Problems of Transition from Aluminum to Exotic Materials in Aerospace Structures

It is now necessary to implement a systems engineering approach to structural design of aerospace vehicles in order to solve interdisciplinary problems encountered between concept and product. Higher temperatures and loads beyond the structural limits of aluminum alloys dictate exotic materials ranging from titanium through the refractory materials to ceramics. This paper presents an approach to transitional problems in application of these materials, from basic material selection considerations across all the design, processing, and manufacturing technologies. Methodologies are summarized in the brazing of molybdenum, the hot forming of titanium alloys, welding and machining of titanium, and adhesive bonding techniques.