properties of advanced ceramics in the paper.

Findings

The study of wetting/hydrophobicity/hydrophilicity of ceramic materials is important by which it can be further modified to achieve the required applications. It also makes some sense that the material should be tested for its wetting properties when it is going to be used in some important applications like biomedical and dental. Also, these advanced ceramics are now often used in the fabrication of filters and membranes to purify liquid/water so the study of wetting characteristics of these materials becomes essential. The optical properties of advanced ceramics are equally making them suitable for many state-of-the-art applications. Dental, medical, imaging and electronics are the few sectors that use advanced ceramics for their optical properties.

Originality/value

This review paper includes various advanced ceramic materials according to their compounding elements, different fabrication techniques of powders and their consolidation, their characteristics, various application area and hydrophobic/hydrophilic properties.

Details

Pigment & Resin Technology, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0369-9420

Keywords

Article
Publication date: 1 January 1987

BRISTOL Composite Materials Engineering Ltd (BCME), with over thirty years experience in composites, has become established as a leading supplier of advanced composites components…

Abstract

BRISTOL Composite Materials Engineering Ltd (BCME), with over thirty years experience in composites, has become established as a leading supplier of advanced composites components and structures to the aerospace industry.

Details

Aircraft Engineering and Aerospace Technology, vol. 59 no. 1
Type: Research Article
ISSN: 0002-2667

Article
Publication date: 5 June 2020

Lai Jiang, Xiaobo Peng and Daniel Walczyk

This paper aims to summarize the up-to-date research performed on combinations of various biofibers and resin systems used in different three-dimensional (3D) printing…

Abstract

Purpose

This paper aims to summarize the up-to-date research performed on combinations of various biofibers and resin systems used in different three-dimensional (3D) printing technologies, including powder-based, material extrusion, solid-sheet and liquid-based systems. Detailed information about each process, including materials used and process design, are described, with the resultant products’ mechanical properties compared with those of 3D-printed parts produced from pure resin or different material combinations. In most processes introduced in this paper, biofibers are beneficial in improving the mechanical properties of 3D-printed parts and the biodegradability of the parts made using these green materials is also greatly improved. However, research on 3D printing of biofiber-reinforced composites is still far from complete, and there are still many further studies and research areas that could be explored in the future.

Design/methodology/approach

The paper starts with an overview of the current scenario of the composite manufacturing industry and then the problems of advanced composite materials are pointed out, followed by an introduction of biocomposites. The main body of the paper covers literature reviews of recently emerged 3D printing technologies that were applied to biofiber-reinforced composite materials. This part is classified into subsections based on the form of the starting materials used in the 3D printing process. A comprehensive conclusion is drawn at the end of the paper summarizing the findings by the authors.

Findings

Most of the biofiber-reinforced 3D-printed products exhibited improved mechanical properties than products printed using pure resin, indicating that biofibers are good replacements for synthetic ones. However, synthetic fibers are far from being completely replaced by biofibers due to several of their disadvantages including higher moisture absorbance, lower thermal stability and mechanical properties. Many studies are being performed to solve these problems, yet there are still some 3D printing technologies in which research concerning biofiber-reinforced composite parts is quite limited. This paper unveils potential research directions that would further develop 3D printing in a sustainable manner.

Originality/value

This paper is a summary of attempts to use biofibers as reinforcements together with different resin systems as the starting material for 3D printing processes, and most of the currently available 3D printing techniques are included herein. All of these attempts are solutions to some principal problems with current 3D printing processes such as the limit in the variety of materials and the poor mechanical performance of 3D printed parts. Various types of biofibers are involved in these studies. This paper unveils potential research directions that would further widen the use of biofibers in 3D printing in a sustainable manner.

Details

Rapid Prototyping Journal, vol. 26 no. 6
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 2 September 2014

Ugur Ozsarac, Salim Aslanlar, Faruk Varol and Mehmet Ekici

The purpose of this study was to investigate wear behaviours of brake pads produced from carbon–carbon (C/C) composites in both wet and dry friction sliding conditions. Carbon is…

Abstract

Purpose

The purpose of this study was to investigate wear behaviours of brake pads produced from carbon–carbon (C/C) composites in both wet and dry friction sliding conditions. Carbon is probably the most remarkable element in science and also C/C composites are a family of advanced composite materials. They are the most advanced form of carbon and consist of fibre based on carbon precursors embedded in a carbon matrix. In the present work, wear test specimens were prepared according to the related standards and they were exposed to pin-on-disc wear testing in wet and dry sliding conditions with different loads as 10, 20, 30 and 40 N with 1 m/s constant sliding speed. Wet friction process was conducted on all specimens by means of rain water collected from the nature.

Design/methodology/approach

Pin-on-disc wear test tribology lubrication was used.

Findings

Mechanical and physical property measurements of C/C composite brake pad materials: hardness, modulus of elasticity, density and water absorption capacity. Wear performance of materials were measured as coefficient of friction, volumetric loss and specific wear rate.

Originality/value

C/C composite brake pads are used in railway vehicles. Wear performances of them are very important for safety. In this study, wear behaviours of these materials were investigated not only in dry sliding friction condition but also in wet sliding one. Because safety braking is important in all weather conditions for trains, and we used natural rain water to observe the wet sliding friction behaviour of brake pads. “Water lubrication” is an important aspect mentioned in tribology handbooks.

Details

Industrial Lubrication and Tribology, vol. 66 no. 6
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 10 July 2021

Stephanie S. Luke, David Soares, Janaye V. Marshall, James Sheddden and Özgür Keleş

Fused filament fabrication of continuous-fiber-reinforced polymers is a promising technique to achieve customized high-performance composites. However, the off-axis tensile…

Abstract

Purpose

Fused filament fabrication of continuous-fiber-reinforced polymers is a promising technique to achieve customized high-performance composites. However, the off-axis tensile strength (TS) and Mode I fracture toughness of fused filament fabricated (FFFed) continuous-glass-fiber-reinforced (CGFR) nylon are unknown. The purpose of this paper is to investigate the mechanical and fracture behavior of FFFed CGFR nylon with various fiber content and off-axis fiber alignment.

Design/methodology/approach

Tensile tests were performed on FFFed CGFR-nylon with 9.5, 18.9 and 28.4 fiber vol. %. TS was tested with fiber orientations between 0 and 90 at 15 intervals. Double cantilever beam tests were performed to reveal the Mode I fracture toughness of FFFed composites.

Findings

TS increased with increasing fiber vol. % from 122 MPa at 9.5 vol. % to 291 MPa at 28 vol. %. FFFed nylon with a triangular infill resulted in 37 vol. % porosity and a TS of 12 MPa. Composite samples had 11–12 vol. % porosity. TS decreased by 78% from 291 MPa to 64 MPa for a change in fiber angle θ from 0 (parallel to the tensile stress) to 15. TS was between 27 and 17 MPa for 300 < θ < 900. Mode I fracture toughness of all the composites were lower than ∼332 J/m2.

Practical implications

Practical applications of FFFed continuous-fiber-reinforced (CFR) nylon should be limited to designs where tensile stresses align within 15 of the fiber orientation. Interlayer fracture toughness of FFFed CFR composites should be confirmed for product designs that operate under Mode I loading.

Originality/value

To the best of the authors’ knowledge, this is the first study showing the effects of fiber orientation on the mechanical behavior and effects of the fiber content on the Mode I fracture toughness of FFFed CGFR nylon.

Details

Rapid Prototyping Journal, vol. 27 no. 7
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 16 October 2018

Johny James and Raja Annamalai A.

This study aims to develop a less weight high wear resistant material to fabricate brake components especially in automotive sector.

113

Abstract

Purpose

This study aims to develop a less weight high wear resistant material to fabricate brake components especially in automotive sector.

Design/methodology/approach

Effort was initiated to design and develop aluminium metal matrix composite by combining aluminium alloy AA6061 and zirconium oxide (ZrO2) with the help of stir casting coupled with squeeze casting unit. Morphology analysis of advanced composite has been carried out by optical microscopy and scanning electron microscopy (SEM). The hardness of composites having different compositions was tested using Vickers micro hardness tester. The tribological property of the developed three specimens having different composition has been tested using pin-on-disc wear test equipment under dry sliding conditions. To obtain better understanding of wear mechanism, SEM image of worn-out surface was captured and analysed. SEM images and the corresponding Energy-dispersive X-ray spectroscopy (EDX) on the wear surface were carried out.

Findings

The optical and SEM images evidenced the existence of ZrO2 particles along the metal matrix composite. Porosity values shows that the porosity level is acceptable as it falls below 7 per cent. Also, the finding proves that increase in the percentage of reinforcement particle instigates agglomeration on the AA6061 composites. Hardness test demonstrated that the inclusion of hard ZrO2 particles leads to substantial improvement in hardness and the hardness value started deteriorating when the composition reaches 15 per cent. The wear test results substantiated the enhancement of tribological property due to the inclusion of distinct ZrO2 particles. Also, despite of addition of reinforcements, the wear rate increased when the load increases. SEM images proved that AA6061/ZrO2-5 per cent composite fashioned steady-state mild and smooth wear. EDX spectrum analysis revealed the existence of ZrO2 particles along with wear debris, which caused wear of 685 µm in AA6061/ZrO2-15 per cent composite.

Originality/value

The developed material possesses low wear rate which is the unique property of composite and frictional force which is directly proportional to load but the coefficient of friction remains apparently constant. As a whole, investigations on developed composites introduce a new material which is suitable for manufacturing of brake components for automobile industry.

Details

Industrial Lubrication and Tribology, vol. 70 no. 9
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 19 July 2021

Kawaljit Singh Randhawa and Ashwin Patel

The mechanical and tribological properties of polymers and polymer composites vary with different environmental conditions. This paper aims to review the influence of…

Abstract

Purpose

The mechanical and tribological properties of polymers and polymer composites vary with different environmental conditions. This paper aims to review the influence of humidity/water conditions on various polymers and polymer composites' mechanical properties and tribological behaviors.

Design/methodology/approach

The influence of humidity and water absorption on mechanical and tribological properties of various polymers, fillers and composites has been discussed in this paper. Tensile strength, modulus, yield strength, impact strength, COF and wear rates of polymer composites are compared for different environmental conditions. The interaction between the water molecules and hydrophobic polymers is also represented.

Findings

Pure polymer matrices show somewhat mixed behavior in humid environments. Absorbed moisture generally plasticizes the epoxies and polyamides and lowers the tensile strength, yield strength and modulus. Wear rates of PVC generally decrease in humid environments, while for polyamides, it increases. Fillers like graphite and boron-based compounds exhibit low COF, while MoS2 particulate fillers exhibit higher COF at high humidity and water conditions. The mechanical properties of fiber-reinforced polymer composites tend to decrease as the rate of humidity increases while the wear rates of fiber-reinforced polymer composites show somewhat mixed behavior. Particulate fillers like metals and advanced ceramics reinforced polymer composites exhibit low COF and wear rates as the rate of humidity increases.

Originality/value

The mechanical and tribological properties of polymers and polymer composites vary with the humidity value present in the environment. In dry conditions, wear loss is determined by the hardness of the contacting surfaces, which may not effectively work for high humid environments. The tribological performance of composite constituents, i.e. matrix and fillers in humid environments, defines the overall performance of polymer composite in said environments.

Details

Industrial Lubrication and Tribology, vol. 73 no. 9
Type: Research Article
ISSN: 0036-8792

Keywords

Book part
Publication date: 13 December 2011

Timothy L. Pett and James Wolff

Purpose – The purpose of the chapter is to sketch the historical and evolutionary development of the Wichita Aircraft Manufacturing Cluster from inception to present and provide a…

Abstract

Purpose – The purpose of the chapter is to sketch the historical and evolutionary development of the Wichita Aircraft Manufacturing Cluster from inception to present and provide a descriptive narrative of aircraft industry knowledge spillovers currently driving effort to establish a Medical Device Manufacturing Cluster. The chapter illustrates how carbon-fiber composite materials knowledge and technology developed for use in the aviation industry is facilitating the creation and growth of medical device manufacturing.

Methodology/approach – We use an historical case study approach to trace the development of the aircraft cluster in the Wichita, KS metropolitan area. A number of technologies are identified that had initially been adopted by one firm but eventually diffused through other firms in the local cluster and ultimately throughout the industry.

Findings – In addition to providing examples of within industry knowledge spillovers, we provide an example of technology-based knowledge that is diffusing through the aircraft manufacturing industry and is now being used as the basis for establishing an unrelated industry manufacturing cluster. The use of carbon-fiber composites in aircraft manufacturing has diffused from one manufacturer to many in the industry. Subsequently, the knowledge base surrounding carbon-fiber composite materials is being used in a local R&D effort to create a second manufacturing cluster producing medical devices ranging from surgical instruments to joint-replacement implants.

Originality/value of paper – The chapter illustrates a unique example of a manufacturing cluster, intra-industry knowledge spillovers, and inter-industry knowledge spillovers to create a new manufacturing cluster.

Details

Entrepreneurship and Global Competitiveness in Regional Economies: Determinants and Policy Implications
Type: Book
ISBN: 978-1-78052-395-8

Keywords

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