High Performance Materials in Aerospace

Transcription

1 High Performance Materials in Aerospace

2 High Performance Materials in Aerospace Edited by Harvey M. Flower Professor of Materials Science Imperial College of Science, Technology and Medicine London, UK I UI11 SPRINGER-SCIENCE+BUSINESS MEDIA, B.V.

3 First edition Springer Science+Business Media Dordrecht Originally published by Chapman & Hali in 1995 Softcover reprint of the hardcover 1 st edition 1995 Typset in 10/12 Times by Pure Tech Corporation, Pondicherry, India ISBN ISBN (ebook) DOI / Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publicat ion may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permis sion in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the infofl!lation.~tained in)liis book and cannot accept any legal responsibility Of liability for any errors or omissions that may be made. A catalogue record for this book is available from the British Library Library of Congress Catalog Card Number: Printed on acid-free text paper, manufactured in accordance with ANSIINISO Z (Permanence of Paper).

4 Contents List of contributors Preface ix xi 1 Design requirements for aerospace structural materials 1 c.j. Peel and PoI. Gregson 1.1 Introduction Properties that affect structural efficiency ab initio Properties affecting cost of ownership Cost-effective design Concluding remarks 47 References 48 2 Aluminium alloys: physical metallurgy, processing and properties P.J. Gregson Introduction Aluminium alloys: processing and properties Conventional aerospace aluminium alloys Advanced aerospace aluminium alloys Conclusions 83 References 83 Further reading 83 3 Titanium alloys: production, behaviour and application 85 J. C. Williams 3.1 Introduction Brief summary of the metallurgy of conventional Ti alloys The production of Ti alloys and Ti alloy components The mechanical behaviour and properties of common Ti alloys 104

5 vi Contents 3.5 Ti-based intermetallic compounds Summary 132 Acknowledgements 132 References 132 Further reading Nickel-based alloys: recent developments for the aero-gas turbine M. McLean Background Alloy constitution and development trends Processing developments Microstructure and high temperature deformation Turbine disk applications Future prospects 153 References Structural steels D.P. Davies Introduction Gear steels Bearing steels Ultra high strength steels 174 Acknowledgements 180 References Ceramic materials in aerospace D.M. Dawson Introduction Monolithic and toughened ceramics Composite ceramics Polymeric-based composite materials N. Marks Introduction Reinforcements Matrices Interface Processing Properties Joining composites Non-destructive testing (NDT) Advantages of composite materials Metal-based composite materials H. M. Flower Introduction Metal-ceramic composites Laminates 235

6 Contents 8.4 Cost Applications Appendix 239 References Superplastic forming D. Stephen Introduction Superplasticity and its characteristics Aerospace superplastic alloys Post-superplastic straining mechanical properties Superplastic forming (SPF) Advantages of SPF in aerospace structural design/manufacture Aerospace applications of SPF SPF/DB Advantages of SPF/DB in aerospace structural design/manufacture Aerospace applications of SPF/DB Background to the application of SPF and SPF/DB in aerospace 277 References Joining advanced materials by diffusion bonding 283 P. G. Partridge and A. Wisbey 10.1 Introduction Diffusion bonding mechanisms Effect of surface roughness and contamination on bond interface defects Testing of diffusion bonded joints Diffusion bonding techniques of metals Diffusion bonding of intermetallics Diffusion bonding of ceramics Diffusion bonding of composites Diffusion bonding of dissimilar metallic materials Diffusion bonding of metastable alloys Manufacture of components by diffusion bonding techniques Conclusions 315 Acknowledgements 316 References Adhesive bonding for aerospace applications D. Driver Introduction Bonded wooden aircraft 319 vii

7 Vlll 11.3 Principles of bonding 11.4 Aerospace adhesive types 11.5 Surface treatments 11.6 Design of bonded joints References Contents Rapid solidification and powder technologies for aerospace 340 H. Jones 12.1 Introduction Production technologies Effects on microstructure Benefits of rapid solidification for aerospace applications Conclusions 353 References Hot isostatic processing B.A. Rickinson and S. Andrews Introduction Removal of porosity Benefits of HIP Applications of HIP Powder products Diffusion bonding Other applications 372 Index 375

8 Contributors S. Andrews HIP Ltd, Chesterfield, UK D. P. Davies Materials Laboratory, Westland Helicopters Ltd, Yeovil, UK D. M. Dawson Rolls-Royce pic, Derby, UK D. Driver Centre for Adhesive Technology, Abingdon Hall, Cambridge, UK H. M. Flower Department of Materials, Imperial College of Science, Technology and Medicine, London, UK P. J. Gregson Department of Engineering Materials, University of Southampton, UK H. Jones Department of Materials Engineering, University of Sheffield, UK M. McLean Department of Materials, Imperial College of Science, Technology and Medicine, London, UK N. Marks Westland Helicopters Ltd, Yeovil, UK P. G. Partridge Interface Analysis Centre, University of Bristol, UK C. J. Peel Materials and Structures Department, Defence Research Agency, Farnborough, UK B. A. Rickinson HIP Ltd, Chesterfield, UK

9 x Contributors D. Stephen IEP Structures Ltd, Holbrook works, Halfway, Sheffield, UK J. C. Williams Engineering Materials and Technology Laboratories, GE Aircraft Engines, Cincinnati, USA A. Wisbey Materials and Structures Department, Defence Research Agency, Farnborough, UK

10 Preface Aerospace presents an extremely challenging environment for structural materials and the development of new, or improved, materials: processes for material and for component production are the subject of continuous research activity. It is in the nature of high performance materials that the steps of material and of component production should not be considered in isolation from one another. Indeed, in some cases, the very process of material production may also incorporate part or all of the component production itself and, at the very least, will influence the choice of material/component production method to be employed. However, the developments currently taking place are to be discovered largely within the confines of specialist conferences or books each dedicated to perhaps a single element of the overall process. In this book contributors, experts drawn from both academia and the aerospace industry, have joined together to combine their individual knowledge to examine high performance aerospace materials in terms of their production, structure, properties and applications. The central interrelationships between the development of structure through the production route and between structure and the properties exhibited in the final component are considered. It is hoped that the book will be of interest to students of aeronautical engineering and of materials science, together with those working within the aerospace industry. Harvey M. Flower Imperial College