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Item level serialization and traceability of aerospace fasteners based on individual inherent surface patterns

Arconic Fastening Systems-Luke Leonard Haylock, Jens Harde, Juergen Roesing PhD, Nils Murray, Torsten Timpe
fraunhofer-Tobias Schmid-Schirling PhD, Norbert Saum lng, Daniel Carl PhD
  • Technical Paper
  • 2020-01-0012
To be published on 2020-03-10 by SAE International in United States
Item level serialization traceability, defined as the ability to track and trace products, items or components through the supply chain from product manufacturing all the way to the end of life service, has significant value in the aerospace industry. Many items become susceptible to counterfeiting when their origin and authenticity cannot be verified and Item level serialization and traceability fosters supply chain integrity. Data Matrix and radio-frequency identification (RFID) are two common methods that enable detailed information about the manufacturer. However, these methods are not generally compatible with fasteners due to the small size of the fasteners and the cost of these methods. Fasteners are the most commonly used parts on an aircraft and rely on lot level traceability associated with packaging to provide a level of supply chain risk management. However, the association of individual fasteners to parental lots is often lost once the fasteners are removed from packaging. We demonstrate a completely new approach to develop item level serialization traceability for aerospace fasteners. It is demonstrated that this label-free traceability can be realized…
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Wire Fed Laser Directed Energy Deposition Additive Manufacturing Process (L-DED-wire)

AMS AM Additive Manufacturing Metals
  • Aerospace Material Specification
  • AMS7010
  • Current
Published 2020-01-14 by SAE International in United States

This specification establishes process controls for the repeatable production of preforms using the wire fed laser directed energy deposition (L-DED-wire) process for additive manufacturing. Preforms are intended to be used to manufacture aerospace parts, but usage is not limited to such applications.

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Characterization of Titanium Alloy (Ti6Al4V) Obtained by Additive Manufacturing

Centro de Tecnologia da Informação Renato Archer-Jorge Vicente Lopes Da Silva
Universidade Federal do ABC-Reyolando Lopes Rebello Da Fonseca Brasil, Rafael Celeghini Santiago
  • Technical Paper
  • 2019-36-0112
Published 2020-01-13 by SAE International in United States
The development of additive manufacturing processes (3D printing), applied to metal alloys, is in line with the industry's current need for optimization, cost and development time reduction, allowing the construction of representative prototypes with equivalent materials / mechanical characteristics and customized end products, such as prostheses and brake system calipers, for which Ti6Al4V alloy has wide application due to biocompatibility and resistance. In addition, the need for more resilient materials is becoming ever greater at same time that failures need to be avoided. The occurrence of failures in structural components generates consumer dissatisfaction, which can result in serious accidents and the use of numerical tools during the project contributes to its prediction. For this, it is necessary to know the structural characteristics of the material resulting from the printing processes to guarantee robust designs. Currently there are few available information regarding mechanical and micro-structural proprieties on titanium alloy Ti6Al4V obtained by 3D printing process compared with other process. Thus, through physical tests of specimens according to ASTM A370-08a and microstructural evaluations, became possible the alloy…
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Effect of Shot Peening Conditions on the Fatigue Life of Additively Manufactured A357.0 Parts

SAE International Journal of Materials and Manufacturing

Università degli Studi di Modena e Reggio Emilia, Italy-Andrea Gatto, Antonella Sola
Università degli Studi di Modena e Reggio Emilia, Italy Maserati S.p.A., Italy-Emanuele Tognoli
  • Journal Article
  • 05-13-02-0009
Published 2020-01-09 by SAE International in United States
Fatigue performance can be a critical attribute for the production of structural parts or components via additive manufacturing (AM). In comparison to the static tensile behavior of AM components, there is a lack of knowledge regarding the fatigue performance. The growing market demand for AM implies the need for more accurate fatigue investigations to account for dynamically loaded applications. A357.0 parts are processed by laser-based powder bed fusion (L-PBF) in order to evaluate the effect of surface finishing on fatigue behavior. The specimens are surface finished by shot peening using ϕ = 0.2 and ϕ = 0.4 mm steel particles and ϕ = 0.21-0.3 mm zirconia-based ceramic particles. The investigation proves that all the considered post-processing surface treatments increase the fatigue resistance of as-built parts, but the effect of peening with ϕ = 0.4 mm steel particles or with ceramic particles is more pronounced than that of peening with ϕ = 0.2 mm steel particles, although this treatment has the same Almen A value as the ceramic one. The surface morphology and the crack surface…
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Refrigeration Tube Fittings—General Specifications

Air Brake Tubing and Tube Ftg Committee
  • Ground Vehicle Standard
  • J513_201912
  • Current
Published 2019-12-19 by SAE International in United States
This SAE Standard covers complete general and dimensional specifications for refrigeration tube fittings of the flare type specified in Figures 1 to 42 and Tables 1 to 15. These fittings are intended for general use with flared annealed copper tubing in refrigeration applications. Dimensions of single and double 45 degree flares on tubing to be used in conjunction with these fittings are given in Figure 2 and Table 1 of SAE J533. The following general specifications supplement the dimensional data contained in Tables 1 to 15 with respect to all unspecified details.
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Multicriteria Optimization, Sensitivity Analysis, and Prediction of Bond Characteristics of Vacuum Diffusion Bonded Aero Engine Ti6Al4V Alloy Joints

SAE International Journal of Aerospace

Annamalai University, India-T. Pragatheswaran, S. Rajakumar, V. Balasubramanian, S. Kavitha
Materials Group, Gas Turbine Research Establishment (GTRE), India-Vijay Petley, Shweta Verma
  • Journal Article
  • 01-12-02-0008
Published 2019-12-13 by SAE International in United States
Joining titanium (Ti) alloys with conventional processes is difficult due to their complex structural properties and ability of phase transformation. Concerning all the difficulties, diffusion bonding is considered as an appropriate process for joining Ti alloys. Ti6Al4V, which is an α+β alloy widely used for aero engine component manufacturing, is diffusion bonded in this investigation. The diffusion bonding process parameters such as bonding temperature, bonding pressure, and holding time were optimized to achieve desired bonding characteristics such as shear strength, bonding strength, bonding ratio, and thickness ratio using response surface methodology (RSM). Empirical relationships were developed for the prediction of the bond characteristics, and sensitivity analysis was performed to determine the increment and decrement tendency of the shear strength with respect to the bonding parameters. Various criteria were applied to achieve the desired bond characteristics and their effects; optimum values and limits were evaluated through graphical and numerical optimization. The predicted and experimented results are validated and found that they are in good agreement with each other. The microstructural examination and X-ray diffraction (XRD) analysis…
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Changing How the Aerospace Industry Makes Parts

  • Magazine Article
  • TBMG-35684
Published 2019-12-01 by Tech Briefs Media Group in United States

Technology that increases production rates and part quality, while reducing setup times and costs, is seeing a surge in demand within the aerospace sector as the commercial aircraft backlog continues to grow.

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Streamlining Post-Processing in Additive Manufacturing

Aerospace & Defense Technology: December 2019

  • Magazine Article
  • 19AERP12_04
Published 2019-12-01 by SAE International in United States

Undoubtedly there are many benefits associated with the use of additive manufacturing (AM) as a production technology. On a pan-industrial basis, manufacturers exploit the fact that through the use of AM they can not only build complex parts, in one piece, which were previously impossible, but they can also build stronger, lighter-weight parts, reduce material consumption, and benefit from assembly component consolidation across a range of applications. These advantages have all been well documented during the last 10-20 years as AM has emerged as a truly disruptive technology for prototyping and production, and are invariably seen as being enabled by the additive hardware that builds the parts. In reality, however, this is a partial picture, particularly for serial production applications of AM. AM hardware systems are actually just one part - albeit a vital part - of an extensive ecosystem of technologies that enable AM, both pre- and post-build.

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New Manufacturing Process for Monocoque Components

  • Magazine Article
  • TBMG-35680
Published 2019-12-01 by Tech Briefs Media Group in United States

Rhodes Interform (Wakefield, West Yorkshire, England) has developed a new process that enables large monocoque components, particularly those produced by super plastic forming (SPF) from very thin material, to more accurately retain their shape on cooling.

Kirigami Inspires New Method for Wearable Sensors

  • Magazine Article
  • TBMG-35627
Published 2019-12-01 by Tech Briefs Media Group in United States

Researchers have applied kirigami architectures to graphene, an ultra-thin material, to create sensors suitable for wearable devices. Simulations were done using online software on a nanomanufacturing node, the first of its kind to be developed.