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Unsettled Technology Domains in Aerospace Additive Manufacturing Concerning Safety, Airworthiness, and Certification

Muelaner Engineering, Ltd.-Jody Muelaner
  • Research Report
  • EPR2019008
To be published on 2019-12-20 by SAE International in United States
Additive manufacturing (AM) is currently being used to produce many certified aerospace components. However, significant advantages of AM are not exploited due to unresolved issues associated with process control, feedstock materials, surface finish, inspection, and cost. Components subject to fatigue must undergo surface finish improvements to enable inspection. This adds cost and limits the use of topology optimization. Continued development of process models is also required to enable optimization and understand the potential for defects in thin walled and slender sections. Costs are high for powder-fed processes due to material costs, machine costs, and low deposition rates. Cost for wire-fed processes are high due to the extensive post-process machining required. In addition, these processes are limited to low-complexity features. Incremental improvements in all of these areas are being made but a step change could potentially be achieved by hybrid processes, which use wire feedstock to deposit the bulk of the part and powder for fine detail. NOTE: SAE EDGE™ Research Reports are intended to identify and illuminate key issues in emerging, but still unsettled, technologies…
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Plating, Nickel Low-Stressed Deposit

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2424F
  • Current
Published 2019-11-04 by SAE International in United States
This specification covers the requirements for electrodeposited low-stressed nickel.
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Coating, Titanium Nitride Physical Vapor Deposition

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2444A
  • Current
Published 2019-11-04 by SAE International in United States
This specification covers the requirements for the application and properties of a titanium nitride coating on metal parts applied by physical vapor deposition (PVD).
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Brazing, Nickel Alloy Filler Metal

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2675H
  • Current
Published 2019-11-04 by SAE International in United States
This specification covers the requirements forproducing brazed joints in parts made of steels, iron alloys, nickel alloys, and cobalt alloys by use of nickel alloy filler metal.
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BRAZING, SILVER For Use Up to 800 °F (427 °C)

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2664F
  • Current
Published 2019-11-04 by SAE International in United States
This specification covers the engineering requirements for producing brazed joints in parts made of steels, iron alloys, nickel alloys, and cobalt alloys by use of silver alloy filler metals, and the properties of such joints.
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Shot Peening, Ultrasonically Activated

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2580A
  • Current
Published 2019-11-04 by SAE International in United States
This specification covers the requirements for inducing compressive residual stresses on the surface of metal parts using ultrasonically activated shot peening.
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Improvement of Mechanical Properties, and Optimization of Process Parameters of AISI 1050 Spheriodized Annealed Steel by Ranking Algorithm

SRM Institute of Science and Technology-Durai Kumaran, Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Raj Rajendran
Tishk International University-Ganesh Babu Loganathan
Published 2019-10-11 by SAE International in United States
AISI 1050 is used in the production of landing gear, actuators and other aerospace components but their application is limited due to machinability of the material. In any metal cutting operation the features of tools, input work materials, machine parameter settings will influence the process efficiency and output quality characteristics. A significant improvement in process efficiency may be obtained by process parameter optimization that identifies and determines the regions of critical process control factors leading to desired outputs or responses with acceptable variations ensuring a lower cost of manufacturing. This experimental study elucidates the problems and machinability issues like failure of tools and accuracy are found while machining and less output in machining. In the present study of spherodizing heat treatment of AISI 1050 was investigated during the turning operation in CNC lathe, under the consideration of several turning process parameters. The microstructures of the as-received, and heated specimens were investigated by Optical Microscopy (OM). A correlation between various process parameters on the desired response namely surface finish, roundness Material Removal Rate (MRR), power consumption…
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Advances in Laser Welding of Stainless Steel Alloys

BSACIST-Varun Kumar Arulvizhi, Selvakumar Alandur Somasundaram, Mohammed Haareeskhan Niyaz, Pradeep Krishna Ranganathan, Afnan Zaid Moolai, Mohamed Ashfaq Ahmed Abdulla Burhanudeen, Mohan Raj Ramu
Published 2019-10-11 by SAE International in United States
As a fusion welding process, Laser welding has proven to be the most promising method for joining of different materials whether it can be either a similar or dissimilar material category. However, few complications still remain unanswered in joining of materials by laser process after successful implementation of laser’s by industries and also the commercial users in previous year’s such as workpiece preparation, fixture issues, atmospheric conditions, nozzle focus on the material, etc., This article will give an elaborate survey on joining of stainless steel alloys, though there are many factors to be considered here concentration is on the metallurgical behaviour and tensile properties of weldments joined by laser welding technique, because the main criteria for a weldment is to have a coarse grain boundary distribution which may be distorted due to high heat generation during a joining process and to possess good tensile strength in order to withstand the impacts given on the weldment when it is being practically deployed in usage. The material behavior of weldment is primarily based on the process parameters…
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Graphite Coating, Thin Lubricating Film Impingement Applied

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2525E
  • Current
Published 2019-10-10 by SAE International in United States
This specification covers a coating consisting of finely-powdered graphite in a heat-resistant inorganic binder.
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Investigation of Silver-Plated Conductor Corrosion (Red Plague)

AE-8D Wire and Cable Committee
  • Aerospace Standard
  • AIR4487B
  • Current
Published 2019-10-02 by SAE International in United States
This SAE Aerospace Information Report (AIR) shall be limited to information about a specific corrosion mechanism of silver-plated conductors that produces cuprous/cupric oxide deposits (Red Plague). It examines some possible causes and some recommendations to minimize the possibility of its occurrence. It also provides a number of reference documents that describe the corrosion in detail, methods to determine conductor damage, methods to produce the corrosion, and other investigative reports of this phenomena and their conclusions.
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