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Research Needs in Aluminum Structure

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Research Needs in Aluminum Structure 10th International Symposium on Practical Design of Ships and Other Floating Structures Houston, Texas, United States of America © 2007 American Bureau of Shipping Research Needs in Aluminum Structure Robert A. Sielski Naval Architect—Structures Indio, California, USA Abstract the size of which has increase greatly over the years. The use of aluminum for the hulls of high-speed The technology required for the design, fabrication, merchant vessels began in the 1990s with increased operation and maintenance of aluminum structures for construction of high-speed ferries. These vessels have ships and craft are reviewed to assess the needs for become so technologically advanced that they have improvements in that technology. The areas reviewed surpassed the capabilities of many naval vessels; many are: material property and behavior, structural design, navies today are adapting derivatives of these high- structural details, welding and fabrication, joining speed vessels to combatant craft. aluminum to steel, residual stresses and distortion, The interest in aluminum structure has increased greatly fatigue design and analysis, fire protection, vibration, over the past decade. Evidence of international interest maintenance and repair, mitigating slam loads and in aluminum ship structure is the International Forum on emerging technologies. Aluminum Ships, the fifth of which took place in Tokyo in 2005. The Ship Structure Committee (SSC) has Keywords recently completed a number of projects concerning aluminum ship structures: Aluminum ship structures; Aluminum high-speed SSC-410, Fatigue of Aluminum Structural vessels. Weldments SSC-438, Structural Optimization for Conversion Introduction of Aluminum Car Ferry to Support Military Vehicle Payload Aluminum has been used for the construction of ships and craft for more than a century. In many cases, the SSC-439, Comparative Structural Requirements vessels have served well for several decades of use for High Speed Craft without any serious structural problems. However, SSC-442, Labor-Saving Passive Fire Protection there have been some difficulties. From the very Systems for Aluminum and Composite beginning, and continuing up to very recently, there Construction have been instances where the selection of the wrong SR-1434, In-Service Performance of Aluminum aluminum alloy has led to corrosion problems so severe Structural Details that the vessels had to be scrapped within a few years of construction. Aluminum has been used for the SR-1446, Mechanical Collapse Testing on deckhouse structure of US Navy combatant and Aluminum Stiffened Panels for Marine amphibious ships for more than 70 years. Those ships Applications served well, but the aluminum structure was the source SR-1447, Fracture Mechanics Characterization of of significant maintenance problems, mostly from Aluminum Alloys for Marine Structural fatigue damage. Serious concerns for survival in Applications shipboard fire and for maintenance reduction led to the SR-1448, Aluminum Marine Structure Design discontinuation of the use of aluminum for major US and Fabrication Guide Navy combatant ships in the 1980s. Towards the close of World War II, some merchant SR-1454, Buckling Collapse Testing on Friction ships built in the U.S. had aluminum in their Stir Welded Aluminum Stiffened Plate Structures deckhouses, and this practice continued after the war, Additionally, the US Navy’s Office of Naval Research primarily in the superstructures of passenger ships. has begun a multi-year research program, Aluminum Aluminum began to be adopted worldwide for Structure Reliability Program, aimed at improving the fabrication of the superstructure of passenger ships, a technology for design construction, operation, and practice that continues today. Aluminum began to be maintenance of high-speed aluminum naval vessels. used in the 1940s for pleasure craft and for workboats, This paper is based on the aluminum guide and on the Table 1:Yield Strength of Some Alloys as Specified ONR program. Research needs will be discussed in the by Different Authorities (MPa) following areas: Alloy Authority Material property and behavior ABS DnV Aluminum AWS US Structural design Association Hull Navy Structural details Welding Welding and fabrication 5086- 131 92 95 131 152 H116 Joining aluminum to steel 5083- 165 116 115 165 Residual stresses and distortion H116 Fatigue design and analysis 5383- 145 140 Fire protection H116 Vibration 5456- 179 125 179 179 Performance metrics, reliability and risk H116 assessment 6061- 138 105 105 138 Maintenance and repair T6 Structural health monitoring Emerging technologies Aluminum alloys, particularly those of the 5xxx-series have shown excellent corrosion resistance in service, with some bare hulls operating for more than 30 years without discernable corrosion. However, there is a Material Property and Behavior general reluctance to place 6xxx-series alloys in similar service. Indeed, classification societies and the U.S. There is vast experience with aluminum alloys in both Navy prohibit most uses of 6xxx-series alloys in contact the 5xxx and 6xxx-series; the most commonly used with seawater. A review of available corrosion data marine alloys. However, there are still fairly large fails to provide any experimental basis for this prejudice knowledge gaps in basic knowledge on these alloys. against 6xxx-series alloys. The most common gap is in fatigue properties and The 6xxx-series alloys generally have excellent fracture toughness, particularly dynamic fracture toughness, with much of the existing fracture data resistance to general corrosion over the surface, but coming from non-standard tests with invalid data. compared to 5xxx-series exhibit more localized pitting. Most of the corrosion testing of aluminum in seawater An important discrepancy in basic material properties is occurred in the 1950 through the 1960s. Goddard et al. the variation among different sources on the strength of (1967) report that the maximum pit depth in three 5xxx- welded aluminum. Table 1 illustrates this discrepancy series alloys (5052, 5056, and 5083) was 0.18 and 0.86 for several alloys. The differences come in part from mm after five and ten years of immersion in seawater, different standards for determining the yield strength respectively. In the same tests, 6061-T6 had 1.30 and from a “dog bone” sample cut across the weld in a plate. 1.65 mm of pit depth when samples were removed after Some use a 50-mm gage length that measures only weld 5 and 10 years of immersion. Although the 6061 had metal and heat-affected zone (HAZ), but others use a twice the depth of pitting in this test, the rate is not 250-mm gage length sample that includes base metal. necessarily unacceptable. Other 6xxx-series, such as Perhaps even more important than the difference in 6082 have less copper that 6061 and should have better yield strength is the manner in which this property is corrosion resistance, although data is lacking used in design. The welded strength is typically 30 to The 6xxx-series are beginning to be used more 50 percent of the strength of the base metal, and this extensively in integrally stiffened deck panels, and there reduced strength is used for most design calculations. is a desire to use these light panels for general hull There are indications that the approach is overly structure. A systematic comparative test of different conservative. In studies on the compressive strength of alloys in corrosive environments will demonstrate if welded panels, Paik et al (2006) used a weighted more extensive use of the 6xxx-series alloys is possible average based on the relative volumes of base metal, and if this can be safely done will result in significant weld metal, and HAZ. In a simplified analysis of a weight and cost savings. welded panel in tension, Collette (2005) found that the While the 5xxx-series alloys have generally shown to yield strength of a 5xxx-series welded plate was close to the yield strength of the base metal, although for a have excellent resistance to corrosion, there is concern 6xxx-series alloy, the strength was closer to that of the that material is becoming sensitized over time to intergranular corrosion and stress-corrosion cracking, HAZ. Research in this basic material property could particularly when subjected to higher service result in significantly increased allowable stresses and temperatures on exposed decks. An accelerated test that reduced weight. would be based on the thermal profile of the decks of operational ships must be developed to screen the Other design issues include: material. Ultimate strength of plates and panels undergoing There are also indications that there are reductions in combined loading such as biaxial compression in corrosion resistance in the heat-affected zones of welds multi-hull cross decks, or a combination of in- in the 5xxx-series alloys such as shown in Fig 1. The plane compression and lateral pressure in the standard ASTM G 67 NAMALT test is designed to slamming zone of high-speed vessels. measure weight loss in a relatively large surface area, The effect of initial imperfections and residual not in the narrow band of the HAZ of a weld. A stresses on the strength of common aluminum standard for weight loss in the HAZ should be structures needs further validation, including developed to allow comparison and optimization of guidance on how to incorporate these values into welding methods. finite-element models for ultimate strength along with simplified methods
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