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Conventional and Innovative Aerospace Joining UNIVERSITÀ DI PISA FACOLTÀ DI INGEGNERIA DIPARTIMENTO DI INGEGNERIA AEROSPAZIALE DOTTORATO DI RICERCA IN INGEGNERIA AEROSPAZIALE XVIII CICLO TESI DI DOTTORATO CCONVENTIONAL AND IINNOVATIVE AAEROSPACE JJOINING TTECHNOLOGIES CURRICULUM COSTRUZIONI AERONAUTICHE TUTORE PROF. ING. AGOSTINO LANCIOTTI PRESIDENTE DEL CORSO DI DOTTORATO PROF. ING. GUIDO BURESTI DOTTORANDA ING. CLAUDIA POLESE ANNO ACCADEMICO 2005 – 2006 ABSTRACT I ABSTRACT The present PhD Thesis was developed in the framework of several Research Programs in which the Department of Aerospace Engineering at University of Pisa was directly involved, with the general aim to characterized the fatigue behavior of conventional and innovative joints typically employed in the production of aeronautical and aerospace structures. Correct predictions could obviously improve design of optimized structures, maintaining or increasing actual safety levels: but the separate or synergic effects of several parameters must be considered to correctly reproduce structure in-service behavior. The logic-flow adopted for each aspect analyzed in the present research had his origin on a consistent database of experimental data, ranging from general mechanical properties material characterization to strain gauge evaluations of associated stress fields, moving toward a more comprehensive description of the faced problem by means of Finite Elements simulations, to finally reach, by fracture mechanics codes, a generalized model. Attention was mainly focused on parameters characterized by a lack of information in literature or unsatisfactory prediction models. Among others aspects, the effect of Secondary Bending on conventional longitudinal fuselage joints was deeply investigated, bringing to a clear improvement of fracture mechanics software. Furthermore were analyzed different technologies capable of decidedly improve joint performance in a standard architecture. Processes as Interference Fit, Split Sleeve Cold Working, StressWave and ForceMate were demonstrated to significantly retard crack initiation and propagation in critical points, introducing beneficial stress fields. Besides currently great efforts are made by the aerospace International Community to investigate the possibility of replacing standard joining methodology by new technologies which are expected to provide considerable weight saving and cost reductions, incorporating integral structures in aircraft constructions. The more promising one, the “Friction Stir Welding”, was widely explored during the present activity in different aeronautical and aerospace applications, demonstrating to be a very robust and reliable process. I ACKNOWLEDGMENTS I ACKNOWLEDGMENTS My deepest thanks to my Tutor, Prof. Ing. Agostino Lanciotti, who has been always the inexhaustible supporter of my research work, giving me continuously a chance to improve a new aspect of my knowledge. I wish to express my sincere gratitude to Prof. Ing. Luigi Lazzeri, who has been extraordinarily helpful with his kind technical and human support throughout all my work. Special thanks to Prof. Ing. Giorgio Cavallini for the interest demonstrated in all my activities and his amazing suggestions during all my stay at the Department. I wish to express my gratitude to all people that in so many different ways making possible the accomplishment of this work: To Dr. Ing. Luisa Boni for her huge friendship, the invaluable support and the precious collaboration To Dr. Ing. Enrico Troiani, luckily our collaboration has gone over the professional relationship by consolidating a really important friendship To the whole Staff of the Department of Aerospace Engineering: to the technicians of the Structural Laboratory: Mr. Mauro Romagnoli, for his invaluable help, the constant attention and his priceless technical suggestions, Mr. Claudio Lippi, Mr. Luca Lombardi and Mr. Fabio Pioli, for the funny camaraderie demonstrated during all the experimental activity to the technicians of the Electronic Laboratory: Ing. Massimo Pisani, Mr. Gabriele Adorni Fontana and Mr. Andrea Rossi. to all the Administrative Staff, Mrs. Fernanda Taddei, the real mother of the Department, Mrs. Martina Casali, Mrs. Roberta Razzi, Mrs. Nuccia Paganelli and Mrs. Franca Braccini to study here without all of you would not have been the same. To all the student that were involved in the experimental and numerical activities of this research activity; I hope to helped them to grow up as good engineers as they helped me to improve both as teacher that as woman: Gregorio Nazzani and Emanuele Vincentini, Federico Tarabella, Guido Becchi, my first FSW student and Ing. Paolo Becchi that gave me the opportunities to know Liguria, Elisabetta Fattorini, a precious friend all over these years, Fabio Forlani and Gianantonio Toniolo, Roberto Marcalli, that reinforced my personality, Igor Azara, Vittorio Cipolla and PierPaolo Pergola, Daniele Fois, Daniele Caprai, Lorenzo Cabiddu for the funny moments in the FEM and Sardinia worlds, Nicola Pasquale, my most faithful student, Carmela Fierro the first nice girl I met in Pisa, Francesco Fruci, Chiara Battistelli, my favorite housemate, Paola Apruzzese, Federico Ferrari, the most cool FSW student, for his great work, Gianluca Magagnini, for his impertinent friendship, and Daniela, Biancamaria Felice and her really nice sisters, II ACKNOWLEDGMENTS I Francesca, Florinda and Mariachiara, and her incredibly kind Family, Alessio Iantorno, who persuaded me to visit Calabria, Emanuele Calvagna, Giuseppe Allegra, her sister Marilena and the nicest Sicilian Family I have ever met, Saverio Picerno, a man of substance, Lia Ruggeri for our great chattering moments and Enrico, Ivan Andreani and Vjola Ristori for their kindness, AndreaSebastian Daquino and Manuel D’Eusebio, Marco Dezi, Gabriella Perrone for her precious optimized friendship and Daniele, Filippo Nogarin, Daniele Dignani and Stefano Maestrini, Sergio Urso Sculco, a great friend in every situation, Luca Niccolini, Anita Catapano for her great young energy. I also want to thank all people involved in the several research programs: at Alcatel Alenia Space Italia Mr. Roberto Laudato, for his great enthusiasm throughout all the FSW activity, Ing. Elena Bonadero, Ing. Secondo Ottaviano, Mr. Angelo Camassa and Mr. Walter Capitani, our NDI men, and Dr. Monica Bosco at EnginSoft, where I found the answers to so many questions, Ing. Roberto Gonella, my more enthusiastic sponsor, for the great opportunities that gave me, Ing. Roberto Merlo, for his precious suggestions, Ing. Francesco Franchini, my optimized men, Ing. Horia Horculescu, for the pleasant assistance, Miss Letizia Palanti and Mrs. Mirella Prestini for their kind and great efficiency. at AerMacchi Ing. Francesca Nigro and Ing. Sergio Peyronel at Agusta Ing. Ugo Mariani at EADS Ottobrun Ing. Frank Palm at the ISS, Italian Welding Institute, Dr. Ing. Michele Lanza at Genova University Prof.ssa Carla Gambaro of for her kind introduction to the FSW world at ABAQUS Italia Ing. Roberto Vitali, Ing. Alberto Mameli and Ing. Sguanci for their guidance in the complex ABAQUS dimension at Piaggio Aero Industries Ing. Enrico Ciompi and Alenia Aeronautica, Breda Costruzioni Ferroviarie, ATR Toulose, Perini Navi, EADS Matra Datavision. I would like to gratefully acknowledge all people that supported my stay at the DLR in Cologne: Dr. Claudio Dalle Donne, for the great attention that he paid to me and to my work, and his brilliant wife Ozlem, Ing. Anne-Laure Lafly, my wonderful French best friend, III ACKNOWLEDGMENTS I Ing. Haiyan Chen, that open my eyes on the Chinese dimension, Dr. Tommaso Ghidini and his precious wife Barbara, Dr. Ulises Alfaro Mercado, Dr. Tamara Vougrin, Mr. and Mrs. Willms, the whole technical staff of DLR-WF laboratories, particularly, Mr. Karl-Heinz Trautmann, for his fundamental supervision of the work, Mr. Uwe Fuchs, Mr. Peter Mecke, Mr. Cristian Sick, Mr. Heinz Sauer, Mr. Herbert Hinderlich, Mr. Klaus Mull, for their patience and their valuable collaboration. A sincere appreciation to all my Engineer and not Engineer Friends that spent so long and joyful time with me in Pisa: Nicola e Francesca, Maurizio, Giovanni, Alessandro, Francesco, Nicola, Guido, Francesco, Rosella, Carmela, Cristiano e Sara, Loredana e Mario. Special thanks to my adoptive Pietra’s Family for their priceless support to this complex experience: Morello, for our long conversation on my little world problems, Carla who created my passion for yoga and a more spiritual life, Federica, who discovered my lyric world, Philippe Gouron, Gabriele Bonelli, Massimo and Luciano Tagliavini for our memorable goliardic dinners and Dr. Mauro Cerchiai for his big support in every field of knowledge. My most profound thanks to my Family that supported me during this long years of study: my father Claudio, probably the man most proud of me, my mother Siriana and my sister Cecilia that correctly still affirm that I spent all my life in a strange world, my grandfather Siriano and my precious grandmother Liliana. Huge thanks to My Francesco for being so incredibly understanding, patient, and most of all for cheerfully tolerating all the distractions of this work and for providing so many wonderful reasons to look up from my computer. You opened my eyes to the world. IV INDEX I INDEX ABSTRACT ........................................................................................................ I ACKNOWLEDGMENTS ........................................................................................ II INDEX .............................................................................................................
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