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Experimental Analysis of Aluminium Alloys For Aerospace Applications
Experimental Analysis of Aluminium Alloys For Aerospace Applications
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Abstract - Manufacturing of any object in the aerospace 2. Experimental materials and methods
components that to particularly through forming process is to This research has considered aluminum alloys to
achieve the product superiority characteristics and study the effects of added alloys on mechanical properties of
mechanical properties with process cost and time, Aluminium the material. Pure aluminum is a weak and ductile material,
alloys with light weight and high performance characteristics but by adding small % of impurities in aluminum its tensile
are important materials for aerospace applications. The strength as well as hardness increased considerably and
mechanical properties of different Aluminium alloys such as many researchers are focusing on Al alloys of 6000, 7000
AA6061, AA7075 were evaluated and tensile test was series due to its application in aerospace, automobile and
performed under annealed condition and these alloys have construction industry. The chemical compositions of two
excellent corrosion resistance and machining properties. In Aluminium alloys considered for this research have been
this project we have done that the hardness test, shown in below tables
Microstructure study and mechanical properties such as
Ultimate tensile strength, Yield strength, and % of elongation The specimens are manufactured as per the ASTM
as well as % of reduction at fracture are performed by standards by sectioning, mounting, grinding and polishing.
experimentally and then these results were compared with Once the specimen are prepared then the chemical
theoretical as well as COSMOS works analysis tool. From the composition of the specimens was determined by
results of AA6061, AA7075 it is observed that the magnesium spectrographic analyzer and then hardness test was done by
content in AA7075 is slightly high as compared to other two using Brinell hardness test machine and then tensile test was
alloys hence the AA7075 has more strength as well as high performed by using universal testing machine.
tensile strength and yield strength than the other two alloys. The tensile test is used to determine the tensile strength
for a material and also measure the percentage of elongation
Key Words: Maximum Tensile strength, Maximum Yield at the fracture. During the test a single axis stress state has
strength, % of Elongation, % of Reduction in Area generated by applying an external load to the specimen in a
longitudinal direction. This results in a uniform normal
distribution of stress across the test cross-section of the
specimen. The load on the specimen is increased slowly and
1. INTRODUCTION continuously by turning the hand wheel until it breaks. The
The mechanical properties of metals and its alloys resulting maximum test force is a measure of the material’s
can be improved by a combination of metallurgical, strength called ultimate tensile strength in N/mm2 is
manufacturing and design measures, which increase the calculated from the maximum test force in N, determined
reliability and service life of the component manufactured. from the force-elongation diagram and the initial cross-
Due to good physical and mechanical properties of section A0 of the specimen in mm2. The elongation at
aluminum and its chemical composition imparts this widely fracture is the ratio of the change in length of the specimen
used metal after the steel. Aluminum and its alloys have high to its original length Lo and is calculated by measuring the
strength-to-weight ratio and other desirable properties like length Lu of the specimen after fracture. After fracture, the
non-toxic, non-magnetic, high thermal and electrical two ends of the specimen are placed together cleanly at the
conductivities, high corrosion resistance and easy to fracture point and the distance between the two measuring
fabricate. By addition of alloys like silicon, magnesium, iron marks has been measured. The result of tensile test has been
and manganese improve its mechanical properties and its represented in a stress-elongation diagram. From the graph,
strength-to-weight ratio and widely used for aircraft and the ultimate tensile strength, the yielding point and the
space vehicles, construction and building materials, and fracture strength, percentage of elongation as well as
electrical transmission lines and the alloys which are used percentage of reduction can be calculated and noted in the
for aerospace applications are 6061, 7075 aluminium alloys Table. Specimens of each material have been tested at room
and the main objective of this research is to investigate the temperature on Universal Testing Machine (UTM) with
influence of alloying elements on the tensile properties and constant crosshead movement of 2 mm/min for tensile
hardness of aluminum alloys and its significance on the strength of the material. An extensometer has been used to
microstructure of the aluminum alloy. This study also calibrate and measure the sample strain upon loading.
focuses the impact of dimensions of the specimen on the Tensile tests were performed at room temperature on 12
strength and ductility of the alloy. mm diameter cylindrical specimen with a gauge length of 60
mm for AA 6061 alloy specimen and the dimensions are
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3930
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
reduced that is gauge diameter 8 mm and length 70 mm for tensile strength of the materials on Universal Testing
6061 alloy and for 7071 Aluminium alloy the initial gauge Machine (UTM) of 20 KN capacity at across head speed of 2
length is 60 mm and diameter is 12 mm and after the tensile mm/min, from which the load deflection curve obtained for
test the dimensions are reduced to final gauge length of 66 each specimen. The mechanical behavior of each specimen
mm and diameter is 11.1mm has been determined from tensile test and data were
generated during the test like applied load, elongation, stress
and % elongation in table and the graphs and curves have
been plotted for each specimen by continuous application of
load until fracture.
3.2 Hardness test The load versus displacement graph is shown below
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3931
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
113.0
4 3.0 12 35.38 5.000
4
113.0
8 3.9 12 70.77 6.500
4
113.0
12 5.0 12 106.15 8.333
4
113.0
16 5.9 12 141.54 9.833
4
113.0
3.5 Calculation results 20 6.3 12
4
176.92 10.500
= 55.56 %
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3932
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
= 14.40 %
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3933
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
Initial %Elongation
Load (P) Elongation Stress
Diameter (D0) mm area
KN (e) mm N/mm2
mm2
Elements Si Fe Cu Mn Mg Cr Ni Zn
Elements Na P Pb Sb Sn Sr V Al
Composition 0.00063 0.00075 0.00138 0.00001 0.00328 0.00001 0.00315 98.00261
(%)
Elements Si Fe Cu Mn Mg Cr Ni Zn
Elements Na P Pb Sb Sn Sr V Al
Composition 0.00001 0.00116 0.00114 0.00173 0.00147 0.00001 0.00772 89.96287
(%)
Force (F) = 20 T = 20000 9.81
5. COSMOS Work
In COSMOS Work analysis tool a hydraulic cylinder which = 196200 N
is used in landing gears of airplanes was designed and the
hydraulic cylinder was designed by using 7075 Aluminium Area (A) = = = 7850 mm2
alloy and the dimensions are used according to the
aerospace standards
d = 100 mm Pressure (P) = = = 25 N/mm2
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3934
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
= = = 250 N/mm2
Longitudinal stress = =
= 125 N/mm2
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3935
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
6 References
1) G.E. Dieter, Engineering Design: A materials and
Processing Approach, 2nd Edition McGraw-Hill
Books Company, Japan, 1988, P-315.
2) I.J. Polmear, Light Alloys, Metallurgy of the Light
Metals, 2nd edition, Arnold, London, 1980.
3) K. Matsuda, Y. Sakaguchi, Y. Miyata, Y. Uetani, T.
Sato, A. Kamio, S. Ikeno, “Precipitation of various
kinds of metastable phases in Al-1.0 mass% Mg2Si-
0.4 mass% Si alloy”, J. Mater Sci, Vol. 35, 2000, pp.
179-189.
4) Avinash V. Gaikwad, Rajesh U. Sambhe, Pravin S.
Ghawade, Modeling and Analysis of Aircraft Landing
gear: Experimental Approach, International Journal
of Science and Research, 7(2), July 2013, ISSN 2319-
7064.
5) Ajayi J. A, Joseph O. O, Oloruntoba D. T & Joseph O.
O, Experimental failure investigation of an Aircraft
Nose Landing gear, International Journal
Metalurgical & Materials Science and Engineering,
1(3), March 2013, 85-92.
6) Journal papers by Dr vijayan, Durgakumari, sujit
Fig 5 Results kumar jha, D.L. stefan
7) Norman S. Currey, Aircraft landing gear design:
5 Conclusion Principles and practices (AIAA Education Series,
Aluminium hydraulic cylinder is an important 1988).
component of the aircraft system, it plays important role in 8) H. G. Conway, Landing gear design (The royal
the hydraulic system of aircraft for actuating various aeronautical society, Chapman & Hall Ltd, 1958).
components. We have done Experimental analysis and FE 9) Nitin S Gokhale, Sanjay S Deshpande, Sanjeev V
analysis on 6061 and 7075 Aluminium alloys. Bedekar, Anand N Thite, Practical Finite Element
Analysis (Dr Peter Fischer, Finite to Infinite, 2008).
Aluminium Hydraulic cylinder is designed
suspiciously and checked properly to achieve the 10) E. F. Bruhn, Analysis and design of flight vehicle
requirements. As experimental analysis is carried out on structures (S. R. Jacobs & Associates, Inc, 1973)
above material the yield stresses and Factor of safety were
found as the yield strength of 6061 Aluminium alloy is
227.74 N/mm2 and FOS is 0.9 and yield strength of 7075
Aluminium alloy is 488.01 N/mm2 FOS is 1.952. After
comparing the above experimental results 7075 Aluminium
alloy has higher yield and Tensile strength than the
6061Aluminium alloy hence the same material is used in
order to manufacture Aluminium hydraulic cylinder in the
aerospace and the results are found satisfactorily.
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3936
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3937