A pesquisa por novos materiais e processos que possam garantir aeronaves mais leves e operacionalmente mais viáveis, tem-se dado praticamente em todos os componentes de uma aeronave, com consequência direta no menor consumo de combustível e benefícios para o fabricante, operadores e a população em geral com aplicação do conceito de \'aeronave verde\'. Nestes quesitos, materiais/processos, destacam-se as ligas de alumínio (2xxx e 7xxx) e a solda por fricção mistura (FSW- Friction Stir Welding) por sua relação custo/benefício. A soldagem por fricção de elementos estruturais aeronáuticos formados de materiais dissimilares que possuem propriedades mecânicas distintas é de grande interesse para a indústria aeronáutica, devido aos ganhos de peso e de custo de operação que esse tipo de junção pode gerar. Sendo assim foram avaliadas as principais propriedades mecânicas de interesse e correlacionar com a microestrutura de ligas dissimilares e similares soldadas pelo processo de FSW e a inteiração destas com os meios ambiente, criogênico e corrosivo aos quais, aeronaves podem ser sujeitas durante os voos. Para tal desenvolvimento a solda dissimilar foi realizada com as ligas de alumínio-lítio 2050-T84 e alumínio 7050-T7451, enquanto que a solda similar foi realizada com a liga de alumínio-lítio 2198-T851. Foram feitas análises de ciclo térmico durante a soldagem e ambas juntas foram classificadas como solda quente, que prevê intensa variação microestrutural e afetam as propriedades mecânicas de dureza, a tenacidade fadiga e corrosão fadiga. A caracterização microestrutural realizada pela técnica de EBSD evidenciou alta quantidade de CAA que resultou na redução da dureza e aumento da tenacidade à fratura na região de contato entre a peça de trabalho e o ombro da ferramenta. De contra partida, a taxa de propagação de trinca por fadiga aumentou ligeiramente no meio salino. / The research for new materials and processes that produce light materials and operationally viable, has occurred in almost all the components of an aircraft, with a direct consequence in the lower fuel consumption and benefits for the manufacturing, operators and the population in application of the concept of \'green aircraft\'. In these questions, materials/processes, the most important are aluminum alloys (2xxx and 7xxx) and friction stir welding for their cost/benefit ratio. Friction stir welding of aeronautical structural elements made of dissimilar materials with distinct mechanical properties is of great interest to the aeronautical industry due to the weight and operating costs that this type of joint can result. Thus, the main mechanical properties of interest and correlate with the microstructure of dissimilar and similar alloys welded by the FSW and their interaction with the ambient, cryogenic and corrosive environments to which aircraft may be subject during flight. To development, the dissimilar weld performed with the lithium-aluminum alloys 2050-T84 and aluminum 7050-T7451, while the similar solder performed with the lithium-aluminum alloy 2198-T851. Thermal cycle analyzes were done during welding and both joints were classified as hot welding, which provides intense microstructural variation and affect the mechanical properties of hardness, fatigue toughness and fatigue corrosion. The microstructural characterization performed by the EBSD technique evidenced a high amount of CAA that resulted in low hardness and high fracture toughness in the region of contact between the workpiece and the tool shoulder. On the other hand, the rate of crack propagation by fatigue increased slightly in the saline atmosphere.

A pesquisa por novos materiais e processos que possam garantir aeronaves mais leves e operacionalmente mais viáveis, tem-se dado praticamente em todos os componentes de uma aeronave, com consequência direta no menor consumo de combustível e benefícios para o fabricante, operadores e a população em geral com aplicação do conceito de \'aeronave verde\'. Nestes quesitos, materiais/processos, destacam-se as ligas de alumínio (2xxx e 7xxx) e a solda por fricção mistura (FSW- Friction Stir Welding) por sua relação custo/benefício. A soldagem por fricção de elementos estruturais aeronáuticos formados de materiais dissimilares que possuem propriedades mecânicas distintas é de grande interesse para a indústria aeronáutica, devido aos ganhos de peso e de custo de operação que esse tipo de junção pode gerar. Sendo assim foram avaliadas as principais propriedades mecânicas de interesse e correlacionar com a microestrutura de ligas dissimilares e similares soldadas pelo processo de FSW e a inteiração destas com os meios ambiente, criogênico e corrosivo aos quais, aeronaves podem ser sujeitas durante os voos. Para tal desenvolvimento a solda dissimilar foi realizada com as ligas de alumínio-lítio 2050-T84 e alumínio 7050-T7451, enquanto que a solda similar foi realizada com a liga de alumínio-lítio 2198-T851. Foram feitas análises de ciclo térmico durante a soldagem e ambas juntas foram classificadas como solda quente, que prevê intensa variação microestrutural e afetam as propriedades mecânicas de dureza, a tenacidade fadiga e corrosão fadiga. A caracterização microestrutural realizada pela técnica de EBSD evidenciou alta quantidade de CAA que resultou na redução da dureza e aumento da tenacidade à fratura na região de contato entre a peça de trabalho e o ombro da ferramenta. De contra partida, a taxa de propagação de trinca por fadiga aumentou ligeiramente no meio salino. / The research for new materials and processes that produce light materials and operationally viable, has occurred in almost all the components of an aircraft, with a direct consequence in the lower fuel consumption and benefits for the manufacturing, operators and the population in application of the concept of \'green aircraft\'. In these questions, materials/processes, the most important are aluminum alloys (2xxx and 7xxx) and friction stir welding for their cost/benefit ratio. Friction stir welding of aeronautical structural elements made of dissimilar materials with distinct mechanical properties is of great interest to the aeronautical industry due to the weight and operating costs that this type of joint can result. Thus, the main mechanical properties of interest and correlate with the microstructure of dissimilar and similar alloys welded by the FSW and their interaction with the ambient, cryogenic and corrosive environments to which aircraft may be subject during flight. To development, the dissimilar weld performed with the lithium-aluminum alloys 2050-T84 and aluminum 7050-T7451, while the similar solder performed with the lithium-aluminum alloy 2198-T851. Thermal cycle analyzes were done during welding and both joints were classified as hot welding, which provides intense microstructural variation and affect the mechanical properties of hardness, fatigue toughness and fatigue corrosion. The microstructural characterization performed by the EBSD technique evidenced a high amount of CAA that resulted in low hardness and high fracture toughness in the region of contact between the workpiece and the tool shoulder. On the other hand, the rate of crack propagation by fatigue increased slightly in the saline atmosphere.

Submitted by Thiago Alexandre Minto null (thiagominto@hotmail.com) on 2016-10-04T14:18:01Z No. of bitstreams: 1 Tese de Doutorado - Thiago Alexandre Minto.pdf: 8423530 bytes, checksum: af8e38b6592428dae96cce5fdfe11214 (MD5) / Approved for entry into archive by Juliano Benedito Ferreira (julianoferreira@reitoria.unesp.br) on 2016-10-07T14:49:36Z (GMT) No. of bitstreams: 1 minto_ta_dr_guara.pdf: 8423530 bytes, checksum: af8e38b6592428dae96cce5fdfe11214 (MD5) / Made available in DSpace on 2016-10-07T14:49:36Z (GMT). No. of bitstreams: 1 minto_ta_dr_guara.pdf: 8423530 bytes, checksum: af8e38b6592428dae96cce5fdfe11214 (MD5) Previous issue date: 2016-08-04 / Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) / O estudo do comportamento em fadiga e corrosão dos materiais é de extrema importância para a indústria aeronáutica, considerando componentes estruturais que estão submetidos a carregamentos cíclicos constantemente. As ligas de alumínio desempenham papel fundamental nesse ramo, principalmente as ligas da série 7xxx de alta resistência. Como esses componentes também operam em ambientes marítimos, os revestimentos anticorrosivos são utilizados como proteção. Dos processos de revestimentos disponíveis atualmente, a substituição dos processos de anodização é considerado como urgente no meio acadêmico e nos setores industriais, devido à liberação de resíduos prejudiciais à saúde e ao meio ambiente gerados na aplicação dos revestimentos. O objetivo deste trabalho é estudar a influência do tratamento de implantação iônica por imersão a plasma (3IP) na vida em fadiga e corrosão da liga AA7050-T7451. Os ensaios de fadiga e corrosão com diferentes condições de tratamento 3IP permitiram uma análise comparativa, estabelecendo uma relação entre os parâmetros de tratamento como: voltagem x frequência x tempo. Observou-se uma grande interferência nas taxas de aquecimento, temperatura máxima, microdurezas e nanodureza superficiais, rugosidade, potenciais de corrosão, análises de EDS, DRX e fadiga principalmente quando há uma variação da frequência do processo 3IP. Os melhores resultados obtidos de resistência à fadiga e à corrosão dentre todas as combinações voltagem x frequência estudadas nesse trabalho, foram obtidos através de procedimentos com menores temperaturas por consequência da menor frequência de impacto. / The fatigue and corrosion behavior study of high strength materials are very important for the aeronautical industry, considering that structural components are constantly loaded to variable amplitude loading. Aluminum alloys play an important role in this subject, especially 7xxx alloys. These components also operate in marina environments, and then coatings are used as protection. The replacement of anodizing processes is considered urgent in the academic and industrial sectors, due to the release of waste and harmful conditions to health and the environment generated from the application of the coatings. The objective of this work is to study the influence of plasma immersion ion implantation (IIIP) on the fatigue life of AA7050-T7451 aluminum alloy. Fatigue and corrosion tests with different PIII treatments, established a relationship between treatment parameters such as voltage x frequency x time. It was observed a large interference on heating rate, maximum temperature, surface microhardness, nanohardness, roughness, corrosion potential, EDS, XRD and fatigue resistance especially with the frequency variation on the PIII process. The best results of fatigue resistance and corrosion with all combinations in this work, were obtained by procedures with lower temperature as a consequence the low impact frequency. / CNPq: 303832/2014-2

This work details an adaptation of the friction taper plug welding (FTPW) process to repair fatigue damage in 6.35mm AA 7050 t-7451 plate. Aircraft components experience fatigue damage around fastener holes. This damage can be mitigated by enlarging fastener holes. There is no effective repair procedure once holes reach a maximum allowable size. Damaged components must be replaced. A suitable repair process would lead to substantial savings in both time and money. A simulated repair process was developed by machining holes in 6.35mm AA 7050 t-7451 plate. These hoes were then plugged using the FTPW process. Microhardness testing and metallographic analysis were used to map the effects of thermomechanical processing in a repair. Simulated repairs were machined into a tensile sample. A 6.35mm hole was bored axially through the repair center to simulate a new fastener hole. Static tensile testing was used to measure ultimate tensile strength and yield strength in the repair. Samples were also subjected to fatigue testing at stresses ranging from 170MPa to 340MPa at a stress ration of R=0.1. The same tensile and fatigue testing was done with unaltered material. A 7.94mm hole was bored through the center of this material to simulate an enlarged fastener hole. This provides baseline level of properties. Ultimate tensile strength of the base material is reduced by 15% and yield strength by 29%. Fatigue properties at a stress of 303 MPa are reduced by 22%. Fracture surfaces of poor performing samples reveal defects on the weld interface.

Made available in DSpace on 2017-07-21T20:43:45Z (GMT). No. of bitstreams: 1 Natany Dayani de Souza Assai.pdf: 1950917 bytes, checksum: a6c8b87bcaabbbdbf5ca798360a90bcc (MD5) Previous issue date: 2014-08-27 / The residual stress may decrease and redistribute through a process called relaxation. The relaxation of the residual stress is an important phenomenon in relation to the estimated fatigue resistance of the material and can occur due to static mechanical loading, thermal, cyclical and extension fatigue effects. Residual stresses are usually harmful for overlapping the operating voltage, while the fatigue resistance of metals and alloys can be improved by compressive residual stresses present in the surface layer by means of shot peening surface. The fatigue life with the compressive residual stress field caused by shot peening or sophisticated models for modeling voltage field Compressive Residual (CTRC) usually does not take into account the possibility of this change during the cyclic loading, ie , place the relaxation process, which also changes the fatigue life. This study aimed to obtain the residual stress profile relaxation by cyclic loading on aluminum alloy samples 7050- T7541 with shot peening glass and ceramics subjected to axial fatigue test. The technique for determining the residual stress was the X-ray diffraction for measuring accurately the redistribution of residual stresses along the depth of fatigue produced by the process. The removal of layers of material was performed by electrolytic attack. Hereby, it was possible to establish the relationship between the maximum stress and number of cycles in relation to the greater or lesser relaxation test specimens in different regimes of cyclic peening conditions with spherical glass and ceramics in the longitudinal and transverse directions. The results showed that the samples with the longitudinal direction shot peening redistribution showed higher compressive residual stresses in the transverse direction along the depth. For the samples of shot peening ceramic was virtually no relaxation on the surface only in depth when compared to the original profile, samples of ceramic shot peening obtained relaxation in remote locations of the surface, due to the influence of roughness. The redistribution of stresses for samples of shot peening glass were higher than those with shot peening ceramic along the depth in all cyclic regimens studied in the L and T directions. The residual stress relaxation occurred in both directions did not compromise beneficial effect of shot peening increase the fatigue life thereof, in relation to the base material. / As tensões residuais podem diminuir e se redistribuir por meio de um processo chamado relaxação. A relaxação das tensões residuais é um fenômeno importante no que se refere à previsão da resistência à fadiga dos materiais e pode ocorrer devido a carga mecânica estática, térmica, cíclica como efeitos de extensão da fadiga. As tensões residuais geralmente são prejudiciais por se sobreporem às tensões de serviço, enquanto a resistência à fadiga dos metais e ligas pode ser melhorada por tensões residuais compressivas presentes nas camadas superficiais por meio do tratamento de superfície de shot peening. A vida em fadiga com o campo de tensão residual compressiva originada pelo shot peening ou modelos sofisticados para a modelagem do Campo de Tensão Residual Compressivo (CTRC), geralmente não leva em consideração, a possibilidade deste alterar-se durante o carregamento cíclico, ou seja, ocorrer o processo de relaxação, que também altera a vida em fadiga. Este trabalho teve como objetivo obter o perfil de tensão residual de relaxação por carregamento cíclico em amostras de liga de alumínio 7050- T7541 com shot peening de vidro e cerâmica submetidas a ensaio de fadiga axial. A técnica para determinação das tensões residuais foi a difração de raios X que permite medir com precisão a redistribuição de tensões residuais ao longo da profundidade produzidas pelo processo de fadiga. A remoção das camadas de material foi realizada por ataque eletrolítico. Por meio deste, foi possível constatar a relação entre a tensão máxima e quantidade de ciclos no que se refere à maior ou menor relaxação de corpos de prova em diferentes regimes cíclicos nas condições de shot peening com esfera de vidro e cerâmica nas direções longitudinal e transversal à laminação.Os resultados mostraram que as amostras com shot peening na direção longitudinal apresentaram redistribuição de tensões residuais compressivas maiores que no sentido transversal ao longo da profundidade. Para os corpos de prova de shot peening de cerâmica praticamente não houve relaxação na superfície apenas na profundidade quando comparado ao perfil original, as amostras de shot peening de cerâmica obtiveram a relaxação em posições mais afastadas da superfície, devido a influência da rugosidade. A redistribuição de tensões para as amostras de shot peening de vidro foram superiores em relação aquelas com shot peening de cerâmica ao longo da profundidade em todos os regimes cíclicos estudados nas direções L e T. A relaxação de tensão residual ocorrida em ambas direções não comprometeu o efeito benéfico do shot peening no aumento da vida em fadiga das mesmas em relação ao material base.

Fatigue is one of the critical design aspects with immense significance where thefatigue life of a material can be stated as the number of cycles that a componentcan withstand under a particular type of loading without failure. The design processhas to include fatigue analysis in order to predict failure due to fatigue. This helpsin maintenance and servicing of a component reducing the chance of failure duringoperation of the component. Increased efficiency of predictive maintenance improvesthe life of the component.This thesis aims to study the relationship between the experimental, analytical andnumerical solutions of two high strength aluminium alloys and one steel alloy fortheir life in aircraft applications covering the effects of geometrical irregularities. Italso aims to answer convergence between the numerical and the analytical methodwhen compared with each other. The simulations are carried out for three materialsamong many used in aircraft and industrial applications (Al 7050-T7451, Al 7075-T6 and AISI 4340 Steel) for a pre-defined set of geometries. The stress field andthe stress concentration factor variations are also studied to identify their effects onfatigue life.The results from this work forms a strong background for the future research alongside SAAB or any other industries using these materials for their structures to findout the failure or predicting it accurately. Also, integral structures can be analysedin detail using this thesis as a base.

Aircraft are often designed with numbers determined by testing in a lab, rather than by repeatedly building prototypes. These lab tests conform to testing specifications so that the numbers can be compared between manufacturers, suppliers, and lab technicians. One such specification is ASTM specification E238 – 84(08), and it is used to determine important properties of a bearing pin joint like hinges, bolt holes, and rivet joints. The properties determined from this fastener-through-plate method are bearing strength, bearing yield strength, and bearing stiffness. Adhering to the methods outlined in ASTM E238, a study was performed, looking at the effects that plate material, fastener used, fastener lubrication, and plate hole preparation method (whether drilled and reamed or just drilled) have on the three bearing joint properties. The plate materials used were Al 7050 – T7451, Ti – 6Al – 4V (mill annealed), and PH13 – 8Mo – H1000. The fasteners were Ti – 6Al – 4V screws, coated A286 screws, and high speed steel (HSS) pins used as a control. Lubrication was tested using a corrosion inhibitor, PR – 1776M B – 2 from PRC – DeSoto, on the fastener or leaving the fastener uncoated. The HSS pins were always tested in the uncoated condition. 54 runs were performed, as outlined by a D-optimal design of experiment. It was discovered from the statistical analysis of the results via ANOVA that both the plate material used and the pin material, whether a screw or a pin, had a significant effect on the bearing strength, bearing yield strength, and bearing stiffness. The interaction between the two factors was also significant on all responses but the bearing stiffness. PH13 – 8Mo – H1000 plates seemed to perform best on average, followed by Ti – 6Al – 4V plates, then Al 7050 – T7451 plates. PH13 – 8Mo – H1000 and Ti – 6Al – 4V plates had similar bearing strength and bearing yield strength averages with the HSS control pins being used, which had the highest mean values for a given plate and fastener. The Ti – 6Al – 4V and A286 screws behaved and performed statistically similar in most cases, except when hole preparation method was take into account. The Ti – 6Al – 4V screws performed better when the hole was drilled and reamed, while the coated A286 screws performed better when the hole was drilled only. All screws had lower resulting bearing properties than the HSS control pins. It was also found that ASTM specification E238 – 84(08) is a precise test method, since the method could be performed repeatably and reliably with no missing data points. Therefore, this ASTM testing method is reasonable for determining bearing properties, which can then be used to design aircraft.

Made available in DSpace on 2017-07-21T20:43:45Z (GMT). No. of bitstreams: 1 Luis Otavio Ribas Lima.pdf: 8124964 bytes, checksum: d16bc8c64f9e15d57f770b1b271d6b3b (MD5) Previous issue date: 2014-06-18 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Aluminum alloys have been the primary material of choice for the aircraft due to their properties such as low density, high mechanical and corrosion resistance. Commercial aircraft apply aluminum alloys for the fuselage, wings and supporting structure due to the extensive knowledge in design and production of aluminum components, and most importantly, aluminum alloys continue to be developed, keeping it highly competitive. A great development happen with the heat-treatable alloys, which allow improvement of the mechanical properties. Among this alloys stand out the Al-Zn-Mg-Cu series, known for high strength, toughness and corrosion resistance. The improvement of those alloys occurs by the precipitation of nanometric particles MgZn2, called η phase. This study’s aim was to promote an interrupted heat treatment T6I4-65 in an AA7050 aluminum alloy, with fatigue crack growth resistance as priority. Interrupted heat treatments’ goal is optimizing the consumption of solute atoms during process of nucleation and growth of precipitates as a finely dispersion. The T6I4-65 condition obtained was analyzed by differential scanning calorimetry, DSC, optical and electronic microscopy, mechanical tests as hardness, tensile and fatigue crack growth. The T6I4-65 treatment results in a microstructure with a fine dispersion of precipitated phase η’, about 75% smaller than those resulting from in current use, T7451. This microstructure resulted in a reduction of up to 24% in fatigue crack growth rate compared to that resulting from T7451 treatment, keeping the ductility of 17% of area reduction and yield strength higher than 400MPa. / Ligas de alumínio são o principal material de uso na indústria aeronáutica devido a suas propriedades como baixa densidade, alta resistência mecânica e a corrosão. Aeronaves comerciais utilizam ligas de alumínio em sua fuselagem, asas e na estrutura de suporte devido ao extenso conhecimento no projeto e produção de componentes em alumínio, e mais importante, as ligas de alumínio continuam a serem desenvolvidas, mantendo-se altamente competitivas. Ocorreu um grande avanço com o desenvolvimento das ligas tratáveis termicamente, que permitiram a otimização das propriedades mecânicas. Entre estas ligas tratáveis, destaca se a família Al-Zn-Mg-Cu, conhecidas pela alta resistência mecânica, tenacidade e resistência a corrosão. O aperfeiçoamento destas ligas ocorre pela precipitação de partículas nanométricas de MgZn2, conhecida como fase η. O objetivo deste trabalho foi obter um tratamento térmico interrompido T6I4-65 em uma liga de alumínio AA7050 com prioridade ao aumento de resistência à propagação de trinca por fadiga. Tratamentos interrompidos tem por objetivo otimizar o consumo de átomos de soluto durante os processos de nucleação e crescimento dos precipitados endurecedores na liga na forma de dispersão finamente dispersa. A condição T6I4-65 obtida foi analisada por meio de calorimetria diferencial de varredura, DSC, microscopia ótica e eletrônica de varredura e transmissão, ensaios mecânicos dureza, tração e propagação de trinca por fadiga. Este tratamento resultou em uma microestrutura com uma dispersão de finos precipitados de fase η’, cerca de 75% menores que os resultantes de tratamentos de uso corrente, T7451. Esta microestrutura promoveu a redução de até 24% na taxa de propagação de trinca por fadiga em comparação à resultante do tratamento T7451, mantendo grande ductilidade, até 17% de redução de área e limite de escoamento superior a 400MPa.