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Utilizing Aluminium Composites
Durability and Damage Tolerance
Precise-to-form extruded 6092 aluminum composite Fan Exit Guide Vanes replaced graphite-epoxy components in Pratt & Whitney’s family of PW4000 gas turbine engines for the Boeing 777. DWA’s aluminum composite solution provides improved dynamic response, better erosion and impact resistance, as well as lower acquisition and life-cycle cost. |
Service Life Extension
Rolled 6092 aluminum composite sheet has replaced AA2024 skins on the F-16 ventral fins and upper
fuselage fuel access covers. The high stiffness-to-weight of aluminum composite results in a greater than
4X service life extension compared to monolithic aluminum.
Weight Reduction
Main rotor blade sleeves manufactured from 2009 aluminum composite replaced titanium on Eurocopter
helicopters resulting in up to a 15 kg (33 lbs) weight savings on the main rotor. The fatigue resistance of
aluminum composite makes it ideal for infinite fatigue life driven designs.
Low CTE and Wear Resistance
Extruded 2009 aluminum composite replaced aluminum-bronze for F-18 e/f hydraulic actuators, resulting in
a 38% weight reduction. Unlike conventional aluminum, aluminum composite can be used in high-pressure
hydraulic systems due to its low CTE and wear, as well as superior fatigue resistance.
Enabling Designs
Due to improved crack initiation resistance, in addition to excellent high-cycle fatigue, 2009 aluminum composite
replaced 7075-T6, enabling Eurocopter’s aluminum-based design for NH90 helicopter swash plates.
High Strength Alloy Development
We are actively involved in high strength alloy development. Major programs center around
L12 phase strengthened alloys
and metallic glasses. DWA has developed unique, inert atmosphere powder handling for size classification and accelerated,
dynamic vacuum degassing that reduces time-at-temperature, thus limiting microstructural coarsening.
Nanotechnology
DWAAC operates a pilot-scale facility for the manufacture of nano-scale aluminum alloys and aluminum composites. Commercially available aluminum powder is mechanically milled in liquid nitrogen (LN2) resulting in the formation of nano-scale grains. This greatly reduced microstructural scale yields monolithic and composite material variations with strengths approaching 1,000 MPa (145 ksi).
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