One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets
A one-step hybrid bending/diffusion bonding process (HB/DBP) was developed for application to Ti-6Al-4V sheets to effectively improve buy-to-fly (BTF) ratio of aircraft parts, integrating sequential diffusion bonding followed by a bending process. The resulting bonding characteristics of these titan...
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2023-06-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/16/13/4516 |
| _version_ | 1797591350556753920 |
|---|---|
| author | Kang Hyun Kim Hyeonil Park Dong Jun Lee Yong Nam Kwon Namhyun Kang Jong-Hwa Hong |
| author_facet | Kang Hyun Kim Hyeonil Park Dong Jun Lee Yong Nam Kwon Namhyun Kang Jong-Hwa Hong |
| author_sort | Kang Hyun Kim |
| collection | DOAJ |
| description | A one-step hybrid bending/diffusion bonding process (HB/DBP) was developed for application to Ti-6Al-4V sheets to effectively improve buy-to-fly (BTF) ratio of aircraft parts, integrating sequential diffusion bonding followed by a bending process. The resulting bonding characteristics of these titanium alloy sheets were analyzed. Microstructural analysis and mechanical lap shear tests were performed to estimate the bonding quality. Additionally, bonding ratio, thickness strain, and shear strength were evaluated in relation to pressure under increasing temperature. When the applied pressure was lower than 0.5 MPa, early failure occurred at the joint of the specimens. However, when high pressure was applied, early failure occurred near the joint. To discuss the phenomenon, time-dependent viscoplastic material properties were characterized, and a numerical simulation analysis was performed. Viscoplastic deformation was observed around the bending area, which caused weakness around the bond under high-pressure conditions. A prototype of a Y-shaped heat shield was manufactured and the buy-to-fly ratio was effectively improved using the newly developed process. This study demonstrates the potential of applying the developed process for producing aircraft parts and the importance of viscoplastic behavior for the analysis of final product reliability. |
| first_indexed | 2024-03-11T01:36:12Z |
| format | Article |
| id | doaj.art-74f91b5a7a9a42afbe4e5a268cbef9e3 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T01:36:12Z |
| publishDate | 2023-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-74f91b5a7a9a42afbe4e5a268cbef9e32023-11-18T16:55:52ZengMDPI AGMaterials1996-19442023-06-011613451610.3390/ma16134516One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy SheetsKang Hyun Kim0Hyeonil Park1Dong Jun Lee2Yong Nam Kwon3Namhyun Kang4Jong-Hwa Hong5Aerospace Materials Center, Korea Institute of Materials Science, 797 Changwon-daero, Changwon 51508, Republic of KoreaAerospace Materials Center, Korea Institute of Materials Science, 797 Changwon-daero, Changwon 51508, Republic of KoreaAerospace Materials Center, Korea Institute of Materials Science, 797 Changwon-daero, Changwon 51508, Republic of KoreaAerospace Materials Center, Korea Institute of Materials Science, 797 Changwon-daero, Changwon 51508, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, 2 Busandaehak-ro 63beon-gil, Busan 46241, Republic of KoreaAerospace Materials Center, Korea Institute of Materials Science, 797 Changwon-daero, Changwon 51508, Republic of KoreaA one-step hybrid bending/diffusion bonding process (HB/DBP) was developed for application to Ti-6Al-4V sheets to effectively improve buy-to-fly (BTF) ratio of aircraft parts, integrating sequential diffusion bonding followed by a bending process. The resulting bonding characteristics of these titanium alloy sheets were analyzed. Microstructural analysis and mechanical lap shear tests were performed to estimate the bonding quality. Additionally, bonding ratio, thickness strain, and shear strength were evaluated in relation to pressure under increasing temperature. When the applied pressure was lower than 0.5 MPa, early failure occurred at the joint of the specimens. However, when high pressure was applied, early failure occurred near the joint. To discuss the phenomenon, time-dependent viscoplastic material properties were characterized, and a numerical simulation analysis was performed. Viscoplastic deformation was observed around the bending area, which caused weakness around the bond under high-pressure conditions. A prototype of a Y-shaped heat shield was manufactured and the buy-to-fly ratio was effectively improved using the newly developed process. This study demonstrates the potential of applying the developed process for producing aircraft parts and the importance of viscoplastic behavior for the analysis of final product reliability.https://www.mdpi.com/1996-1944/16/13/4516one-step hybrid bending/diffusion bonding processtitanium alloy sheetsnumerical simulationviscoplasticityaircraft parts |
| spellingShingle | Kang Hyun Kim Hyeonil Park Dong Jun Lee Yong Nam Kwon Namhyun Kang Jong-Hwa Hong One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets Materials one-step hybrid bending/diffusion bonding process titanium alloy sheets numerical simulation viscoplasticity aircraft parts |
| title | One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets |
| title_full | One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets |
| title_fullStr | One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets |
| title_full_unstemmed | One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets |
| title_short | One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets |
| title_sort | one step hybrid bending diffusion bonding process and analysis of the bonding characteristics of titanium alloy sheets |
| topic | one-step hybrid bending/diffusion bonding process titanium alloy sheets numerical simulation viscoplasticity aircraft parts |
| url | https://www.mdpi.com/1996-1944/16/13/4516 |
| work_keys_str_mv | AT kanghyunkim onestephybridbendingdiffusionbondingprocessandanalysisofthebondingcharacteristicsoftitaniumalloysheets AT hyeonilpark onestephybridbendingdiffusionbondingprocessandanalysisofthebondingcharacteristicsoftitaniumalloysheets AT dongjunlee onestephybridbendingdiffusionbondingprocessandanalysisofthebondingcharacteristicsoftitaniumalloysheets AT yongnamkwon onestephybridbendingdiffusionbondingprocessandanalysisofthebondingcharacteristicsoftitaniumalloysheets AT namhyunkang onestephybridbendingdiffusionbondingprocessandanalysisofthebondingcharacteristicsoftitaniumalloysheets AT jonghwahong onestephybridbendingdiffusionbondingprocessandanalysisofthebondingcharacteristicsoftitaniumalloysheets |