Light-weighting in aerospace component and system design

Light-weighting involves the use of advanced materials and engineering methods to enable structural elements to deliver the same,or enhanced,technical performance while using less material.The concept has been extensively explored and utilised in many industries from automotive applications to fashion and packaging and offers significant potential in the aviation sector.Typical implementations of light-weighting have involved use of high performance materials such as composites and optimisation of structures using computational aided engineering approaches with production enabled by advanced manufacturing methods such as additive manufacture,foam metals and hot forming.This paper reviews the principal approaches used in light-weighting,along with the scope for application of light-weighting in aviation applications from power-plants to airframe components.A particular area identified as warranting attention and amenable to the use of lightweighting approaches is the design of solar powered aircraft wings.The high aspect ratio typically used for these can be associated with insufficient stiffness,giving rise to non-linear deformation,aileron reversal,flutter and rigid-elastic coupling.Additional applications considered include ultralight aviation components and sub-systems,UAVs,and rockets.Advanced optimisation approaches can be applied to optimise the layout of structural elements,as well as geometrical parameters in order to maximise structural stiffness,minimise mass and enable incorporation of energy storage features.The use of additive manufacturing technologies,some capable of producing composite or multi-material components is an enabler for light-weighting,as features formally associated with one principal function can be designed to fulfil multiple functionalities。

Progress in Light-weight High Entropy Alloys

High entropy alloys(HEAs)possess good mechanical properties and a wide range of industrial applications.In this paper,phase formation prediction theory,microstructure,properties and preparation methods of light-weight HEAs(LWHEAs)were reviewed.The problems and challenges faced by LWHEAs development were analyzed.The results showed that many aspects are still weak and require investigation for future advanced alloys,such as clarification of the role of entropy in phase formation and properties of HEAs,improved definition and different generations division of HEAs,close-packed hexagonal(HCP)phase structure prediction and corresponding alloy design and fabrication.Finally,some suggestions were presented in this paper including in-depth research on formation mechanism of multi-component alloy phase and strengthening of large-scale HEA preparation methods via technology compounding and 3D printing technology.Also,there is a need for more research on the in-situ preparation of HEA coatings and films,as well as developing LWHEAs with superior strength and elevated temperature resistance or ultra-low temperature resistance to meet the requirements of future engineering applications.

Preparation of Light-weight Spinel Refractories by Foaming-gel Process

Light-weight magnesium -aluminate spinel materi- als were prepared by foaming-gel process with polyalumi- nium chloride （PAC） as gel. Effect of solid loading in initial slurry on microstructure, porosity, pore size distri- bution, thermal conductivity and mechanical properties was investigated. The results show that the bulk density of the light-weight magnesium -aluminate spinel mate- rials is in the range of O. 7 1.2 g cm-3 ; pore size distribution curves show single-peak characteristics and the mean pore size is in the range of 30. 83 - 61.37 μm ; with the increase of solid loading, the linear shrinkage of the green body during firing and the permanent change in dimensions on heating at l 600 ℃ for 3 h de- crease, but the bulk density increases, the mechanical properties increase obviously; the maximum compressive strength and bending strength reach 35. 25 MPa and 9. 92 MPa, respectively, while the bulk density is 1. 16 g · cm ; and the thermal conductivity at 1 000 ℃ tea- ches 0. 371 W · m-1 . K-1 while the bulk density is O. 7 -3 g · cm

Investigation on microstructures and properties of semi-solid Al_(80)Mg_(5)Li_(5)Zn_(5)Cu_(5)light-weight high-entropy alloy during isothermal heat treatment process

The Al_(80)Mg_(5)Li_(5)Zn_(5)Cu_(5)light-weight high-entropy alloy with globular microstructure was fabricated by isothermal heat treatment.The effects of isothermal temperatures and holding times on the semi-solid microstructure evolution were investigated.The results indicate that,with increase of the isothermal temperature,the average grain size increases and the spheroidization time shortens.With prolongation of holding time,the shape factor increases firstly and then decreases,and the average grain size decreases at first and then increases when the isothermal temperature is below 520°C,however it increases gradually at 540℃.The optimal semi-solid microstructure is obtained at 520℃ for 30 min,whose shape factor and average grain size are 0.90 and 56.4μm,respectively.Compared with as-cast Al_(80)Mg_(5)Li_(5)Zn_(5)Cu_(5) light-weight high-entropy alloy,the compressive strength and plasticity of semi-solid Al_(80)Mg_(5)Li_(5)Zn_(5)Cu_(5) light-weight high-entropy alloy are increased by 36%and 108%,respectively.The formation of semi-solid microstructures includes three stages:melting separation,spheroidization,and coarsening growth.The sluggish diffusion effect of Al_(80)Mg_(5)Li_(5)Zn_(5)Cu_(5) light-weight high-entropy alloy leads to a low coarsening rate,resulting in slow grain growth.

Ultra-thin and light-weight spoof surface plasmon polariton coupler achieved by broadside coupled split ring resonators

Low profile and light weight are very important for practical applications of a spoof surface plasmon polariton（SSPP）coupler, especially at low frequencies. In this paper, we propose and design an ultra-thin, light-weight SSPP coupler based on broadside coupled split ring resonators（BC-SRRs）. The size of BC-SRR can be far less than λ/100 and can extremely well control the reflective phases within a subwavelength thickness. Due to the broadside capacitive coupling, the electrical size of BC-SRR is dramatically reduced to guarantee the ultra-thin thickness of the SSPP coupler. The weight of the SSPP coupler is reduced by a low occupation ratio of BC-SRR in the unit cell volume. As an example, a C-band SSPP coupler composed of phase gradient BC-SRRs is designed, fabricated, and measured. Due to the ultra-small size and low occupation ratio of BC-SRRs, the thickness of the coupler is λ/12 and the surface density is only 0.98 kg/m^2. Both simulation and experiment results verify that the coupler can achieve high-efficiency SPP coupling at 5.27 GHz under normal incidence.

Effect of Commercial Synthappret BAP Treatment on the Tailorability of Light-Weight Worsted Wool Fabrics

By means of measurement with the FAST instruments,the effect of commercial Synthappret BAP treatment on the tailorability of light-weight wool worsted fabrics has been investigated. It was found that the commercial Synthappret BAP treatment improved the tailorability of the light-weight wool fabrics mainly by increasing the bending stiffness of the light-weight wool fabrics.

Principles and Chief Technologies in Developing Light-weighted Worsted Fabrics

More and more light-weighted fabrics are being required by the market, especially for the worsted manufacture.In the past, such fabrics are produced mainly through changing the structure of woven goods or by using finer yarns. But these possibilities are very limited. In this paper, new devices are discussed: (1) on the yarn level- to use single yarns instead of conventional doubled ones, to decrease number of fibers in yarn cross sections beth during spinning and after finishing; (2) on the fiber level - to use finer fibers in blends with wool and modification of the wool fibers; (3) on the macromolecule level - to stretch the macromolecules in alpha keratin, to get super fine wool fibers.

Effects of Spherical Light-weight Aggregates Additions on Workability and Mechanical Properties of Al_2O_3-SiO_2 System Castables

In order to clarify the effect of spherical light-weight aggregates addition on properties of A12 07 - Si02 system castables, adopting ATO mullite traditional light-weight aggregates and ATO mullite spherical light-weight aggre- gates, bauxite homogenization powder, microsilica , cal- cium aluminate cement as main raw materials, light- weight Al2 03 - SiO2 system castables were prepared by replacing conventional light-weight aggregate with spherical light-weight aggregates. The effects of spheri- cal light-weight aggregates addition on workability, me- chanical properties of castables after heated at different temperatures were researched; the microstructure of the aggregates was analyzed by SEM. The result shows that the introduction of spherical light-weight aggregates can significantly improve the flowability and reduce the water addition of the castables. Water demand of the castable is reduced from 18% with the conventional light-weight aggregates to 14% with spherical light-weight aggre- gates. In addition, light-weight castables prepared by spherical aggregates can keep the same workability with- in a wider range of water addition. Therefore, spherical aggregates are user-friendly. The introduction of spheri- cal light-weight aggregates is favorable to packing densi- ty and mechanical properties of castables, such as cold crushing strength, cold modulus of rupture, hot modulus of rupture at 1 200℃.

A Study of Thermal Response and Flow Field Coupling Simulation around Hayabusa Capsule Loaded with Light-Weight Ablator

The numerical simulation of flow field around Hayabusa capsule loaded with light-weight ablator thermal response coupled with pyrolysis gas flow inside the ablator was carried out. In addition, the radiation from high temperature gas around the capsule was coupled with flow field. Hayabusa capsule reentered the atmosphere about 12 km/sec in velocity and Mach number about 30. During such an atmospheric entry, space vehicle is exposed to very savior aerodynamic heating due to convection and radiation. In this study, Hayabusa capsule was treated as a typical model of the atmospheric entry spacecraft. The light-weight ablator had porous structure, and permeability was an important parameter to analyze flow inside ablator. In this study, permeability was a variable parameter dependent on density of ablator. It is found that the effect of permeability of light-weight ablator was important with this analysis.

Stress-rupture measurements of cast magnesium strengthened by in-situ production of ceramic particles

We have introduced a polymer precursor into molten magnesium and then in-situ pyrolyzed to produce castings of metal matrix composites(P-MMCs)containing silicon-carbonitride(SiCNO)ceramic particles.Stress-rupture measurements of as-cast P-MMCs was performed at 350 ℃(0.69TM)to 450 ℃(0.78TM)under dead load condition corresponding to tensile stress of 2.5 MPa to 20 MPa.The time-to-fracture data were analyzed using the classical Monkman–Grant equation.The time-to-fracture is thermally activated and follows a power-law stress exponent exhibiting dislocation creep.Fractography analysis revealed that while pure magnesium appears to fracture by dislocation slip,the P-MMCs fail from the nucleation and growth of voids at the grain boundaries.

Epistemic-Based Investigation of the Probability of Hazard Scenarios Using Bayesian Network for the Lifting Operation of Floating Objects

Owing to the increase in unprecedented accidents with new root causes in almost all operational areas, the importance of risk management has dramatically risen. Risk assessment, one of the most significant aspects of risk management, has a substantial impact on the system-safety level of organizations, industries, and operations. If the causes of all kinds of failure and the interactions between them are considered, effective risk assessment can be highly accurate. A combination of traditional risk assessment approaches and modern scientific probability methods can help in realizing better quantitative risk assessment methods. Most researchers face the problem of minimal field data with respect to the probability and frequency of each failure. Because of this limitation in the availability of epistemic knowledge, it is important to conduct epistemic estimations by applying the Bayesian theory for identifying plausible outcomes. In this paper, we propose an algorithm and demonstrate its application in a case study for a light-weight lifting operation in the Persian Gulf of Iran. First, we identify potential accident scenarios and present them in an event tree format. Next, excluding human error, we use the event tree to roughly estimate the prior probability of other hazard-promoting factors using a minimal amount of field data. We then use the Success Likelihood Index Method(SLIM) to calculate the probability of human error. On the basis of the proposed event tree, we use the Bayesian network of the provided scenarios to compensate for the lack of data. Finally, we determine the resulting probability of each event based on its evidence in the epistemic estimation format by building on two Bayesian network types: the probability of hazard promotion factors and the Bayesian theory. The study results indicate that despite the lack of available information on the operation of floating objects, a satisfactory result can be achieved using epistemic data.

Mechanism of weld-line movement within hydroforming of tailor-welded tube

To reveal the reason of weld-line movement in hydroforming of a tailor-welded tube (TWT) with dissimilar thickness,the stress ratio of axial stress to circumferential stress is derived by mechanical analysis and analyzed between the thicker and thinner tubes,as well as the property of the axial strain. During TWT hydroforming,tensile strain along axial direction happens on the thinner tube. On the contrary,compressive strain happens on the thicker tube. Experiments are conducted to varify the weld-line movement regularity and strain distribution. It indicates that the weld-line moves from the thinner part to the thicker during TWT hydroforming. The thinning ratio of the thinner tube is bigger than that of the thicker tube,especially in the zone near weldline. Stress ratio difference between the thicker tube and the thinner tube is the main reason of weld-line movement and non-uniform thinning ratio distribution.

Secret Sharing Using Visual Cryptography

Compared with the traditional crypto- graphy, visual cryptography （VC） decrypts secret images referring to the characteristics of human vision, rather than the cryptography knowledge or complex computations. Furthermore, seeing to the freeness of the secret key, the whole process of encryption as well as deeryption for the visual cryptography meets a fast dealing course. As to the security concern, it is able to guarantee that no one can have access to any clues about the content of a secret image from individual cover images. Thus, owing to the studies on this area, the target of light-weighted cryptography is reached. Now the visual cryptography has been developed from the meaningless shadows to the meaningful ones. Seeing to the highly developed technique, some advanced VC techniques are introduced in this survey, respectively.

Effect of Alumina Micropowders on Properties of Calcium Hexaluminate

Calcium hexaluminate （ CA6 ） was synthesized by mixing light-weight calcium carbonate and Al2O3 mi- cropowder （calcined α-Al2O3, activated α-Al2O3 or α-Al2O3） according to the stoichimetric ratio of CA6, and reaction sintering at 1 200, 1 300, 1 400 and 1 500 ℃fin 3 h, respectiely. Efcts of the three alu- mina micropowders on the phase composition, micro- structure and properties of CA were investigated. The re- sults show that ： （ 1 ） for the three Al2O3 micropowders, the reaction to generate CA6 in specimens basically com- plete. at about 1 500 ℃ ; CA6 generated in all specimens is planar, bat the array modes are slightly different; （2） the specimel＇s prepared from, calcined α-Al2O3or ρ-Al2O3 shrink almost, while the specimens prepared from activated α-Al2O3 expand ; （ 3 ） the cold crushing strength of the specimen prepared from activated α-Al2O3 is the highest, reaching 42.5 MPa when only CA6 exists （ after firing at 1 500 ℃ ） ; （ 4 ） the specimen prepared from ρ-Al2O3 has the lowest generation temperature of CA6 and the highest apparent porosity, reaching 70. 1% when only CA exists （after firing at 1 500 ℃）; （5） the specimen prepared from calcined α-Al2O3 has the biggest bulk density.

Rational cathode configuration with bilayer membranes to engineer current-collector-free high-areal-sulfur lithium-sulfur batteries

The application of light-weight current collectors is preferred because of the increased energy density of the batteries.Bearing it in mind,the cathode is designed with self-made paperlike memberane as current collector coupled with another interlayer to enable the high-energy-density lithium-sulfur batteries.Via a facile and green step-by-step methodology,the hybrid membrane is finalized successfully,consisting of reduced graphene oxide sheets covering paper-derived carbon(GPC)bearing Fe@Fe2O3 and Fe1−xS@Fe2O3 core-shell nanoparticles(FeFeO/FeSFeO@GPC).The film works as the current collector and interlayer simultaneously considering the porous and conductive features.As demonstrated by the electrochemical testing,the FeFeO/FeSFeO@GPC hybrid cell exhibits attractive cycling stability and superior rate capability.The cell configuration and structural/composition merits of FeFeO/FeSFeO@GPC film facilitate the faster reaction kinetics,conducive to the improvement of capacity retention.In view of the effective cathode design,the areal sulfur loading is increased to 10.46 mg·cm^(−2)and a reversible capacity of 6.67 mAh·cm^(−2)can be retained after 60 cycles at 0.1 C.

Light-Weight Design of CRH Wind Deflector Panels based on Woven Textile Sandwich Composites

The woven textile sandwich composite（WTSC） is a promising lightweight composite.In bending,two competing core shearing failure modes reduce the strength;deflection induced by the core shearing deformation reduces the flexural rigidity.To replace a solid composite laminate,the span of WTSC panel must be greater than a critical value,which was deduced on the condition that the load capacity and flexural rigidity of the WTSC panel are equal to those of the composite laminate.Three WTSC panels were tested in bending,so that the failure modes were observed,and the critical spans were determined.Using the alternative design method,the WTSC based wind deflector with reduced weight has been fabricated and mounted on the CRH（China Railway High-speed）.

Bio-inspirations for the Development of Light Materials based on the Nanomechanical Properties and Microstructures of Beetle Dynastes tityus

Dynastes tityus(D.tityus)is a typical beetle whose elytra are light and strong.The primary function of elytra is to protect beetle's hindwings.In this paper,D.tityus elytra were selected as the biological prototype for the investigation to obtain bio-inspirations for the design and development of light materials with high ratio of strength to mass.Firstly,the microstructure investigation and quasi-static nanoindentation tests have been carried out on the ten samples of the selected elytra ofD.tityus to reveal their mechanical properties and microstructures.Secondly,based on the fmdings from the microstructure investigation and nanoindentation tests,three models of bio-inspired materials have been proposed for further study to gain the deep understanding of the relationships between the special mechanical characteristics and microstructures.Then Finite Element Analysis(FEA)simulations have been performed on the three models for harvesting the bio-inspirations for the initial design of light materials.Finally,through comparative analysis of the findings from the microstructure investigation,the nanoindentation tests and the simulations,some meaningful bio-inspirations have been reaped for the future optimization of the design and development of light materials with high ratio of strength to mass.

An Isolation Principle Based Distributed Anomaly Detection Method in Wireless Sensor Networks

Anomaly detection plays an important role in ensuring the data quality in wireless sensor networks(WSNs).The main objective of the paper is to design a light-weight and distributed algorithm to detect the data collected from WSNs effectively.This is achieved by proposing a distributed anomaly detection algorithm based on ensemble isolation principle.The new method offers distinctive advantages over the existing methods.Firstly,it does not require any distance or density measurement,which reduces computational burdens significantly.Secondly,considering the spatial correlation characteristic of node deployment in WSNs,local sub-detector is built in each sensor node,which is broadcasted simultaneously to neighbor sensor nodes.A global detector model is then constructed by using the local detector model and the neighbor detector model,which possesses a distributed nature and decreases communication burden.The experiment results on the labeled dataset confirm the effectiveness of the proposed method.

Materials-oriented integrated design and construction of structures in civil engineering—A review

Design is a goal-oriented planning activity for creating products,processes,and systems with desired functions through specifications.It is a decision-making exploration:the design outcome may vary greatly depending on the designer’s knowledge and philosophy.Integrated design is one type of design philosophy that takes an interdisciplinary and holistic approach.In civil engineering,structural design is such an activity for creating buildings and infrastructures.Recently,structural design in many countries has emphasized a performance-based philosophy that simultaneously considers a structure’s safety,durability,serviceability,and sustainability.Consequently,integrated design in civil engineering has become more popular,useful,and important.Material-oriented integrated design and construction of structures(MIDCS)combine materials engineering and structural engineering in the design stage:it fully utilizes the strengths of materials by selecting the most suitable structural forms and construction methodologies.This paper will explore real-world examples of MIDCS,including the realization of MIDCS in timber seismic-resistant structures,masonry arch structures,long-span steel bridges,prefabricated/on-site extruded light-weight steel structures,fiber-reinforced cementitious composites structures,and fiber-reinforced polymer bridge decks.Additionally,advanced material design methods such as bioinspired design and structure construction technology of additive manufacturing are briefly reviewed and discussed to demonstrate how MIDCS can combine materials and structures.A unified strengthdurability design theory is also introduced,which is a human-centric,interdisciplinary,and holistic approach to the description and development of any civil infrastructure and includes all processes directly involved in the life cycle of the infrastructure.Finally,this paper lays out future research directions for further development in the field.

3D Printing of Continuous Fiber Reinforced Polymer Composites:Development,Application,and Prospective

Continuous fiber reinforced polymer composites(CFRPC)have been widely used in the field of automobile,air-craft,and space due to light weight,high specific strength and modulus in comparison with metal as well as alloys.Innovation on 3D printing of CFRPCs opened a new era for the design and fabrication of complicated composite structure with high performance and low cost.3D printing of CFRPCs provided an enabling technol-ogy to bridge the gaps between advanced materials and innovative structures.State-of-art has been reviewed according to the correlations of materials,structure,process,and performance as well as functions in 3D printing of CFRPCs.Typical applications and future perspective for 3D printing of CFRPCs were illustrated in order to grasp the opportunities and face the challenges,which need much more interdisciplinary researches covering the advanced materials,process and equipment,structural design,and final smart performance.