Report
Teaser, summary, work performed and final results
Periodic Reporting for period 1 - ASTRASY (Avantis STructural Rod Adjustment SYstem)
Teaser
Call for project: three high loaded rods are used in innovative Body Landing Gear development. However, there are no lightweight and low RC adjustable connecting-rods for high loaded configuration available on the market.Important for society:To date, there is no industrial...
Summary
Call for project: three high loaded rods are used in innovative Body Landing Gear development. However, there are no lightweight and low RC adjustable connecting-rods for high loaded configuration available on the market.
Important for society:
To date, there is no industrial and reproducible process for junction between aluminum and titanium.
The ASTRASY project is investigating a promising process for this type of junction.
Overall objectives:
Development of three different high loaded adjustable rods up to TRL4.
Simplify rod installation and reduce the time of assembly.
Develop solution compatible with a high rate of aircrafts production.
Manufacture a scale 1 demonstrator.
Final weight ≤ 1.2 x weight of reference rod (to be provide by the Topic leader).
Work performed
1- The ASTRASY project concepts needed to be compared. To do this, reference rods were designed, calculated and weight and cost optimized.
2- Design, stress and weight/cost optimization of ASTRASY project concept for each rod configuration.
3- According to the answer (need to assemble titanium and aluminum), a lot of test of Friction Stir Welding bi-material aluminum/titanium were performed.
- FSW overlap joint AA 2024-T3/ TA6V4 (Steel tool) -> Mechanical strength of the weld: 34 % of aluminum based material characteristics .
- FSW butt joint AA 2024-T3/ TA6V4 (Steel tool) -> Mechanical strength of the weld: 40 % of aluminum based material characteristics .
- FSW butt joint AA 2024-T3/ TA6V4 (Tungsten tool) -> Mechanical strength of the weld: 20 % of aluminum based material characteristics .
Unfortunately, the bi-material (aluminum/titanium) FSW readiness level achieved was not sufficient for ASTRASY project.
So, other processes were explored.
Magnetic Pulse Welding:
- Commissioning of MPW means is in progress. So far, it has not been possible to perform MPW tests. The commisionning is still on progress and the objective is to perform a test before the end of the project.
Rotative Friction Welding:
- RFW butt joint AA 7175 T73511 / TA6V4 -> Mechanical strength of the weld: 100 % of aluminum based material characteristics (basic tensile test).
For the most promising configuration, the objectives were to investigate the effects of the assembly process on microstructural features and mechanical properties on the laboratory specimens.
According to the ASTRASY laboratory results, we selected with the Topic leader advices the Baseline solution by Rotative Friction Welding during the TRL3 criteria review (2019/06/27).
According to the ASTRASY laboratory results, Rotative Friction Welding was selected as the Baseline solution with the Topic leader during the TRL3 criteria review (2019/06/27).
Final results
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We want to define lines of research for corrosion.
Progress beyond the state of the art is:
• The FSW process does not allow today to reach the level of performance required for this project.
• The ability of the RFW process to provide welds resistant to static stresses has been demonstrated.
Expected results until the end of the project:
A clearly defined and robust industrial process
A demonstrator scale 1:1 with strenght ok.
The definition of a test plan to continue experiments on the protective treatment of the hybrid junction titanium / aluminum to avoid galvanic corrosion.
Impacts:
• The performance of the \"\"baseline\"\" rod in terms of weight, cost and assembly time is currently being assessed. The objectives initially set should be achieved.
• The RFW process now represents a new skill for AVANTIS Project.
• The MPW means are being installed and the first tests should be done before the end of the project.
• AVANTIS Project can position now itself as a development center for solid state welding technologies (FSW, RFW, MPW).
• AVANTIS Project\'s R&D department was developed and stabilized thanks to activities related to the ASTRASY project.
• The collaboration with the ARMINES laboratory has been strengthened.
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Website & more info
More info: http://www.avantis-group.com.