Microstructure and mechanical properties of laser beam welded Al–Li alloy 2060 with Al–Mg filler wire

Alloy 2060-T8 is a newly developed high-strength Al–Li alloy for applications in aircraft industry. Crack-free welds were obtained in laser beam welding with 5087 filler wire under optimized welding conditions. In this paper, fusion zone microstructure and joint mechanical properties were investigated. Microstructure typical for the weld metal consists of α-Al matrix with a few nanoscale precipitates inside and a coarse icosahedral quasicrystalline T₂ phase at the dendritic and grain boundaries. The quasicrystalline occurred normally in Al–Li–Cu alloys with higher Li contents. Our investigations show that the icosahedral quasicrystalline phase T₂ phase forms in the laser-welded Al–Li alloy 2060 with lower Li content as a result of segregation and replacement of Mg element. The joint tensile strength in as-welded condition is around 317 MPa, about 63% of that of the base metal, and fracture occurs within the fusion zone.     

The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel

In literature, five different sets of work material constants used in the Johnson–Cook's (J–C) constitutive equation are implemented in a numerical model to describe the behaviour of AISI 316L steel. The aim of this research is to study the effects of five different sets of material constants of the J–C constitutive equation in finite-element modelling of orthogonal cutting of AISI 316L on the experimental and predicted cutting forces, chip morphology, temperature distributions and residual stresses. Several experimental equipments were used to estimate the experimental results, such as piezoelectric dynamometer for cutting forces measurements, thermal imaging system for temperature measurements and X-ray diffraction technique for residual stresses determination on the machined surfaces; while an elastic–viscoplastic FEM formulation was implemented to predict the local and global variables involved in this research. It has been observed that all the considered process output and, in particular the residual stresses are very sensitive to the J–C's material constants.     

Preparation and tribological behavior of polytetrafluoroethylene/metal mesh composites with sandwich structure

Polytetrafluoroethylene (PTFE) owns an excellent self-lubricating performance, but its wear rate is very high due to the large-scale spalling of the matrix in the friction. In this paper, A new kind of PTFE composites with sandwich structure was prepared by layer-press technology, whose middle layer is filled with metal mesh. The influence of the mesh structure and mesh density of middle metal layer on tribological properties of composites were researched in detail. The results revealled that the metal mesh located in the composites can efficiently prevent the large-scale spalling of PTFE, which induces the sample of PTFE/500# plain woven dutch metal mesh (PTFE-500#PWD) to have a lower wear rate (9 × 10⁻⁵ mm³/Nm) and COF (0.106) under the fixed experimental condition. The prepared PTFE/metal mesh composites reveal excellent anti-friction and anti-wear performance, which can be used to fabricate a new kind of self-lubricating materials.     

Extended sliding mode observer based robust adaptive backstepping controller for electro-hydraulic servo system: Theory and experiment

This paper firstly presents an extended sliding mode observer (ESMO) for the electro-hydraulic servo systems (EHSSs) to deal with nonlinear factors like the external disturbance, parameter uncertainties as well as unmodeled characteristics in the EHSS. The model for the EHSS is established by taking these nonlinear factors into consideration and then the statespace representation is obtained. According to the state space, the ESMO for the EHSS is presented, the equivalence principle is properly utilized to simplify the ESMO and some saturation functions are employed to eliminate high frequency interferences caused by the chattering phenomenon. Based on estimated values from the ESMO, a robust adaptive backstepping controller (RABC) is presented in detail with taking some parameter uncertainties into consideration to further improve the tracking performance. The proposed controller has the following advantages: (1) utilizing the ESMO to cope with these nonlinear factors; (2) parameter online adaptive laws are employed in the RABC design to further improve the tracking performance. In order to verify the performance of the proposed controller, an experiment bench was established. Two sine waves reference signal (one amplitude 0.01 m, 1 Hz; the other 0.015 m, 2 Hz) are employed to verify the performance of the controller. Comparative experimental results show that: (1) the tracking performance of the proposed controller is better than that of a DOs based BC, a BC and a PI controller; (2) estimation values from the ESMO contains fewer noise than two conventional disturbance observers (DOs), which will decrease the control input ripples.     

Experimental and finite element studies on hot sizing process for L-shaped composite beams

This work aims at developing a hot sizing process on composite materials to correct the profiles of composite structures during manufacture. Hot sizing experiments were carried out at 150 °C with different sizing loads and hot sizing periods for L-shaped composite beams made of carbon fiber plain-weave fabric and epoxy resin. To predict the springback in hot sizing process, a corresponding finite element simulation method was developed using stress relaxation equations determined at the same temperature. Excellent agreements between the predicted and observed results were obtained. The effects of the component thickness and 45° ply percentage on the springback rate were investigated by simulation. Springback rate in hot sizing process on composite materials ranges from 60% to 95%. In conclusion hot sizing process is proved to be a valid method for compensation for the process-induced deformation (PID) of L-shaped composite beams.     

负加速度飞行载荷下APU滑油系统功能试验验证与研究

对民用飞机辅助动力装置(APU)在负加速度飞行条件下的滑油系统功能的试验验证方法进行了总结与研究。同时,通过对典型的APU负加速度飞行试验数据的分析,对典型的APU滑油系统在负加速度载荷下的工作特性进行了总结,为民用飞机APU滑油系统的验证提供依据。     

民用飞机辅助动力装置安装布局研究

安装系统作为整个APU主要承力结构,其能否轻便可靠将直接影响到APU的性能,系统重量,经济性以及维修性等。对早期及现役民机APU安装系统进行了分析,对比了各个形式的安装特点以及相应的设计考虑,阐述了APU安装系统的关键设计要求,为后续机型研制提供参考。     

民用飞机主起舱过热探测系统设计研究

民用飞机防火系统为多个区域提供防护。主起舱是民用飞机主要防火区域之一。对民用飞机主起舱过热探测系统的设计依据、设计原则及布置分析进行阐述,描述了主起舱特点及相关设备功能,为民用飞机发动机着火探测系统设计提供一定支持。     

民用飞机副翼卡阻故障试验技术研究

描述了某型号支线飞机的副翼卡阻角度的选取原则,给出了一种卡阻故障的设置方法,并分析了该设置方法对原有飞控系统造成的影响,最后给出了一个副翼卡阻故障的试验方案。已完成的飞行试验结果表明,该方案操作简单,且安全可靠。     

基于自动特征工程的飞行器轴承故障诊断

针对飞行器轴承信号单一且噪声多、需要针对性特征以及需要高可解释性的问题,开发了涵盖具有自适应噪声的完全集合经验模态分解（CEEMDAN）、自动特征工程以及随机森林的故障诊断模型,模型核心为自动进行特征生成以及提取的特征工程。通过该特征工程能够根据不同对象的信号差异,自动提取出不同对象的有效特征,具备对象间的通用性,且该特征工程可根据样本量的不同调整有效特征的数量,丰富特征空间,具备灵活的可扩展性。验证表明,该涵盖自动特征工程的模型的故障分类准确率为95.32%,可较好地在大样本量下区分压缩机轴承上的不同故障。