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Aerospace Materials and Material Technologies : Volume 1: Aerospace Materials PDF

594 Pages·2017·15.89 MB·English
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Indian Institute of Metals Series N. Eswara Prasad R. J. H. Wanhill Editors Aerospace Materials and Material Technologies Volume 1: Aerospace Materials Metallurgy Materials Engineering Indian Institute of Metals Series Editors-in-chief Baldev Raj, National Institute of Advanced Studies, Bengaluru, Karnataka, India U. Kamachi Mudali, Indira Gandhi Centre for Atomic Research, Kalpakkam, Tamil Nadu, India More information about this series at http://www.springer.com/series/15453 N. Eswara Prasad R.J.H. Wanhill (cid:129) Editors Aerospace Materials and Material Technologies Volume 1: Aerospace Materials 123 Editors N.EswaraPrasad R.J.H.Wanhill Defence Materials andStores R&D Emmeloord, Flevoland Establishment(DMSRDE) TheNetherlands Kanpur,Uttar Pradesh India ISSN 2509-6400 ISSN 2509-6419 (electronic) Indian Institute of Metals Series ISBN978-981-10-2133-6 ISBN978-981-10-2134-3 (eBook) DOI 10.1007/978-981-10-2134-3 LibraryofCongressControlNumber:2016948239 ©SpringerScience+BusinessMediaSingapore2017 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor foranyerrorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerNatureSingaporePteLtd. Theregisteredcompanyaddressis:152BeachRoad,#22-06/08GatewayEast,Singapore189721,Singapore To our eminent teachers and close associates for aerospace materials and material technologies; and to our partners and families for their support, notably during 2014–2016, the years in which these books were prepared. N. Eswara Prasad and R.J.H. Wanhill Foreword by Prof. Dipankar Banerjee If the world has shrunk rapidly in recent centuries, thishasbeeninnosmallmeasureduetotheimpactof materials on aerospace transport. The specific fuel consumptionofcommercialaircrafthas,forexample, decreased by an astonishing 70 % using the De Havilland Comet as baseline. The reliability of their propulsion systems allows long-haul flights that encircle the globe, travelling non-stop for 15–20 h. Wehavemasteredspace,withfootstepsonthemoon and images and analysis of the Martian terrain. The international space station has been continuously occupied since 2000. While it is hard to dissect and breakdowncontributionsofanyspecificengineeringdisciplinetothesespectacular achievements, surely materials have played a significant enabling role, whether fromthe‘fine-tuning’oftraditionalmetallicmaterials,orthedevelopmentofnewer composites and speciality materials including functional coatings. The integration of stealth materials into aerospace structures has added an extra dimension to militaryaerospacevehicles.Theemergenceofseveralhightemperaturemonolithic and compositeceramic materials based on carbon andsilicon carbidematrices and reinforcements has resulted in vastly improved material capabilities for high tem- perature aerospace applications. Several new refractory materials are finding ultrahightemperatureapplicationsas2000K+materials,especiallyforreusableand re-entry hypersonic vehicles. Aviation accounts for about 3 % of global energy consumption, and the growth of energy use by the aviation sector exceeds that of othertransportationsectors.Aircraftemissions,whicharecurrentlyunregulated,are about60%intheuppertroposphereand20%inthestratosphere.Theindustrywill demand further materials-enabled improvements to address these challenges. It is encouraging that the present volume on aerospace materials for the two-volume source book series of IIM/Springer Publication provides concise overviews of all the above. Development, physical metallurgy, processing, vii viii ForewordbyProf.DipankarBanerjee properties and applications of each of nearly 26 categories of aerospace materials have been covered. Dr. N. Eswara Prasad has been my close associate and colleague and has accumulated much experience and expertise with aerospace materials over the last 30years.Iamhappythathehasacceptedthemajorresponsibilityimposedonhim by the Indian Institute of Metals (IIM), and the architect of its book series Dr. Baldev Raj, to co-author and co-edit with Dr. R.J.H. Wanhill (an international expert in the field of aerospace materials and technologies) the contents of these volumes. I am sure their readers will find them extremely useful, and the two-volume series will serve as a ready reference for engineering students, prac- ticing engineers and aerospace structural designers. Itakethisopportunitytocongratulatealltheauthorsandeditors—Dr.N.Eswara Prasad, Dr. R.J.H. Wanhill and Dr. Baldev Raj, Editor-in-Chief, and Springer on the successful completion of this mammoth endeavour. This kind of international book project also serves as a road map for the future. We are reminded that materials development and translation into engineering practice is still a long and arduous task, with significant reliance on trial and error approaches. As a com- munity we are now engaged in the task of redefining the processes of materials insertion into engineering products through integration of multiscale modelling, data analytics and materials informatics, uncertainty quantification and multi-objective optimisation into thematerials designeffort.Ihopefuturevolumes in this series will capture also these dramatic advances as the field matures. Prof. Dipankar Banerjee FASc, FNA, FNAE, FNASc Former Director, Defence Metallurgical Research Laboratory Hyderabad, India Former Chief Controller R&D (Aeronautics & Materials Science) DRDO, New Delhi, India Former President, Indian Institute of Metals (IIM) Former President, Electron Microscopy Society (EMS) and Presently Professor, Department of Materials Engineering Indian Institute of Science, Bengaluru, 560 012, India Foreword by Prof. Indranil Manna Advancements in aerospace systems, materials and technologies in the last century are both voluminous and phenomenal. Several countries in both the developed and developing world have become prin- cipal players in developing aeronautical materials, thereby earning the credit for the advancement of aerospace systems including civil and military air- craft, helicopters, airborne surveillance systems, unmanned aerospace vehicles, guided missiles, supersonic re-entry vehicles and satellites. All these systems require advanced materials and cutting-edge material processing technologies. Hence synthesis, processing, characterisation and testing of materials form the basis for the devel- opment and realization of aerospace components, sub-systems and systems. It is a well-recognized fact that aerospace engineering is principally responsible for developing several critical technologies that include (i) design and development of advanced materials, components and sub-systems; (ii) aeronautical material speci- fications and standards for materials and testing; (iii) characterisation and testing methodologies; and (iv) life estimations and predictions based on fatigue and fracture mechanics principles. In addition, aerospace engineering has advanced several other critical technologies such as propulsion, aeroengines, electronics, communication and guidance. There are a number of text books and monographs on aerospace materials and related technologies. As well, several ASTM standards, metals handbooks and special volumes have compiled scientific and design data on various aerospace materialsthatareusedbyaerospaceengineersfordesigningstructuresandsystems. Such efforts have invariably brought out the latest information and also shown directions for future materials and systems developments. However, supplemental documentation on recent advances in core domain and interdisciplinary areas is always needed. ix x ForewordbyProf.IndranilManna In this respect, the present two-volume book set is a carefully thought out compilation of overview articles on materials (both established and evolving) and materialtechnologiesthatareimportantforaerospacesystems.Volume1considers aerospace materials in three Parts. Part I covers Metallic Materials (Mg, Al, Al-Li, Ti, Aero steels, Ni, Intermetallics, Bronzes and Nb alloys); Part II deals with Composites (GLARE, PMCs, CMCs and Carbon based CMCs); and Part III con- siders SpecialMaterials. Thiscompilation hasensuredthatnoimportantaerospace material system is ignored. Emphasis has been placed in each book chapter on the underlining scientific principles as well as basic and fundamental mechanisms leading to processing, characterisation/property evaluation and applications. Each chapter ends with a bibliography of several reference works, followed by standard setsofreferencesappearinginthechapter.Aconsiderableamountofmaterialsdata is compiled and presented in appendices at the end of each volume. Isincerelywishthatthesevolumeswillserveasreadyandusefulreferencesand source ofrelevant information for manyaspectsofaerospacematerials,processing technologies, and component and structural designs. Prof. Indranil Manna FTWAS, FNA, FNAE, FASc., FNASc., FIIM, FIE Professor, Department of Metallurgical and Materials Engineering IIT, Kharagpur, India (On Lien) Former Director, CSIR—Central Glass and Ceramic Research Institute (CGCRI), Kolkata India Vice-President, Indian Institute of Metals and Indian National Academy of Engineering Presently, Director, Indian Institute of Technology Kanpur, India

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