Integration Of Strength and Process Modelling of Friction-Stir-Welded Fuselage Panels

In order to reduce potential uncertainties and conservatism in welded panel analysis procedures, understanding of the relationships between welding process parameters and static strength is required. The aim of this study is to determine and characterize the key process induced properties of advanced welding assembly methods on stiffened panel local buckling and collapse performance. To this end, an in-depth experimental and computational study of the static strength of a friction stir welded fuselage skin-stiffener panel subjected to compression loading has been undertaken. Four welding process effects, viz. the weld joint width, the width of the weld Heat Affected Zone, the strength of material within the weld Heat Affected Zone and the magnitude of welding induced residual stress, are investigated. A fractional factorial experiment design method (Taguchi) has been applied to identify the relative importance of each welding process effect and investigate effect interactions on both local skin buckling and crippling collapse performance. For the identified dominant welding process effects, parametric studies have been undertaken to identify critical welding process effect magnitudes and boundaries. The studies have shown that local skin buckling is principally influenced by the magnitude of welding induced residual stress and that the strength of material in the Heat Affected Zone and the magnitude of the welding induced residual stress have the greatest influence on crippling collapse behavior.


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Modified stiffened panel analysis methods for laser beam and friction stir welded aircraft panels

The introduction of advanced welding methods as an alternative joining process to riveting in the manufacture of primary aircraft structure has the potential to realize reductions in both manufacturing costs and structural weight. Current design and analysis methods for aircraft panels have been developed and validated for riveted fabrication. For welded panels, considering the buckling collapse design philosophy of aircraft stiffened panels, strength prediction methods considering welding process effects for both local-buckling and post-buckling behaviours must be developed and validated. This article reports on the work undertaken to develop analysis methods for the crippling failure of stiffened panels fabricated using laser beam and friction stir welding. The work assesses modifications to conventional analysis methods and finite-element analysis methods for strength prediction. The analysis work is validated experimentally with welded single stiffener crippling specimens. The experimental programme has demonstrated the potential static strength of laser beam and friction stir welded sheet-stiffener joints for post-buckling panel applications. The work undertaken has demonstrated that the crippling behaviour of welded stiffened panels may be analysed considering standard-buckling behaviour. However, stiffened panel buckling analysis procedures must be altered to account for the weld joint geometry and process altered material properties. © IMechE 2006.

Plane wave and Coulomb asymptotics

A simple plane wave solution of the Schrodinger-Helmholtz equation is a quantum eigenfunction obeying both energy and linear momentum correspondence principles. Inclusion of the outgoing wave with scattering amplitude f asymptotic development of the plane wave, we show that there is a problem with angular momentum when we consider forward scattering at the point of closest approach and at large impact parameter given semiclassically by (l + 1/2)/k where l is the azimuthal quantum number and may be large (J. Leech et al., Phys. Rev. Lett. 88. 257901 (2002)). The problem is resolved via non- uniform, non-standard analysis involving the Heaviside step function, unifying classical, semiclassical and quantum mechanics, and the treatment is extended to the case of pure Coulomb scattering.

The Characterization of Friction Stir Welding Process Effects on Stiffened Panel Buckling Performance

The introduction of advanced welding methods as an alternative joining process to riveting in the manufacture of primary aircraft structure has the potential to realize reductions in both manufacturing costs and structural weight. However, welding processes can introduce undesirable residual stresses and distortions in the final fabricated components, as well as localized loss of mechanical properties at the weld joints. The aim of this research is to determine and characterize the key process effects of advanced welding assembly methods on stiffened panel static strength performance. This in-depth understanding of the relationships between welding process effects and buckling and collapse strength is required to achieve manufacturing cost reductions without introducing structural analysis uncertainties and hence conservative over designed welded panels. This current work is focused at the sub-component level and examines the static strength of friction stir welded multi stiffener panels. The undertaken experimental and computational studies have demonstrated that local skin buckling is predominantly influenced by the magnitude of welding induced residual stresses and associated geometric distortions, whereas panel collapse behavior is sensitive to the lateral width of the physically joined skin and stiffener flange material, the strength of material in the Heat Affected Zone as well as the magnitude of the welding induced residual stresses. Copyright © 2006 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.


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Measurement of Polymer-to-Polymer Contact Friction in Thermoforming

Contact friction plays a critical role in all the major thermoforming processes for polymers. However, these effects are very difficult to measure in practice and, as a result, have received little scientific investigation. In this work, two independently developed test methods for the measurement of elevated temperature polymer-to-polymer contact friction are presented, and their results are compared in detail for the first time. One is based on a modified moving sled friction test, whereas the other uses a rotational rheometer. In each case, friction tests were conducted between two plug and two sheet materials. The results show that broadly similar coefficients of friction were obtained from the two test methods. The measured values were quite low (<0.3) at lower temperatures and typically were higher for polypropylene (PP) sheet than for polystyrene (PS). On approaching the glass transition temperature for PS (95°C) and the crystalline melting point for PP (165°C), the friction coefficients rose very sharply, and both test techniques became increasingly unreliable. It was concluded that despite their physical differences, both test techniques were able to capture the highly temperature sensitive nature of friction between polymer materials used in thermoforming.

Strong-field approximation for Coulomb explosion of H-2(+) and D-2(+) by short intense laser pulses

We present a simple quantum mechanical model to describe Coulomb explosion of H-2(+) and D-2(+) by short, intense infrared laser pulses. The model is based on the length gauge version of the molecular strong-field approximation and is valid when the process of dissociation prior to ionization is negligible. The results are compared with recent experimental data for the proton kinetic energy spectrum [Th. Ergler , Phys. Rev. Lett. 95, 093001 (2005); D. S. Murphy , J. Phys. B 40, S359 (2007)]. Using a Franck-Condon distribution over initial vibrational states, the theory reproduces the overall shape of the spectrum with only a small overestimation of slow protons. The agreement between theory and experiment can be made perfect by using a non-Frank-Condon initial distribution characteristic for H-2(+) (D-2(+)) targets produced by strong-field ionization of H-2 (D-2). For comparison, we also present results obtained by two different tunneling models for this process.

Ramsey interferometry with a spin embedded in a Coulomb chain

We show that the statistical properties of a Coulomb crystal can be measured by means of a standard interferometric procedure performed on the spin of one ion in the chain. The ion spin, constituted by two internal levels of the ion, couples to the crystal modes via spatial displacement induced by photon absorption. The loss of contrast in the interferometric signal allows one to measure the autocorrelation function of the crystal observables. Close to the critical point, where the chain undergoes a second-order phase transition to a zigzag structure, the signal gives the behavior of the correlation function at the critical point.

The Influence of Friction Stir Welding Process Idealization on Residual Stress and Distortion Predictions for Future Airframe Assembly Simulations

The ability to accurately predict residual stresses and resultant distortions is a key product from process assembly simulations. Assembly processes necessarily consider large structural components potentially making simulations computationally expensive. The objective herein is to develop greater understanding of the influence of friction stir welding process idealization on the prediction of residual stress and distortion and thus determine the minimum required modeling fidelity for future airframe assembly simulations. The combined computational and experimental results highlight the importance of accurately representing the welding forging force and process speed. In addition, the results emphasize that increased CPU simulation times are associated with representing the tool torque, while there is potentially only local increase in prediction fidelity.