Search results

Presently, the materials used in light combat aircraft structures are aluminium alloys and composites. These structures are joined together through riveted joints. The weight of these rivets for the entire aircraft is nearly one ton. In addition to weight, the riveted connection requires a lot of tools, equipments, fixtures and manpower, which makes it an expensive and time-consuming process. Moreover, Al alloy is also welded using tungsten inert gas (TIG) welding process by proper control of process parameters. This process has limitations such as porosity, alloy segregation and hot cracking. To overcome the above limitations, an alternative technology is required. One such technology is friction stir welding (FSW), which can be successfully applied for welding of aluminium alloy in LCA structures. Therefore, this paper aims to compare the load carrying capabilities of FSW joints with TIG welded and riveted joints.

FSW joints and TIG welded joints were fabricated using optimized process parameters, followed by riveted joints using standard shop floor practice in the butt and lap joint configurations.

The load-carrying capabilities of FSW joints are superior than those of other joints. FSW joints exhibited 75 per cent higher load-carrying capability compared to the riveted joints and TIG-welded joints.

From this investigation, it is inferred that the FSW joint is suitable for the replacement of riveted joints in LCA and TIG-welded joints.

Friction stir butt joints exhibited 75 per cent higher load-carrying capability than riveted butt joints. Friction stir welded lap joints showed 70 per cent higher load-carrying capability than the riveted lap joints. Friction stir butt joints yielded 41 per cent higher breaking load capabilities than the TIG-welded butt joints. Moreover, Friction stir lap weld joints have 57 per cent more load-carrying capabilities than the TIG-welded lap joints.

The fuselage riveted lap-joints are susceptible to multiple site damage (MSD) and should be considered in damage tolerance analysis. This paper aims to investigate the stress intensity factor (SIF) and crack growth simulation for lap-joints based on three-dimensional (3D) finite element analysis.

The 3D finite element model of lap-joints is established by detailed representation of rivets and considering the rivet clamping force and friction. Numerical study is conducted to investigate the SIF distribution along the thickness direction and the effect of clamping force. A predictive method for the cracks propagation of MSD is then developed, in which an integral mean is adopted to quantify the SIF at crack tips, and the crack closure effect is considered. For comparison, a fatigue test of a lap-joint with MSD cracks is conducted to determine the cracks growth live and measure the cracks growth.

The numerical study shows that the through-thickness crack at riveted hole in lap-joints can be treated as mode I crack. The distribution of SIF along the thickness direction is inconstant and nonmonotonic. Besides, the increase in clamping force will lead to more frictional load transfer at the faying surfaces. The multiple crack growth simulation results agreed well with the experimental data.

The novelty of this work is that the SIF distribution along the thickness direction and the MSD cracks growth simulation for lap-joints are investigated by 3D finite element analysis, which can reflect the secondary bending, rivet clamping, contact and friction in lap-joints.

The purpose of this study is to investigate the microstructure of fretting wear behavior in 6061-T6 aluminum alloy. The fretting wear of blind riveted lap joints of 6061-T6 aluminum alloy plates, which are widely used in aircraft construction, was investigated. Fretting damages were investigated between the contact surface of the plates and between the plate and the rivet contact surface.

Experiments were carried out using a computer controlled Instron testing machine with 200 kN static and 100 kN dynamic load capacity. Max package computer program was used for the control of the experiments. Fretting scars, width of wear scars, microstructure was investigated by metallographic techniques and scanning electron microscopy.

It was found that fretting damages were occurred between the plates contacting surface and between the plate and rivet contact surface. As load and cycles increased, fretting scars increased. Fretting wear initially begins with metal-to-metal contact. Then, the formed metallic wear particles are hardened by oxidation. These hard particles spread between surfaces, causing three-body fretting wear. Fretting wear surface width increases with increasing load and number of cycles.

The useful life of many tribological joints is limited by wear or deterioration of the fretting components due to fretting by oscillating relative displacements of the friction surfaces. Such displacements are caused by vibrations, reciprocating motion, periodic bending or twisting of the mating component, etc. Fretting also tangibly reduces the surface layer quality and produces increased surface roughness, micropits, subsurface microphone.

The current corrosion maintenance philosophy reflected in aviation regulations and recommended practices does not stimulate progress in corrosion related technology. A US Air Force (USAF)‐sponsored survey has recommended re‐examination of corrosion maintenance policies and practices to identify lower cost alternatives, and has encouraged research into tools and techniques that reduce maintenance costs while preserving safety. In particular, these include models to predict the impact of existing corrosion damage on structural integrity, methods of predicting corrosion growth rates and nondestructive inspection systems capable of providing corrosion metrics. The Institute for Aerospace Research of the National Research Council Canada (IAR/NRC) has pioneered work on the application of enhanced visual methods for corrosion detection in lap joints and the assessment of the impact of corrosion on lap‐joint structural integrity. The role of these enhanced visual methods in the new corrosion management is described.

The purpose of this paper is to examine the effect of changing some riveting parameters on the riveting quality of a riveted aircraft structure. In this study, riveting was performed by applying friction under pressure.

During this friction riveting process, a feed of 3 mm/min was applied in the axial direction. Rotation speed values of 2,000, 2,200 and 2,400 rpm were selected. A 3-axis die milling machine was used to achieve the required positioning, pressing force and friction effect. 1.27 mm-thick Al 7075-T6 sheets and 2117-T3 forged rivets were used. The feed rate was applied at 1 mm/min in both tensile shear and cross-tensile tests.

The feasibility of friction riveting in 2117-T3 rivets was examined, it was shown that it could be done, and the most suitable rotation value for this process was determined.

Clamping force is one of the most important parameters for riveting quality. This study will contribute to a better understanding of the friction-forging riveting process along with the effects of riveting parameters. At the same time, it will lead to more research and expand the application of friction forging riveting to more structural connections.

The riveting process is a metal forming process involving complex elastic-plastic deformation, which will induce a compressive residual stress field and cause local distortions in the connecting areas. Regarding to the aircraft panel assemblies with plenty of rivets, the global deformation is inevitable and undesired, leading difficulties to downstream assembly processes. This paper aims to present a new method for the local distortion calculation and the global deformation prediction of sheet panel assemblies during the automated riveting process.

In this paper, a simplified algebraic study is presented to analyze the local distortion of single countersunk rivet joint with the consideration of the barrel-like shape of the driven head and the through-thickness variations along the rivet shank. Then, an equivalent rivet unit is proposed based on the result of the algebraic study and embedded into the global-level model for the prediction of the overall distortions of riveted panels.

The algebraic study is able to reach a more precise contour of the deformed rivet than the traditional assumption of cylindrical deformations and rapidly determine the equivalent coefficients of the riveting unit. The result also shows an industrial acceptable accuracy of the prediction for the global deformations of the double-layered panel assemblies widely used in the aircraft panel structures.

A new local-global method for predicting the deformations of the riveted panel assembly based on the algebraic study of the local distortions is proposed to help the engineers in the early design stages or in the assembly process planning stage.

To investigate the effect of different welding configurations on the mechanical properties of friction stir welding (FSW) overlap joints. The application of FSW in an overlap configuration could be an attractive replacement to the riveting process for assembly of fuselage primary structures due to the similarity in tolerance management. However, the mechanical properties of welded overlap joints are often inferior to the respective riveted lap‐joint properties.

In order to quantify the static and fatigue strength of FSW overlap joints, numerical and experimental investigation on overlap welds were performed in the current work. Several single shear overlap joints welding configurations were investigated, including single and multiple pass friction stir welds. The static and fatigue behaviour of these joints was assessed through tensile and fatigue tests.

Static and fatigue behaviour were found to strongly depend on the welding process parameters and configuration. With respect to the static behaviour, it was found that values close to base material can be achieved. However, depending on configuration and process parameters, static properties can be as low as about 30% of the base material properties. As for the fatigue behaviour, the fatigue limit for all configurations tested was found to be unrealistic for structural applications.

The distance between the outermost welds in multiple pass welds were found to influence the mechanical properties, although no direct relationship can be derived. Indications have been found but no clear conclusion has been reached with respect to the optimum configuration. In some cases, specimens with superior tensile properties exhibited reduced fatigue properties whereas the exact opposite effect was observed for other configurations.

The standard diagram is described, giving the relationship between R and S for constant value of N. The line of infinite endurance is obtained, and the relationship of N and S is shown. The effects of stress concentration and of shape are studied and tabulated. The variation of KF with S1 is plotted, and the relationship between KF, KT and S1 is examined. Comments are made on the variation of KF with material, on high compressive stress, on surface finish effect and on the relationship between the grades of light alloy. The effects of bending, riveting and bolting are shown. General discussion summarizes the results and makes suggestions for future research and testing for fatigue. An appendix contains notes on practical use of the results in design, and some examples of fatigue stress analysis and its application to pressurized cabins.

Contrary to the general conception of adding weight for fatigue resistance it is sometimes possible to reduce the fatigue hazard by removing weight. The theory of having bearing area, tear‐out area, and tension area sufficient to develop the full shear strength of a rivet is not necessarily sound when fatigue life is considered. Accordingly, marked improvements in fatigue resistance can be achieved by reducing the underlying areas to such an extent that they are incapable of inducing loads causing fatigue failures of the main structure. Results of tests involving fatigue failure are given, and seven basic considerations in the design of fatigue resistant structures are listed.

IN order to appreciate how surface finish affects drag one must be familiar with the main characteristics of boundary layer flow. These have been described in great detail elsewhere, see, for example, Ref. 1, but a brief outline will not be out of place here. At the surface of a body moving through air there is a thin layer of air called the boundary layer in which the velocity relative to the body rapidly falls to zero as the surface of the body is approached. Because of the large velocity gradients across the boundary layer the viscous forces are appreciable there; outside the boundary layer the flow approximates closely to the ideal inviscid flow of classical hydrodynamics. The flow in the boundary layer beginning at the forward stagnation point is usually laminar for some distance, then after a transition region the flow becomes turbulent. The transition region is appreciable in extent at low Reynolds numbers and in turbulent airstreams, but at the Reynolds numbers usual in flight it is short enough to be referred to as a point. Wo now know enough about both laminar and turbulent types of flow over smooth surfaces and the associated frictional forces to be able to calculate with fair accuracy the profile and skin friction drags of a smooth aerofoil given its thickness, Reynolds number and the position of the transition points2. It is found that the skin friction in the laminar boundary layer is much smaller than the skin friction in the turbulent boundary layer; this is illustrated in Fig. 1, which shows the skin friction distribution on one side of a smooth flat plate at a Reynolds number of 107 and with the transition points at 05 c. and 25 c. Fig. 2 shows the variation of drag with the position of the transition point for the flat plate. Similar curves are obtained for aerofoils and bodies of revolution. It is evident that the further back transition occurs the less will be the drag. Fig. 3 illustrates a point that is worth emphasizing, namely, the relative importance of the drag change due to a given transition point movement increases with wing thickness and Reynolds number.