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WOODHEAD PUBLISHING IN MATERIALS

Introductionto aerospacematerials

Adrian P. Mouritz

WPWOODHEADPUBLISHING

Introduction to aerospace nnaterials

fECHNISCHE UNIVERSITAT DARMSTADTFachgebiet Konstruktiver Leichtbau und BauweisenProf. Dr.-lng. Helmut Schumann64287 Darmstadt, PetersenstraBe 30

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TU DarmstadtFB Maschinenbau

60052

© Woodhead Publishing Limited, 2012

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introductionto aerospace

materials

Adrian P. Mouritz

rECHMiSCHE UMIVERSITAT DARMSTADTFachgebist Konstruktiver Leichtbau und BauweisenProf. Dr.-ing. Helmut Schlirmann^4287 Darmstadt, PetersenstraBe 30

WPWOODHEADPUBLISHING

iOxford Cambridge Philadelphia New Delhi


Published by Woodhead Publishing Limited,80 High Street, Sawston, Cambridge CB22 3HJ, UKwww.woodheadpublishing.comwww.woodheadpublishingonline.com

Woodhead Publishing, 1518 Walnut Street, Suite 1100, Philadelphia, PA 19102-3406, USA

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FECHNISCHE UNiVERSITAT DARMSTADTFachqebiet Konstruktiver Leichtbau und Bauweisen

Prof.'-Diving. Helmut Schurmann<U237 Darmstadt, petersenstra&e 30

Contents

Preface

Introduction to aerospace materials

Xlll

1.11.21.31.41.51.6

22.12:22.32.42.52.6

3

3.13.23.33.43.53.6

4

4.14.24.3

The importance of aerospace matenalsUnderstanding aerospace materialsIntroducing the main types of aerospace materialsWhat makes for a good aerospace material?SummaryFurther reading and research

Aerospace materials: past, present and futureIntroductionBrief history of aerospace materialsMaterials for the global aerospace industryFuture advances in aerospace materialsSummaryFurther reading and research

Materials and material requirements for aerospacestructures and enginesIntroductionFixed-wing aircraft structuresHelicopter structuresSpace shuttle structuresSummaryFurther reading and research

Strengthening of metal alloys

IntroductionCrystal structure of metalsDefects in crystal structures

124

111314

15

151932353738

39

394051545556

57

575860


VI Contents

4.4 Strengthening of metals 684.5 Summary 874.6 Terminology 884.7 Further reading and research 89

5 Mechanical and durability testing of aerospacematerials 91

5.1 Introduction 915.2 Tension test 925.3 Compression test 1065.4 Flexure test 1075.5 Hardness test 1085.6 Fracture test 1115.7 Drop-weight impact test 1135.8 Fatigue test 1145.9 Creep test 1155.10 Environmental durability testing 1165.11 Certification of aerospace materials 1185.12 Summary 1235.13 Terminology 1265.14 Further reading and research 127

6 Production and casting of aerospace metals 128

6.1 Introduction 1286.2 Production of metal alloys 1286.3 Casting of metal alloys 1346.4 Casting processes 1436.5 Summary 1496.6 Terminology 1506.7 Further reading and research 1516.8 Case study: casting defects causing engine disc failure in

United Airlines flight 232 151

7 Processing and machining of aerospace metals 154

7.1 Introduction 1547.2 Metal-forming processes 1567.3 Hot and cold working of metal products 1617.4 Powder metallurgy for production of aerospace

superalloys 1677.5 Machining of metals 1687.6 Summary 1707.7 Terminology 171


7.8

8

8.18.28.38.48.58.68.78.88.9

9

9.19.2

9.39.49.59.69.79.8

10

10.110.210.310.4

11

11.111.211.311.411.511.611.711.8

12

12.1

Contents

Further reading and research

Aluminium alloys for aircraft structures

IntroductionAluminium alloy typesNon-age-hardenable aluminium alloysAge-hardenable aluminium alloysSpeciality aluminium alloysHeat treatment of age-hardenable aluminium alloysHigh-temperature strength of aluminiumSummaryFurther reading and research

Titanium alloys for aerospace structures and engines

IntroductionTitanium alloys: advantages and disadvantages foraerospace applicationsTypes of titanium alloyTitanium aluminidesShape-memory titanium alloysSummaryTerminologyFurther reading and research

Magnesium alloys for aerospace structures

IntroductionMetallurgy of magnesium alloysSummaryFurther reading and research

Steels for aircraft structures

IntroductionBasic principles of steel metallurgyMaraging steelMedium-carbon low-alloy steelStainless steelSummaryTerminologyFurther reading and research

Superalloys for gas turbine engines

Introduction

vii

172

173

173175179181186188197200201

202

202

205207216218221222223

224

224225231231

232

232234244246246247249249

251

251


viii Contents

12.2 A simple guide to jet engine technology12.3 Nickel-based superalloys12.4 Iron-nickel superalloys12.5 Cobalt superalloys12.6 Thermal barrier coatings for jet engine alloys12.7 Advanced materials for jet engines12.8 Summary12.9 Further reading and research

13 Polymers for aerospace structures

13.1 Introduction13.2 Aerospace applications of polymers13.3 Advantages and disadvantages of polymers for

aerospace applications13.4 Polymerisation13.5 Thermosetting polymers13.6 Thermoplastics13.7 Elastomers13.8 Structural adhesives13.9 Mechanical properties of polymers13.10 Polymer additives13.11 Polymers for radar-absorbing materials (RAMs)13.12 Summary13.13 Terminology13.14 Further reading and research13.15 Case study: space shuttle Challenger accident

14 Manufacturing of fibre-polymer compositematerials

14.1 Introduction14.2 Fibre reinforcements for composites14.3 Production of prepregs and fabrics14.4 Core materials for sandwich composites14.5 Composites manufacturing using prepreg14.6 Composites manufacturing by resin infusion14.7 Machining of composites14.8 Summary14.9 Terminology14.10 Further reading and research14.11 Case study: carbon nanotubes in composites

254256262262263265265266

268

268270

270271276279283285288294296298299301301

303

303306315319321326333334335336336


Contents IX

15 Fibre-polymer composites for aerospacestructures and engines 338

15.1 Introduction 33815.2 Types of composite materials 33915.3 Aerospace applications of fibre-polymer composites 34215.4 Advantages and disadvantages of using fibre-polymer

composites 34815.5 Mechanics of continuous-fibre composites 35415.6 Sandwich composites 37815.7 Environmental durability of composites 38415.8 Summary 39015.9 Terminology 39215.10 Further reading and research 393

16 Metal matrix, fibre-metal and ceramic matrixcomposites for aerospace applications 394

16.1 Metal matrix composites 39416.2 Fibre-metal laminates 40016.3 Ceramic matrix composites 40216.4 Summary 40616.5 Terminology 40716.6 Further reading and research 40816.7 Case study: ceramic matrix composities in the space

shuttle orbiter 408

17 Wood in small aircraft construction 411

17.1 Introduction 41117.2 Advantages and disadvantages of wood 41217.3 Hardwoods and softwoods 41217.4 Structure and composition of wood 41417.5 Engineering properties of wood 41817.6 Summary 42417.7 Terminology 42517.8 Further reading and research 42617.9 Case study: Spruce Goose (Hughes H-4 Hercules) 426

18 Fracture processes of aerospace materials 428

18.1 Introduction 42818.2 Fracture processes of aerospace materials 43118.3 Stress concentration effects in materials 43918.4 Fracture mechanics 44418.5 Application of fracture mechanics to aerospace materials 448


x Contents

18.6 Summary 44918.7 Terminology 45018.8 Further reading and research 45118.9 Case study: fracture in the space shuttle Columbia disaster 45118.10 Case study: fracture of aircraft composite radome 452

19 Fracture toughness properties of aerospacematerials 454

19.119.219.319.419.519.619.7

20

20.120.220.320.420.520.620.720.820.920.1020.1120.12

21

21.121.221.321.421.521.621.721.8

22

22.1

IntroductionFracture toughness propertiesDuctile/brittle fracture transition for metalsImproving the fracture toughness of aerospace materialsSummaryTerminologyFurther reading and research

Fatigue of aerospace materialsIntroductionFatigue stressFatigue life (S-N) curvesFatigue-crack growth curvesFatigue of metalsFatigue of fibre-polymer compositesFretting, acoustic and thermal fatigueSummaryTerminologyFurther reading and researchCase study: aircraft fatigue in Japan Airlines flight 123Case study: metal fatigue in Comet aircraft accidents

Corrosion of aerospace metalsIntroductionCorrosion processTypes of corrosionCorrosion protection of metalsSummaryTerminologyFurther reading and researchCase study: corrosion in the Aloha Airlines flight 243

Creep of aerospace materialsIntroduction

454454463465467468468

469

469470475477480487492493494495495496

498

498501504513517517518519

521

521


Contents XI

22.2 Creep behaviour of materials22.3 Creep of metals22.4 Creep of polymers and polymer composites22.5 Creep-resistant materials22.6 Summary22.7 Terminology22.8 Further reading and research

23 Nondestructive inspection and structural healthmonitoring of aerospace materials

23.1 Introduction23.2 Nondestructive inspection methods23.3 Structural health monitoring (SHM)23.4 Summary23.5 Terminology23.6 Further reading and research

24 Disposal and recycling of aerospace materials

24.1 Introduction24.2 Metal recycling24.3 Composite recycling24.4 Summary24.5 Further reading and research

25 Materials selection for aerospace

25.1 Introduction25.2 Materials selection in design25.3 Stages of materials selection25.4 Materials property charts25.5 Structural properties in materials selection25.6 Economic and business considerations in materials

selection25.7 Manufacturing considerations in materials selection25.8 Durability considerations in materials selection25.9 Environmental considerations in materials selection25.10 Specialist properties in materials selection25.11 Summary25.12 Terminology25.13 Further reading and research

Index

522525526530532533533

534

534537548553555557

558

558562566568568

569

569571574580582

586589593597597598599600

607


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