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Full-Text Articles in Engineering
Non-Destructive Material Analysis Of Metals And Composites Via Thermography, Jonathan R. Doubt, James L. Chapman
Non-Destructive Material Analysis Of Metals And Composites Via Thermography, Jonathan R. Doubt, James L. Chapman
Materials Engineering
The Naval Surface Warfare Center, Port Hueneme Division, is interested in the development of non-destructive damage assessment of shipboard materials via drones at distance. Long Pulsed Thermography (LPT), a method of non-destructive evaluation, was investigated as a possible method for detecting damage in metals (5005h24 Al alloy and 1008 carbon steel) and composites (aramid fiber honeycomb sandwich structure) at distances from 0.5 m to 3.0 m. LPT was conducted using two 1000 W can lights to heat the samples, and a FLIR E8-XT thermal camera. The images were then analyzed using ImageJ software to determine if damage could be detected …
Strengthening Of 7175 Aluminum Alloy Through Multi-Step Aging Process, Colin E. Masterson, Ryland W. Jolliffe
Strengthening Of 7175 Aluminum Alloy Through Multi-Step Aging Process, Colin E. Masterson, Ryland W. Jolliffe
Materials Engineering
7175 is a heat-treatable aluminum alloy commonly used in aerospace forgings. This alloy is aged with a multi-step heat treatment. This treatment must balance strength with stress corrosion cracking resistance through a degree of overaging. The team was tasked by Weber Metals to increase the strength of this treatment without sacrificing stress corrosion cracking resistance. Both two-step and retrogression and reaging treatments were tested in experiments to find a heat treatment that could increase the yield and tensile strength by 1-2 ksi while maintaining a minimum electrochemical conductivity equivalence of 38% relative to copper. Two-step aging is the more conventional …
Effect Of Thermal Exposure On Tensile Strength And Microhardness Of Welded And Precipitation Hardened Rx82 Aluminum Alloy Extrusions In The T4 And T6 Conditions, Lucien Miller
Materials Engineering
This investigation is focused on the effect paint-bake cycles have on the tensile strength and microhardness of GMAW welded RX82 aluminum extrusions in T4 and T6 base conditions. To simulate the paint-bake cycle, T4 and T6 RX82 aluminum samples were GMAW welded and heat treated at 350°F, 390°F, and 425°F for durations of 30 minutes, 1.0 hour, and 2.0 hours, with five replicates for each treatment. Microhardness profiles of T4 samples treated at 350°F for 30 minutes and 1.0 hour display weld/HAZ HV values of 86.04 and 82.51 respectively, followed by maximums of 123.21 and 121.10. Average ultimate tensile strength …
Investigation Of Outlife Time On The Environmental Durability Of P2-Etched, Adhesively-Bonded Aluminum Alloys Using The Astm Wedge Test, Daniel Gross, Corey Sutton
Investigation Of Outlife Time On The Environmental Durability Of P2-Etched, Adhesively-Bonded Aluminum Alloys Using The Astm Wedge Test, Daniel Gross, Corey Sutton
Materials Engineering
P2 etchant is an environmentally-friendly aluminum etchant which has the potential to replace the Forest Products Laboratory (FPL) etchant as the industry standard. Environmental durability of adhesively-bonded aluminum surfaces etched using a paste version of the P2 etchant were tested using the Boeing-developed wedge test (ASTM D3762 - 03(2010)). This project specifically aimed to examine the relationship between outlife time (the time between etching and adhering) and the ability of bonded aluminum samples to pass the wedge test. Two aluminum alloys, 2024-T3 and 7075-T6, were wedge tested and the etched surfaces examined with an atomic force microscope (AFM) and a …
Elevated Temperature Effects On The Mechanical Properties Of Age Hardened 6xxx Series Aluminum Alloy Extrusions, Rachael Donovan, Rose Fortune, Robert Trout
Elevated Temperature Effects On The Mechanical Properties Of Age Hardened 6xxx Series Aluminum Alloy Extrusions, Rachael Donovan, Rose Fortune, Robert Trout
Materials Engineering
The purpose of this project is to determine if over-aging of aluminum causes the yield or tensile strength to fall below the minimum strength values set by the aluminum industry. Extruded aluminum alloys, 6061-T6, 6063-T6, and two proprietary alloys, HS6X-T6 and RX82-T6, were exposed to reheating treatments at extended times and temperatures. The three temperatures were 350°F, 390°F, and 425°F. The times of reheat increased logarithmically from 30 minutes to 64 hours. The samples were tensile tested to determine the tensile strength and yield strength. Statistical methods helped model the behavior of yield and tensile strength as a function of …
Effect Of Time Delay Between Etching And Adhesive Bonding (“Outlife” Time) On Lap-Shear Strength Of Aluminum Alloys Using Environmentally-Friendly P2 Etch, Josh Barkhimer, Matthew Erich, Gokul Nair
Effect Of Time Delay Between Etching And Adhesive Bonding (“Outlife” Time) On Lap-Shear Strength Of Aluminum Alloys Using Environmentally-Friendly P2 Etch, Josh Barkhimer, Matthew Erich, Gokul Nair
Materials Engineering
Raytheon Company currently uses a Forest Products Laboratory (FPL) paste etchant for preparing aluminum surfaces for adhesive bonding, and FPL is a source of hazardous hexavalent chromium. The goal of this study was to evaluate a less-toxic P2 paste etchant as a possible replacement. Coupons of 2024-T3, 6061-T6, and 7075-T6 grades of aluminum alloy were solvent-degreased, abrasively cleaned, and etched at room temperature using P2 paste following a strict protocol adopted from Raytheon. Coupons were then left exposed to air for assigned time intervals (or “outlife” times) of 0, 1, 4, 8, 16, and 63 or 72 hours. The aluminum …
High Cycle Rotating Bending Fatigue Of 6061-T6 Friction Stir Welded Extrusions, John Chang, Travis Miller
High Cycle Rotating Bending Fatigue Of 6061-T6 Friction Stir Welded Extrusions, John Chang, Travis Miller
Materials Engineering
Fatigue testing was done on friction stir welded joints of 6061-T6 aluminum extrusions. Tests were run using a rotating bending fatigue machine at stresses from 111.5 to 138.7 MPa. Failures occurred on the order of 105 to 107 cycles, and an S-N curve was generated based off of the failure results. After the samples failed, the location of the failure and the number of cycles to failure were noted. Fatigue samples were designed in SolidWorks with a tapered 2 inch reduced section. The 2 inch reduced section will include the entire weld region as seen from the microhardness …
Relationship Between Bagging Methods And Pre-Weld Holding Times On Porosity Formation In 2219 Aluminum Ac-Tig Welds, Mariah Grace Head, Tyson Daniel Mobley
Relationship Between Bagging Methods And Pre-Weld Holding Times On Porosity Formation In 2219 Aluminum Ac-Tig Welds, Mariah Grace Head, Tyson Daniel Mobley
Materials Engineering
The purpose of this study was to determine relationships between bagging methods and pre-weld holding times on the formation of porosity when AC-TIG welding 2219 aluminum. Considering the strict guidelines and specifications required within the aerospace industry, maintaining quality welds is of paramount importance to control part integrity for aerospace applications. This project focused on two parameters involved in the preparation of aluminum parts for welding: bagging method and pre-weld holding time. Welding geometry was simplified to bead-on plate instead of the standard joint welds. Radiographic analysis of the samples showed that all levels of both parameters produced “passing welds.” …
Residual Stress Measurement Of 7050 Aluminum Alloy Open Die Forgings Using The Hole-Drilling Method, Alexandra Viksne
Residual Stress Measurement Of 7050 Aluminum Alloy Open Die Forgings Using The Hole-Drilling Method, Alexandra Viksne
Materials Engineering
Open die forged 7050 aluminum alloy has residual stresses that can be measured by the hole-drilling method following standard ASTM E837-01. Weber Metals (Paramount, CA) assumes that the stress is uniform throughout the thickness of an open die forged plate. Four different stress relieved 7050 aluminum samples were tested to confirm if the measurements by the hole-drilling method at the surface of a plate is indicative of the stress throughout. The different stress relief methods included: two water quenched samples at temperature ranges of 60°-90°F and 120°-130°F and two samples plastically deformed by forging at room temperature 1% and 3%. …
Evaluation Of Forging Strain For Maximum Grain Size In Open-Die Forged 6061 Aluminum, Eric Strehl
Evaluation Of Forging Strain For Maximum Grain Size In Open-Die Forged 6061 Aluminum, Eric Strehl
Materials Engineering
In an effort to maximize grain growth of open-die forged 6061 aluminum alloy parts, samples from three of Weber Metals’s suppliers (Hidal Co-Almex USA Inc., TST Inc., and Vista Metals Corp.; to be called Supplier H, Supplier T, Supplier V respectively) were cut into cylinders with diameters of 0.75˝ and heights of 2˝, and put through a simulated forging process and heat treatment. It is possible that additional alloying elements may be promoting or inhibiting grain growth in the final part. Maximizing grain growth for aluminum alloy parts results in improved resistance to intergranular corrosion. Samples from each vendor had …
An Exploratory Investigation Into How Cold Working Can Affect The Acoustic Performance Of Thin Aluminum Foil In A Ribbon Microphone, Alexander (Alex) Stanley
An Exploratory Investigation Into How Cold Working Can Affect The Acoustic Performance Of Thin Aluminum Foil In A Ribbon Microphone, Alexander (Alex) Stanley
Materials Engineering
Ribbons of 4 μm thin 99.1% pure aluminum foil were cut and corrugated to replace the stock ribbon in an Apex 205 ribbon microphone. Prior to corrugation, half of the ribbons were sandwiched between two KimWipes and two pieces of cardstock then hammered to impart strain hardening. Each ribbon was placed into the microphone capsule and the frequency response of each ribbon was measured. A 10 second sine sweep from 20-20,000 Hz was played through a KRK Rokit 5 speaker and recorded through a ribbon microphone placed 6 inches away from the speaker cone. The signal generated by the ribbon …
Characterization Of Positive Macrosegregation At The Subsurface Of Direct-Chill Cast 7050 Aluminum Forging Billets, Aaron Youril
Characterization Of Positive Macrosegregation At The Subsurface Of Direct-Chill Cast 7050 Aluminum Forging Billets, Aaron Youril
Materials Engineering
Segregation of alloying elements during casting of forging billets may persist to the final forged component leading to unacceptable surface appearance. Determination of the elements or compounds that segregate is the essential first step to solving this problem. Differential Scanning Calorimetry (DSC) was used to determine a composition profile of the macrosegregation occurring at the subsurface of an as-cast 7050 aluminum alloy billet. Data collection was carried out by separating 10 to 20 mg samples from the outer centimeter along the radius of the billet, as well as samples from the bulk interior of the billet for comparison with the …
Characterization Of Aluminum-Boron Carbide Particulate Metal Matrix Composites, Eric Blank
Characterization Of Aluminum-Boron Carbide Particulate Metal Matrix Composites, Eric Blank
Materials Engineering
The analysis of die-cast 380 aluminum-boron carbide particulate metal matrix composites (MMC) was performed in order to see if the samples had the required tensile strength of 300 MPa. 10wt% B4C die-cast samples were produced and tested. Half were heat treated to the T6 condition and the others were left as cast. Using ASTM standard B 557M it was found that the average tensile strength for the as-cast samples was 130 MPa and the heat treated samples had a tensile strength of 93 MPa. These values were both lower than expected. The heat treated samples were not expected to have …