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Tapered Hole Automation for Hard Metals – Enabling Producibility

Electroimpact Inc.-Russell DeVlieg
The Boeing Company-Trevor Hartnagel
  • Technical Paper
  • 2020-01-0006
To be published on 2020-03-10 by SAE International in United States
Assembly of the F-15 wing utilizes the Taper-Lok fastening system which requires precise preparation of conical holes to enable tapered fasteners to provide a uniform interference fit. The controlled interference fit directly affects fastener preload to reduce stress and improve fatigue life. Traditional methods for generating tapered holes in thick aluminum and titanium structures require heavy duty tooling. Fixtures are clamped to aircraft structure which hold large power feed to complete the hole generation processes in multiple steps. Manual drilling for Taper-Loks is labor intensive, non-ergonomic, and requires extreme care to ensure quality holes are produced. Automated hole generation was a logical solution to the complex Taper-Lok fastening system, however replicating traditional drilling methods proved challenging. Extensive testing was completed to ensure hole quality generated with automation would meet or exceed existing power feed equipment. Once process capabilities were proven and equipment requirements were generated, an articulated arm-based drilling system was developed and implemented. The automation was designed to accurately position and complete the hole preparation process in a single pass by the use of…
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Composite Electrical Connectors

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AIR4567B
  • Current
Published 2020-01-21 by SAE International in United States
This SAE Aerospace Information Report (AIR) establishes guidelines for evaluating composite electrical connectors and accessories.
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Influence Of The Portevin-Le Chatelier Phenomenon On The Ultimate Tensile Strengh Limit Of Alloys Al-0.18%Zr-2%Mg And Al-0.18%Zr-6%Mg

Federal University of Pará, Augusto Corrêa Street, nº 01, Gu-Natália Luiza Abucater Brum, Aélcio de Jesus Monteiro dos Santos, Brenda Thayssa Figueira Daniel, Clóvis Iarlande Oliveira Santana, Laís Mota de Brito da Fonseca, José Maria do Vale Quaresma, Vinicius Silva dos Reis
  • Technical Paper
  • 2019-36-0301
Published 2020-01-13 by SAE International in United States
The effect of Portevin-Le Châtelier (PLC) effect and its influence on the mechanical properties of aluminum, have aroused interest in the scientific community, aiming possible applications in the industry. The respective effect has been commonly observed in the solid solution state in Al-Mg alloys. Therefore, the objective of this work is to analyze the effect of the PLC phenomenon on the mechanical properties of the material with additions of 2% and 6% of Mg in the base alloy of Al-0.18%. For this purpose, the alloys were cast in a muffle furnace and cast in copper mold (section of the properzi wheel), followed by cooling in water. Samples were cut and machined to 9.5 mm in diameter. Subsequently, they underwent sanding and polishing processes in order to obtain their macrostructures. The results obtained in this step show that Mg refined the grain structures. The tensile test was performed for mechanical characterization. The results showed that increasing Mg contents resulted in grain refining, tensile strength limit and elongation losses. In order to analyze the effect of PLC…
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ACCESSORY, COVER, PROTECTIVE, PLUG CONNECTOR, ELECTRICAL, CIRCULAR, HIGH DENSITY, QUICK DISCONNECT, ENVIRONMENT RESISTING (SERIES 2)

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AS81511/17
  • Current
Published 2019-12-26 by SAE International in United States
No Abstract Available.
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ACCESSORY, COVER, PROTECTIVE, RECEPTACLE, CONNECTOR, ELECTRICAL, CIRCULAR, HIGH DENSITY, QUICK DISCONNECT, ENVIRONMENT RESISTING (SERIES 1 OR 2)

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AS81511/18
  • Current
Published 2019-12-26 by SAE International in United States
No Abstract Available.
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A New Methodology to Study the Mechanisms of Combustion-Chamber Deposit Formation and the Effects of Engine Parameters on the Quantity and Morphology of Combustion-Chamber Deposits

IFP Energies Nouvelles, 1 et 4 avenue de Bois-Préau, 92852 R-L. Ganeau, M. Alves Fortunato, G. Pilla, G. Bruneaux
Institute for Combustion and Gas Dynamics – Reactive Fluids,-C. Schulz
  • Technical Paper
  • 2019-01-2355
Published 2019-12-19 by SAE International in United States
In this work, a methodology is developed to study engine deposit formation mechanisms. It relies on analyzing the deposit with electron microscopy for morphology and infrared absorption spectroscopy for identifying typical chemical functions. Two lab-scale experiments are used to calibrate these measurement techniques by creating deposits through the two main phases: liquid film and soot deposition. To test this methodology, an optical engine is used to create a library of deposits. Two main deposit morphologies are found: a homogeneous underlayer as well as soot-like agglomerates. The underlayer is attributed to a fuel-film mechanism whereas the latter is attributed to particles formed through the combustion process. The influence of engine parameters, such as injection phasing and cooling temperature, on the quantity and morphology of the deposits is studied. Various substrate materials, such as quartz, sapphire, aluminum, and steel were used on the piston surface to investigate the materials influence on the morphology, the composition, and the quantity of the deposits.
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Aluminum Alloy, Hand Forgings 8.0Zn - 1.0Cu - 1.6Mg - 0.12Zr (7037-T7452) Solution Heat Treated, Compression Stress Relieved, and Overaged

AMS D Nonferrous Alloys Committee
  • Aerospace Material Specification
  • AMS4456A
  • Current
Published 2019-11-25 by SAE International in United States
This specification covers an aluminum alloy in the form of hand forgings 11.000 inches (280 mm) and under in nominal thickness and of forging stock of any size (see 8.6).
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Aluminum Alloy, Plate (2397-T87) 2.8Cu - 1.4Li - 0.30Mn - 0.12Zr - 0.10Zn Solution Heat Treated, Cold Worked, and Artificially Aged

AMS D Nonferrous Alloys Committee
  • Aerospace Material Specification
  • AMS4328B
  • Current
Published 2019-11-25 by SAE International in United States
This specification covers an aluminum alloy in the form of plate 3.000 to 6.000 inch (76.20 to 152.40 mm), inclusive, in nominal thickness (see 8.5).
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Aluminum Sheet, Laminated Surface Bonded

AMS D Nonferrous Alloys Committee
  • Aerospace Material Specification
  • AMS4013H
  • Current
Published 2019-11-25 by SAE International in United States
This specification covers aluminum and aluminum alloy foil in the form of laminated sheet.
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Material Characterization of Extruded Aluminum Axial Tubes as Energy-Absorbing Structural Members

SAE International Journal of Materials and Manufacturing

Ohio University, USA-Eboreime Ohioma, Frank Kraft, Sean Jenson
USA-Muhammad Ali
  • Journal Article
  • 05-13-01-0004
Published 2019-11-21 by SAE International in United States
The increasing use of aluminum alloy extrusion in automotive vehicle chassis as structural members has necessitated the need to investigate their crushing behaviors. This article experimentally examines in detail, for the first time with respect to strength, ductility, and microstructure, AA6063-T7 (overaged) condition and the standard T6 temper and their capacity to meet crashworthiness requirements. Both tempers were assessed based on their mechanical properties (strength, ductility, true stress/strain behavior to necking, plastic anisotropy, strain rate sensitivity, and post-instability ductility to fracture) and microstructure, which were determined using basic tensile testing methods and metallographic approach. The implications of these properties/microstructures were further assessed experimentally by investigating the crushing behavior and energy absorption capacities of two extruded geometric profiles: a general rectangular profile and a novel cross-shaped profile investigated in a previous study. Typical modes of collapse were observed for rectangular tubes. In the case of the cross-shaped tubes, geometric modifications in the form of horizontal grooves along the sidewalls were introduced to promote controlled, stable, and repeatable folding patterns during the collapse in addition to serving…