M. Landy, E. T. Easterbrook, StressWave Incorporated, Kent, WA; J. E. Pillers, The Boeing Company, Seattle, WA; B. Zlicaric, Boeing Integrated Defense Systems, Seattle, WA
A structural repair method for reworking damaged titanium structure using inertial welding has been developed. Damage is removed from the structure by drilling slightly tapered holes or series of holes within the repair area. Tapered titanium plugs are then inertially welded into the holes using a automated machine tool that accurately controls rotational speed, applied force and displacement. By controlling the welding parameters using continuous feedback the plug is perfectly bonded to the hole wall with minimum change to the base mechanical property and grain structure. The residual stresses resulting from the localized frictional heating and subsequent cooling are mechanically stress relieved using the StressWave cold working process. The StressWave process can also be used to impart beneficial compressive stresses around the plug giving the repaired area better fatigue life than the base material. In many cases disassembly of the structure is not required prior to repair as the heating is very localized. The process parameter of the entire process are well predicted and allow for a high degree of automation. Fatigue cracks at holes and battle damaged structure can be readily repaired.
A structural repair method for reworking damaged titanium structure using inertial welding has been developed. Damage is removed from the structure by drilling slightly tapered holes or series of holes within the repair area. Tapered titanium plugs are then inertially welded into the holes using a automated machine tool that accurately controls rotational speed, applied force and displacement. By controlling the welding parameters using continuous feedback the plug is perfectly bonded to the hole wall with minimum change to the base mechanical property and grain structure. The residual stresses resulting from the localized frictional heating and subsequent cooling are mechanically stress relieved using the StressWave cold working process. The StressWave process can also be used to impart beneficial compressive stresses around the plug giving the repaired area better fatigue life than the base material. In many cases disassembly of the structure is not required prior to repair as the heating is very localized. The process parameter of the entire process are well predicted and allow for a high degree of automation. Fatigue cracks at holes and battle damaged structure can be readily repaired.
