Welding and joining of aerospace materials

448 Pages·2012·6.91 MB·English

by  Mahesh C. Chaturvedi

Welding and joining of aerospace materials
© Woodhead Publishing Limited, 2012
Related titles:
Welding processes handbook ( Second edition )
(ISBN 978-0-85709-510-7)
Written by a leading expert, this book provides a concise and practical guide to the
main techniques in welding. Chapters on individual welding methods cover prin-
ciples and applications, equipment, consumables and quality issues (including com-
mon defects). The new edition has been substantially revised and is 20% longer, with
expanded coverage of key welding processes and new chapters on topics such as
power sources, welding residual stress and distortion.
Minimization of welding distortion and buckling
(ISBN 978-1-84569-662-7)
Weld distortion and buckling is caused by expansion and contraction of the weld and
base metal during the heating and cooling cycle of the welding process. This book
reviews ways of understanding and modelling welding residual stress and distortion.
It also discusses a range of techniques for minimising bowing, buckling and angular
distortion.
Fracture and fatigue of welded joints and structures
(ISBN 978-1-84569-513-2)
Fatigue is often a precursor to the fracture of a welded joint. This book summarises
the latest research in understanding fatigue and fracture in welded joints and struc-
tures. Part I reviews welded joints, with chapters on fatigue strength assessment of
local stresses, the use of fracture mechanics in fatigue and failure analysis and ways
of improving weld-joint class systems. Part II discusses welded structures, with chap-
ters on fatigue design rules for welded structures, fatigue assessment methods for
variable amplitude loading, improving fatigue design using local approaches and
modelling residual stresses in predicting the service life of welded structures.
Details of these and other Woodhead Publishing materials books can be obtained by:
• visiting our web site at www.woodheadpublishing.com
• contacting Customer Services (e-mail: [email protected]; fax:
[phone]; tel.: [phone] ext. 130; address: Woodhead
Publishing Limited, 80 High Street, Sawston, Cambridge CB22 3HJ, UK)
• contacting our US offi ce (e-mail: [email protected]; tel.
[phone]; address: Woodhead Publishing, 1518 Walnut Street, Suite 1100,
Philadelphia, PA 19102-3406, USA)
If you would like to receive information on forthcoming titles, please send your
address details to: Francis Dodds (address, tel. and fax as above; e-mail: francis.
[email protected]). Please confi rm which subject areas you are
interested in.
© Woodhead Publishing Limited, 2012
Welding and joining
of aerospace materials
Edited by
M. C. Chaturvedi

Oxford Cambridge Philadelphia New Delhi
© Woodhead Publishing Limited, 2012
Published by Woodhead Publishing Limited,
80 High Street, Sawston, Cambridge CB22 3HJ, UK
www.woodheadpublishing.com
Woodhead Publishing, 1518 Walnut Street, Suite 100, Philadelphia,
PA 19102-3406, USA
Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road,
Daryaganj, New Delhi – 110002, India
www.woodheadpublishingindia.com
First published 2012, Woodhead Publishing Limited
© Woodhead Publishing Limited, 2012; Chapter 1 © R. Freeman , 2012 ; Appendix ©
TWI Ltd, 2012
The authors have asserted their moral rights.

This book contains information obtained from authentic and highly regarded
sources. Reprinted material is quoted with permission, and sources are indicated.
Reasonable efforts have been made to publish reliable data and information, but
the authors and the publisher cannot assume responsibility for the validity of all
materials. Neither the authors nor the publisher, nor anyone else associated with
this publication, shall be liable for any loss, damage or liability directly or indirectly
caused or alleged to be caused by this book.
Neither this book nor any part may be reproduced or transmitted in any form or
by any means, electronic or mechanical, including photocopying, microfi lming and
recording, or by any information storage or retrieval system, without permission in
writing from Woodhead Publishing Limited.
The consent of Woodhead Publishing Limited does not extend to copying for
general distribution, for promotion, for creating new works, or for resale. Specifi c
permission must be obtained in writing from Woodhead Publishing Limited for
such copying.
Trademark notice: Product or corporate names may be trademarks or registered
trademarks, and are used only for identifi cation and explanation, without intent to
infringe.

British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Control Number: 2011941157
ISBN 978-1-84569-532-3 (print)
ISBN 978-0-85709-516-9 (online)
The publisher’s policy is to use permanent paper from mills that operate a
sustainable forestry policy, and which has been manufactured from pulp which is
processed using acid-free and elemental chlorine-free practices. Furthermore, the
publisher ensures that the text paper and cover board used have met acceptable
environmental accreditation standards.
Typeset by Newgen Publishing and Data Services
Printed by TJI Digital, Padstow, Cornwall, UK
© Woodhead Publishing Limited, 2012
Contents
Contributor contact details xi
Preface xv
Part I Welding techniques 1
1 New welding techniques for aerospace engineering 3
R. Freeman , TWI Ltd, UK
1.1 Introduction 3
1.2 Airworthiness implications of new welding and joining
technologies 4
1.3 New developments in welding and joining of aerospace
materials 9
1.4 Failure of welded and bonded joints in service 15
1.5 The importance of international standards 23
1.6 References 23
2 Inertia friction welding (IFW) for aerospace
applications 25
M. M . Attallah , University of Birmingham , UK
and M . Preuss , University of Manchester , UK
2.1 Introduction 25
2.2 Process parameters, heat generation and modelling 34
2.3 Microstructural development 44
2.4 Development of mechanical properties 55
2.5 Residual stress development 66
2.6 Future trends 69
2.7 Sources of further information and advice 70
2.8 References 70
v
© Woodhead Publishing Limited, 2012
vi Contents
3 Laser welding of metals for aerospace
and other applications 75
J. Blackburn , TWI Ltd , UK
3.1 Introduction 75
3.2 Operating principles and components of laser sources –
an overview 76
3.3 Key characteristics of laser light 79
3.4 Basic phenomena of laser light interaction with metals 82
3.5 Laser welding fundamentals 87
3.6 Laser weldability of titanium alloys 94
3.7 Future trends 102
3.8 Sources of further information and advice 102
3.9 References 103
4 Hybrid laser-arc welding of aerospace
and other materials 109
J. Zhou , Pennsylvania State University , USA,
H. L. Tsai , Missouri University of Science and Technology ,
USA and P. C. Wang , GM R&D Center , USA
4.1 Introduction 109
4.2 Fundamentals of hybrid laser-arc welding 112
4.3 Hybrid laser-arc welding of aeronautical materials 125
4.4 Future trends 135
4.5 References 136
5 Heat-affected zone cracking in welded
nickel superalloys 142
O. A . Ojo and N. L. Richards , University of
Manitoba , Canada
5.1 Introduction 142
5.2 Characteristics of crack-inducing intergranular
liquid and factors that affect heat-affected zone (HAZ)
cracking 145
5.3 Formation of HAZ grain-boundary liquid 151
5.4 Constitutional liquation of second-phase particles
in nickel-based superalloys 152
5.5 Role of minor elements in HAZ intergranular liquation
cracking 158
5.6 Conclusions 171
5.7 References 172
© Woodhead Publishing Limited, 2012
Contents vii
Part II Other joining techniques 179
6 Assessing the riveting process and the quality
of riveted joints in aerospace and other applications 181
G. Li, G. Shi and N. C . Bellinger ,
National Research Council Canada , Canada
6.1 Introduction 181
6.2 Riveting process and quality assessment of
the rivet installation 182
6.3 Determination of residual strains and interference
in riveted lap joints 184
6.4 Summary and recommendations for the
riveting process research 187
6.5 Case studies using the force-controlled riveting method 188
6.6 Conclusions 211
6.7 Acknowledgements 212
6.8 References 212
7 Quality control and non-destructive testing of
self-piercing riveted joints in aerospace and other
applications 215
P. Johnson , Liverpool John Moores University , UK
7.1 Introduction 215
7.2 Computer vision 217
7.3 Ultrasonic testing 232
7.4 Conclusion 233
7.5 References 233
8 Improvements in bonding metals for aerospace
and other applications 235
A . Kwakernaak, J . Hofstede, J . Poulis and R . Benedictus ,
Delft University of Technology , The Netherlands
8.1 Introduction: key problems in metal bonding 235
8.2 Developments in the range of adhesives for metal 236
8.3 Developments in surface treatment techniques for metal 246
8.4 Developments in joint design 256
8.5 Developments in modelling and testing the
effectiveness of adhesive-bonded metal joints 271
8.6 Future trends 279
8.7 Sources of further information and advice 280
8.8 References 281
© Woodhead Publishing Limited, 2012
viii Contents
9 Composite to metal bonding in aerospace
and other applications 288
R. A . Pethrick , University of Strathclyde , UK
9.1 Introduction 288
9.2 Testing of adhesive bonded structures 291
9.3 Bonding to the metal substrate 294
9.4 Composite pre-treatment 297
9.5 Bonding composite to metal 298
9.6 Adhesives 298
9.7 Composite–metal bonded structures 305
9.8 Conclusions 314
9.9 Acknowledgements 314
9.10 References 314
10 Diffusion bonding of metal alloys in aerospace
and other applications 320
H.-S. Lee , Korea Aerospace Research Institute ,
Republic of Korea
10.1 Introduction 320
10.2 Diffusion-bonding process 323
10.3 Conclusions and future trends 342
10.4 References 342
11 H igh-temperature brazing in aerospace engineering 345
A . Elrefaey , Dortmund University of Technology , Germany
11.1 Introduction 345
11.2 Filler metals 346
11.3 Trends in brazing at high temperature 365
11.4 Conclusion and future trends 379
11.5 References 380
Appendix: Linear friction welding in
aerospace engineering 384
I . Bhamji, A. C. Addison and P. L . Threadgill , TWI , UK
and M . Preuss , University of Manchester , UK
A.1 Introduction to linear friction welding 384
A.2 History and major applications of linear friction welding 385
A.3 Linear friction welding machines 388
© Woodhead Publishing Limited, 2012
Contents ix
A.4 Macroscopic features of and defects in
linear friction welds 394
A.5 Microscopic features of linear friction welds 396
A.6 Linear friction welding of titanium alloys 397
A.7 Linear friction welding of nickel-based superalloys 406
A.8 Linear friction welds in other materials 407
A.9 Conclusion 410

A.10 References 411
Index 416
© Woodhead Publishing Limited, 2012