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Title: Application of Abrasive-Waterjets for Machining Fatigue-Critical Aircraft Aluminum Parts

Abstract

Current specifications require AWJ-cut aluminum parts for fatigue critical aerospace structures to go through subsequent processing due to concerns of degradation in fatigue performance. The requirement of secondary process for AWJ-machined parts greatly negates the cost effectiveness of waterjet technology. Some cost savings are envisioned if it can be shown that AWJ net cut parts have comparable durability properties as those conventionally machined. To revisit and upgrade the specifications for AWJ machining of aircraft aluminum, “Dog-bone” specimens, with and without secondary processes, were prepared for independent fatigue tests at Boeing and Pacific Northwest National Laboratory (PNNL). Test results show that the fatigue life is proportional to quality levels of machined edges or inversely proportional to the surface roughness Ra . Even at highest quality level, the average fatigue life of AWJ-machined parts is about 30% shorter than those of conventionally machined counterparts. Between two secondary processes, dry-grit blasting with aluminum oxide abrasives until the striation is removed visually yields excellent result. It actually prolongs the fatigue life of parts at least three times higher than that achievable with conventional machining. Dry-grit blasting is relatively simple and inexpensive to administrate and, equally important, alleviates the concerns of garnet embedment.

Authors:
; ; ;
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
989441
Report Number(s):
PNNL-SA-66161
TRN: US201019%%493
DOE Contract Number:  
AC05-76RL01830
Resource Type:
Conference
Resource Relation:
Conference: ASME 2009 Pressure Vessels and Piping Conference (PVP2009) , Paper No. PVP2009-77003
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ABRASIVES; AIRCRAFT; ALUMINIUM; CONTAMINATION; EXPLOSIVE FRACTURING; INDUCTION; MACHINING; OXIDES; PERFORMANCE; PRESSURE VESSELS; REMOVAL; ROUGHNESS; STRESSES; STRIATIONS; waterjet; aluminum; fatigue

Citation Formats

Liu, H T, Hovanski, Yuri, Dahl, Michael E, and Zeng, J. Application of Abrasive-Waterjets for Machining Fatigue-Critical Aircraft Aluminum Parts. United States: N. p., 2010. Web. doi:10.1115/PVP2009-77003.
Liu, H T, Hovanski, Yuri, Dahl, Michael E, & Zeng, J. Application of Abrasive-Waterjets for Machining Fatigue-Critical Aircraft Aluminum Parts. United States. doi:10.1115/PVP2009-77003.
Liu, H T, Hovanski, Yuri, Dahl, Michael E, and Zeng, J. Thu . "Application of Abrasive-Waterjets for Machining Fatigue-Critical Aircraft Aluminum Parts". United States. doi:10.1115/PVP2009-77003.
@article{osti_989441,
title = {Application of Abrasive-Waterjets for Machining Fatigue-Critical Aircraft Aluminum Parts},
author = {Liu, H T and Hovanski, Yuri and Dahl, Michael E and Zeng, J},
abstractNote = {Current specifications require AWJ-cut aluminum parts for fatigue critical aerospace structures to go through subsequent processing due to concerns of degradation in fatigue performance. The requirement of secondary process for AWJ-machined parts greatly negates the cost effectiveness of waterjet technology. Some cost savings are envisioned if it can be shown that AWJ net cut parts have comparable durability properties as those conventionally machined. To revisit and upgrade the specifications for AWJ machining of aircraft aluminum, “Dog-bone” specimens, with and without secondary processes, were prepared for independent fatigue tests at Boeing and Pacific Northwest National Laboratory (PNNL). Test results show that the fatigue life is proportional to quality levels of machined edges or inversely proportional to the surface roughness Ra . Even at highest quality level, the average fatigue life of AWJ-machined parts is about 30% shorter than those of conventionally machined counterparts. Between two secondary processes, dry-grit blasting with aluminum oxide abrasives until the striation is removed visually yields excellent result. It actually prolongs the fatigue life of parts at least three times higher than that achievable with conventional machining. Dry-grit blasting is relatively simple and inexpensive to administrate and, equally important, alleviates the concerns of garnet embedment.},
doi = {10.1115/PVP2009-77003},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Aug 19 00:00:00 EDT 2010},
month = {Thu Aug 19 00:00:00 EDT 2010}
}

Conference:
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