ELIMIMATION OF RANDOM DEFACTS IN AEROSPACE MATERIALS

In the pastfew years,severalnew melting processeshavebeenindustrialised forthe produc tion ofsuperalloys,titanium alloysand high qualitysteelsfor useintheaero engineindustry.Theseincludeelectron beam , plasma,inductionskull,andthe”triple melt”process( VIM + ESR+ VAR) . These developments have allbeen instituted in responsetothe major per ceived problem oftheindustry ;that oftheincidence of random defectsin the alloys whichcause problemsinregardto predictablelifing ofthefinished partinservice. Thedirectconse quenceofthe uncertaintyislossof revenue due to premature retirement of parts which mayhavecompleted on a fraction oftheir actualservicelife; a conservatism on the partof design parameters whichleadsto uneccesary weightin thepart;and ariskofeitherservicefailuresor partrecalls whichinterruptengine performance. Thebenefitsoftheprocesschangesinrespectoftheproducts’absolute propertiesand alsoonthereproducibility and inspectability ofthose properties have been substantial. Itisclearthattheprocesses offer the industry a solution to the present dilem ma of how to treatthe ”rare”defectsfrom the pointof view of fracture mechanicslifing methodology. The use ofprocesscontrols which guarantee”zero defect”productisdevelopingintoacriticaltoolfortheextension oftherangeof a given alloy’s use. Itislikelyto permit very substantial gainsinboth componentlife and intheallowablestressin rotating parts withoutthe needtointroduce new materials carrying new problems of user confidence, production reliability and data base. Weconcludethatthenew processesareatastageof development wherethey arereadyforwideindustry usein production. They will not add significantly tothecomponentcost andthey willgive a renwed lifespan to the more familiar materials and methodsof aero engineconstruction.

R & D ACTIVITIES ON AEROSPACE MATERIALS IN KOREA

This paper briefly reviews research and development programs in Korean aerospace industry,with an emphasis on aircraft materials technology. International collaborations in these areas are outlined and the R & D activities are highlighted against the background of the national economy.It is shown that the investment from government agencies and large enterprises has led to healthy development of aerospace materials industries in Korea.

Durability Testing of Composite Aerospace Materials Based on a New Polymer Carbon Fiber-Reinforced Epoxy Resin

In this study,the durability of a new polymer carbonfiber-reinforced epoxy resin used to produce composite material in the aerospacefield is investigated through analysis of the corrosion phenomena occurring at the microscopic scale,and the related infrared spectra and thermal properties.It is found that light and heat can con-tribute to the aging process.In particular,the longitudinal tensile strength displays a non-monotonic trend,i.e.,itfirst increases and then decreases over time.By contrast,the longitudinal compressive and inter-laminar shear strengths do not show significant changes.It is also shown that the inter-laminar shear strength of carbonfiber/epoxy resin composites with inter-laminar hybrid structure is better than that of pure carbonfiber materials.The related resistance to corrosion can be improved by more than 41%.

Recent innovations in laser additive manufacturing of titanium alloys

Titanium(Ti)alloys are widely used in high-tech fields like aerospace and biomedical engineering.Laser additive manufacturing(LAM),as an innovative technology,is the key driver for the development of Ti alloys.Despite the significant advancements in LAM of Ti alloys,there remain challenges that need further research and development efforts.To recap the potential of LAM high-performance Ti alloy,this article systematically reviews LAM Ti alloys with up-to-date information on process,materials,and properties.Several feasible solutions to advance LAM Ti alloys are reviewed,including intelligent process parameters optimization,LAM process innovation with auxiliary fields and novel Ti alloys customization for LAM.The auxiliary energy fields(e.g.thermal,acoustic,mechanical deformation and magnetic fields)can affect the melt pool dynamics and solidification behaviour during LAM of Ti alloys,altering microstructures and mechanical performances.Different kinds of novel Ti alloys customized for LAM,like peritecticα-Ti,eutectoid(α+β)-Ti,hybrid(α+β)-Ti,isomorphousβ-Ti and eutecticβ-Ti alloys are reviewed in detail.Furthermore,machine learning in accelerating the LAM process optimization and new materials development is also outlooked.This review summarizes the material properties and performance envelops and benchmarks the research achievements in LAM of Ti alloys.In addition,the perspectives and further trends in LAM of Ti alloys are also highlighted.

HIGH CYCLE FATIGUE PROPERTIES OF NICKEL-BASE ALLOY 718

The fatigue properties of nickel-base Alloy 718 with fine- and grain-coarse grains were investigated. In the fine-grain alloy, the fatigue strength normalized by the tensile strength was 0.51 at 107 cycles. In contrast, the fatigue strength of the coarse-grain alloy was 0.32 at the same cycles, although the fatigue strengths in the range from 103 to 105 cycles are the same for both alloys. The fracture appearances fatigued at around 106 cycles showed internal fractures originating from the flat facets of austenite grains for both alloys. The difference in fatigue strength at 107 cycles between the fine- and coarse-grain alloys could be explained in terms of the sizes of the facets from which the fractures originated.

Minimum quantity lubrication machining of aeronautical materials using carbon group nanolubricant: From mechanisms to application

It is an inevitable trend of sustainable manufacturing to replace flood and dry machining with minimum quantity lubrication(MQL)technology.Nevertheless,for aeronautical difficult-tomachine materials,MQL couldn’t meet the high demand of cooling and lubrication due to high heat generation during machining.Nano-biolubricants,especially non-toxic carbon group nano-enhancers(CGNs)are used,can solve this technical bottleneck.However,the machining mechanisms under lubrication of CGNs are unclear at complex interface between tool and workpiece,which characterized by high temperature,pressure,and speed,limited its application in factories and necessitates in-depth understanding.To fill this gap,this study concentrates on the comprehensive quantitative assessment of tribological characteristics based on force,tool wear,chip,and surface integrity in titanium alloy and nickel alloy machining and attempts to answer mechanisms systematically.First,to establish evaluation standard,the cutting mechanisms and performance improvement behavior covering antifriction,antiwear,tool failure,material removal,and surface formation of MQL were revealed.Second,the unique film formation and lubrication behaviors of CGNs in MQL turning,milling,and grinding are concluded.The influence law of molecular structure and micromorphology of CGNs was also answered and optimized options were recommended by considering diverse boundary conditions.Finally,in view of CGNs limitations in MQL,the future development direction is proposed,which needs to be improved in thermal stability of lubricant,activity of CGNs,controllable atomization and transportation methods,and intelligent formation of processing technology solutions.

BARK-MIMETIC LAYER-BY-LAYER ASSEMBLED MONTMORILLONITE/POLY(p-AMINOSTYRENE) FLEXIBLE NANOCOMPOSITES SHIELDING ATOMIC OXYGEN EROSION

Inspired by the birch bark, which has multilayered structures, we fabricated layer-by-layer （LbL） assembled montmorillonite （MMT） and poly（p-aminostyrene） （PPAS） nanocomposites on cotton fiber curved surfaces to provide protection from atomic oxygen （AO） erosion. The multilayer coated fibers had high flexibility, uniformity, defect free, ease of preparation and low cost. The AO erosion durability has been dramatically enhanced which was evidenced by testing in the ground-based AO effects simulation facility. And the dimension and surface morphologies of the fibers observed by SEM had few changes, indicating excellent AO erosion resistant ability of the coatings. These results provide us a new method to design fibrous materials exposed directly in low earth orbit environment.