Materials, Structures and Manufacturing for Aircraft (Sustainable Aviation)

Contents
Chapter 1: Aluminum-Lithium Alloys in Aircraft Structures
	1.1 Introduction
	1.2 Production of Al–Li Alloys
	1.3 Microstructural Properties of Al–Li Alloys
	1.4 Mechanical Properties of Al–Li Alloys
	1.5 Corrosion Properties of Al–Li Alloys
	1.6 Applications of Al–Li Alloys in Aircraft Structures
		1.6.1 Fuselage
		1.6.2 Upper Wing Structures
		1.6.3 Lower Wing Structures
	1.7 Conclusions
	References
Chapter 2: Metal Foams and Their Applications in Aerospace Components
	2.1 Introduction
	2.2 Primary Processing
	2.3 Secondary Processing
	2.4 Aircraft Applications
	2.5 Spacecraft Applications
	References
Chapter 3: Advanced Polymers in Aircraft Structures
	3.1 Introduction
	3.2 Polymer Composites in Aircraft
	3.3 Structural Components in Aircraft
		3.3.1 Engine Fan Blades
		3.3.2 Brackets
		3.3.3 Interiors
		3.3.4 Nacelles
		3.3.5 Wings
		3.3.6 Fuselage
		3.3.7 Empennage
	3.4 Manufacturing Processes for Aircraft Composites
		3.4.1 Automated Tape Layup
		3.4.2 Resin Transfer Molding
		3.4.3 Automated Fiber Placement
		3.4.4 Vacuum-Assisted Resin Transfer Molding
		3.4.5 Pultrusion
		3.4.6 Filament Winding
		3.4.7 Autoclave Process
	3.5 Conclusions
	3.6 Future Scope
	References
Chapter 4: Advanced Fibrous Composites for Aircraft Application
	4.1 Introduction
	4.2 Fibrous Composite Structures
		4.2.1 Fibrous Materials
		4.2.2 Fibrous Architectures
			Nonwoven Fabrics
			Woven Fabrics
			Knitted Fabrics
			Braided Fabrics
			Three-Dimensional Textiles Preforms
		4.2.3 Matrices
		4.2.4 Fabrication of Fibrous Composites
		4.2.5 Interface of Fiber and Matrix
	4.3 Properties of Fibrous Composites
		4.3.1 Mechanical Behavior
		4.3.2 Types of Mechanical Tests
	4.4 Fibrous Composites in Aircraft Applications
	4.5 Conclusions
	References
Chapter 5: Natural Composites in Aircraft Structures
	5.1 Introduction
	5.2 Natural Composites in Aerospace Industry
	5.3 Aerospace Component from Natural Fibers
	5.4 Natural Fibers in Aerospace Applications and Their Properties
	5.5 Natural Resins in Aerospace Applications and Their Properties
	5.6 Natural/Synthetic Hybrid Composites for Aerospace Applications
	5.7 Conclusions, Challenges, and Future Outlook
	References
Chapter 6: Aeroengines: Principles, Components, and Eco-friendly Trends
	6.1 Introduction
	6.2 Brief Historical Overview and Classification of Aeroengines
	6.3 Engine Classification
	6.4 Piston Aeroengines
	6.5 Jet Engines
		6.5.1 Turbojet Engines
		6.5.2 Turbofan Engines
		6.5.3 Turboprop/Turboshaft Engines
	6.6 Benefits of New Materials for Gas Turbine Engines
	6.7 Materials Used in Aero-gas Turbine Engine Components
		6.7.1 Fan Section
		6.7.2 Compressor Section
		6.7.3 Combustor Section
		6.7.4 Turbine Section
		6.7.5 Shaft
	6.8 Eco-friendly Aeroengines
		6.8.1 Environmental Impacts of Aeroengine Materials
	References
Chapter 7: Landing Gear Systems in Aircraft
	7.1 Introduction
		7.1.1 Landing Gear Layouts
	7.2 Fixed and Retractable Landing Gears
	7.3 Struts
		7.3.1 Spring Steel Struts
		7.3.2 Rigid Struts
		7.3.3 Bungee Cord
		7.3.4 Shock Struts
	7.4 Wheels
	7.5 Braking Systems
	7.6 Tires
		7.6.1 Type Classification
		7.6.2 Ply Rating
		7.6.3 Tubeless/Tubed
		7.6.4 Bias Ply or Radial
	7.7 Components of Tire
	7.8 Extend: Retract System and Controls
	7.9 Nose Wheel Steering Mechanism
	7.10 Tail Skid
	References
Chapter 8: Manufacturing and Maintenance Operations for Bladder-Type Aircraft Fuel Tanks
	8.1 Introduction
	8.2 Aircraft Fuel System
		8.2.1 Aircraft Fuel System Component Requirements
	8.3 Aircraft Fuel Tanks
		8.3.1 Discrete Tanks
		8.3.2 Integral Tanks (Wet Wing)
		8.3.3 Bladder Tanks
	8.4 The Specifications of the Aircraft Fuel Tanks
		8.4.1 The Safety Precautions of the Fuel Tanks
		8.4.2 Crashworthiness Feature
		8.4.3 Self-Sealing Feature
		8.4.4 Anti-Slosh Feature
		8.4.5 Freeform Feature
		8.4.6 Collapsibility/Foldability Feature
		8.4.7 Lightweight Feature
	8.5 Manufacturing Process of Bladder-Type Aircraft Fuel Tank
		8.5.1 Material Requirement List—MRL
			Materials
			Consumables
			Tools and Devices
			Test Equipment
		8.5.2 Manufacturing Steps of an Ultra/Light Aircraft Bladder Fuel Tank
			Test and Control Procedures
	8.6 Maintenance, Repair, and Overhaul (MRO) of the Bladder-Type Fuel
		8.6.1 Unscheduled Maintenance Operations
		8.6.2 Scheduled Maintenance Operations
		8.6.3 MRO Operations of Bladder Fuel Tanks
			Visual Control
			Removal Operations
			Back-Shop Inspection
			Repair Operations
	8.7 Conclusions
	References
Chapter 9: Structural Health Monitoring Method for In Situ Inspection of Landing Gears
	9.1 Introduction
	9.2 Experimental and Numerical Method
		9.2.1 Experimental Method
		9.2.2 Numerical Method
			Stiffness/Compliance Matrix
			Piezoelectric Charge Constants
			Dielectric Constants
			Density
			Modulus of Elasticity of Samples with Piezoelectric Sensor Added at Varying Temperatures
			Damping Ratio
			Damage Metrics
	9.3 Experimental and Numerical Results
		9.3.1 Experimental Results
		9.3.2 Numerical Results
		9.3.3 Experimental/Numerical Results in Terms of Damage Metrics (Compensated and Non-compensated)
	9.4 Conclusions
	References
Chapter 10: Major Units and Systems in Aircraft
	10.1 Introduction
	10.2 Auxiliary Power Unit (APU)
		10.2.1 The Flow Mechanism of the APU
	10.3 Environmental Control System (ECS)
	10.4 Black Box (Flight Data Recorder (FDR) and Cockpit Voice Recorder (CVR)
		10.4.1 The Flight Data Recorder (FDR)
		10.4.2 The Cockpit Voice Recorder (CVR)
	10.5 Autopilot System
		10.5.1 Autoland System
		10.5.2 Instrument Landing System (ILS)
	10.6 Conclusions
	References
Chapter 11: Vibration-Assisted Machining of Aerospace Materials
	11.1 Introduction
	11.2 Classification of Vibration-Assisted Machining Systems
		11.2.1 One-Dimensional UVAM (1D UVAM) Method
		11.2.2 Two-Dimensional UVAM (2D UVAM) Method
		11.2.3 Three-Dimensional UVAM (3D UVAM) Methods
		11.2.4 Differences Between Different Vibration-Assisted Methods
	11.3 Kinematics of Vibration-Assisted Machining
	11.4 Machining Characteristics of Vibration-Assisted Machining
		11.4.1 Surface Roughness
		11.4.2 Tool Life
		11.4.3 Cutting Forces
		11.4.4 Other Benefits and Limitations of VAM
	11.5 Case Study (Longitudinal Vibrated Ultrasonic-Assisted Milling of Ti-6Al-4V)
		11.5.1 Introduction
		11.5.2 Material and Method
		11.5.3 Results
		11.5.4 Discussion
	11.6 Conclusions
	11.7 Future Studies
	References
Chapter 12: Potential of Incremental Forming Techniques for Aerospace Applications
	12.1 Definition of Incremental Forming Processes
	12.2 Incremental Forming Machinery
	12.3 Incremental Forming: Materials and Process Limitations
	12.4 Incremental Forming for Low Batches or Prototypes
	12.5 Combing ISF with Welding Techniques
	12.6 Incremental Forming as Rapid Tooling
	12.7 Future Directions in Aerospace Industry
	References
Chapter 13: Welding of Dissimilar Materials in Aerospace Systems
	13.1 Introduction
	13.2 Dissimilar Liquid State Welding for Aerospace Systems
		13.2.1 Dissimilar GMAW in Aerospace Systems
		13.2.2 Dissimilar GTAW in Aerospace Systems
		13.2.3 Dissimilar Flash Welding in Aerospace Systems
		13.2.4 Dissimilar Laser Welding in Aerospace Systems
		13.2.5 Dissimilar Electron Beam Welding in Aerospace Systems
			Electron Beam Braze Welding
	13.3 Dissimilar Solid-State Welding for Aerospace Systems
		13.3.1 Dissimilar Microwave Welding in Aerospace Systems
		13.3.2 Dissimilar Magnetic Pulse Welding in Aerospace Systems
		13.3.3 Dissimilar Explosion Welding in Aerospace Systems
		13.3.4 Dissimilar Forge Welding in Aerospace Systems
		13.3.5 Dissimilar Ultrasonic Welding in Aerospace Systems
		13.3.6 Dissimilar Brazing in Aerospace Systems
			Filler Materials
			Vacuum Brazing
			Dissimilar Brazing of Al-base Alloys
			Dissimilar Brazing of Titanium-Base Alloys
			Dissimilar Brazing of Beryllium-Base Alloys
			Dissimilar Brazing of Ti–Al IMCs
		13.3.7 Dissimilar Diffusion Bonding in Aerospace Systems
			Diffusion Welding of Al-Base Alloys
		13.3.8 Dissimilar Friction Welding in Aerospace Systems
			Friction Surfacing
			Dissimilar Friction Stir Welding in Aerospace Systems
				Dissimilar Friction Stir Welding of Al and Mg Alloys
				Aircraft Fuselages and Wings in Europe
				Dissimilar FSW of Aluminum Alloys
				FSW of 2xxx–7xxx Series Aluminum Alloys
				FSW of the 6xxx–7xxx Series Aluminum Alloys
			Dissimilar Inertia Friction Welding in Aerospace Systems
			Dissimilar Linear Friction Welding in Aerospace Systems
	13.4 Dissimilar Bolt Fastening in Aerospace Systems
	13.5 Dissimilar Welding of Aluminum Alloys in Aerospace Systems
	13.6 Dissimilar Welding of Composites in Aerospace Systems
	13.7 Dissimilar Welding of Plastics in Aerospace Systems
	13.8 Summary
	13.9 Conclusions
	References
Chapter 14: Design, Analysis, and Production of Lattice Structures Through Powder Bed Fusion Additive Manufacturing
	14.1 Introduction
	14.2 Design and Analysis of Lattice Structures
		14.2.1 Background and Development
		14.2.2 Types and Characteristics of Lattice Structures
		14.2.3 Design and Analysis
	14.3 Production of Lattice Structures
	14.4 Applications of Lattice Structures
	14.5 Summary and Conclusions
	References
Chapter 15: Application of Wire Arc Additive Manufacturing for Inconel 718 Superalloy
	15.1 Introduction
	15.2 Experimental Procedures
		15.2.1 Raw Materials
		15.2.2 Experimental Setup
		15.2.3 Process Parameters and Test Conditions
		15.2.4 The Modified Heat Treatment and Characterization
		15.2.5 Oxidation Study and Oxide Layer Analysis
	15.3 Results and Discussion
		15.3.1 Raw Materials Characterization
		15.3.2 Effects of Welding Process Parameters
			Heat Input and Deposition Rate
			Bead Geometry
			As-Fabricated Macro- and Microstructural Evolution
			Mechanical Properties
		15.3.3 Effects of Heat Treatment on Microstructure and Mechanical Properties
		15.3.4 High-Temperature Oxidation Performance of WAAM IN718 Alloys
	15.4 Conclusions
	References
Index