One-Step Hybrid Bending/Diffusion Bonding Process and Analysis of the Bonding Characteristics of Titanium Alloy Sheets

Author:

Kim Kang Hyun12,Park Hyeonil1,Lee Dong Jun1,Kwon Yong Nam1,Kang Namhyun2ORCID,Hong Jong-Hwa1

Affiliation:

1. Aerospace Materials Center, Korea Institute of Materials Science, 797 Changwon-daero, Changwon 51508, Republic of Korea

2. Department of Materials Science and Engineering, Pusan National University, 2 Busandaehak-ro 63beon-gil, Busan 46241, Republic of Korea

Abstract

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.

Funder

Ministry of Trade, Industry and Energy

Publisher

MDPI AG

Subject

General Materials Science

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