Aluminium Design and Construction

by Dwight,John

• ISBN13: 9780419157106
• ISBN10: 0419157107
• eBook ISBN(s): 9781135831752
• Additional ISBN(s): 9781135831769
• Edition: 1st
• Format: Hardcover
• Copyright: 1999-04-08
• Publisher: CRC Press
• More Book Details

Summary

This highly illustrated book is a practical design guide to the structural use of aluminum. The chapters include this history of aluminum, range of applications, alloys and their properties. The book also deals with structural design, and is an invaluable resource for designers, with numerous diagrams, charts and examples.

Table of Contents

Preface	xiv
Acknowledgements	xv
List of symbols and conversion factors	xvi
About aluminium	1	(22)
General description	1	(2)
The element	1	(1)
The name	1	(1)
The industrial metal	2	(1)
Alloys	2	(1)
Castings	2	(1)
Supposed health risk	2	(1)
Supposed fire risk	3	(1)
Physical properties	3	(2)
Comparison with steel	5	(3)
The good points about aluminium	6	(1)
The bad points	6	(2)
History	8	(3)
The precious metal stage	8	(1)
The big breakthrough	9	(1)
Early applications	9	(1)
Establishment of the alloys	10	(1)
The first major market	10	(1)
Aluminium since 1945	11	(5)
Growth in output	11	(1)
New technology	12	(1)
Structural engineering	13	(1)
Architecture	14	(1)
Land transport	14	(1)
Marine usage	15	(1)
Sources of information	16	(7)
Manufacture	23	(17)
Production of aluminium metal	23	(1)
Primary production	23	(1)
Secondary metal	24	(1)
Flat products	24	(3)
Rolling mill practice	24	(1)
Plate	25	(1)
Sheet	25	(1)
Tolerance on thickness	25	(1)
Special forms of flat product	26	(1)
Extruded sections	27	(11)
Extrusion process	27	(1)
Heat-treatment of extrusions	28	(1)
Correction	29	(1)
Dies	29	(2)
Hollow sections	31	(2)
Extrudability of different alloys	33	(1)
Size and thickness limits	34	(1)
Tolerances	35	(1)
Design possibilities with extrusions	36	(2)
Tubes	38	(2)
Extruded tube	38	(1)
Drawn tube	38	(1)
Welded tube	39	(1)
Fabrication	40	(19)
Preparation of material	40	(2)
Storage	40	(1)
Cutting	40	(1)
Holing	40	(1)
Forming	41	(1)
Machining	42	(1)
Mechanical joints	42	(4)
Bolting and screwing	42	(2)
Friction-grip bolting	44	(1)
Riveting	44	(2)
Arc welding	46	(4)
Use of arc welding	46	(1)
MIG welding	46	(1)
TIG welding	47	(1)
Filler metal	48	(1)
Weld inspection	49	(1)
Friction-stir welding	50	(3)
The process	50	(2)
Features of FS welding	52	(1)
Limitations	52	(1)
Applications	53	(1)
Other welding processes	53	(1)
Adhesive bonding	53	(3)
Use of bonding	53	(1)
Surface preparation	54	(1)
Two-component adhesives	55	(1)
One-component adhesives	55	(1)
Applying the adhesive	55	(1)
Clamping	56	(1)
Curing	56	(1)
Protection and finishing	56	(3)
General description	56	(1)
Pretreatment	57	(1)
Anodizing	57	(1)
Painting	58	(1)
Contact with other materials	58	(1)
Aluminium alloys and their properties	59	(28)
Numbering system for wrought alloys	59	(5)
Basic system	59	(1)
Standardization of alloys	59	(1)
Work hardening	60	(1)
The O and F conditions	61	(1)
Relation between temper and tensile strength	62	(1)
Availability of different tempers	63	(1)
Heat-treated material	63	(1)
Characteristics of the different alloy types	64	(4)
Non-heat-treatable alloys	65	(2)
Heat-treatable alloys	67	(1)
Data on selected wrought alloys	68	(10)
How mechanical properties are specified	68	(1)
Specific alloys and their properties	69	(1)
Comments on certain alloys	70	(4)
Minimum bend radius	74	(1)
Strength variation with temperature	75	(1)
Properties of forgings	76	(2)
Stress--strain curves	78	(2)
Empirical stress--strain relation	78	(1)
Stress--strain curve for minimum strength material	79	(1)
Casting alloys	80	(2)
Numbering system	80	(1)
Three useful casting alloys	81	(1)
Alloys used in joints	82	(1)
Fastener materials	82	(1)
Weld filler wire	82	(1)
Corrosion	82	(5)
Corrosion of exposed surfaces	82	(2)
When to protect against corrosion	84	(1)
Bimetallic corrosion	85	(2)
Limit state design and limiting stresses	87	(15)
Limit state design	87	(7)
General description	87	(1)
Definitions	87	(2)
Limit state of static strength	89	(3)
Serviceability limit state	92	(1)
Limit state of fatigue	93	(1)
The use of limiting stresses	94	(1)
Limiting stresses based on material properties	94	(4)
Derivation	94	(2)
Procedure in absence of specified properties	96	(1)
Listed values	97	(1)
Limiting stresses based on buckling	98	(4)
General form of buckling curves	98	(1)
Construction of the design curves	99	(1)
The design curves	100	(2)
Heat-affected zone softening at welds	102	(24)
General description	102	(1)
Thermal control	103	(1)
Patterns of softening	104	(4)
Heat-treated material	104	(1)
Work-hardened material	105	(1)
Stress--strain curve of HAZ material	106	(1)
Multi-pass welds	107	(1)
Recovery time	107	(1)
Severity of HAZ softening	108	(1)
Softening factor	108	(1)
Heat-treated material	108	(1)
Work-hardened material	109	(1)
Extent of the softened zone	109	(11)
General considerations	109	(2)
Nominal HAZ	111	(1)
One-inch rule	111	(1)
RD method	112	(1)
Weld geometry	112	(2)
Single straight MIG weld	114	(2)
Variation of HAZ extent with weld size	116	(1)
Overlapping HAZs	117	(1)
Attachment welds	118	(1)
Definition of an isolated weld (10A-rule)	119	(1)
RD method, summary	120	(1)
Application of HAZ data to design	120	(2)
Design of members	120	(1)
Design of joints	121	(1)
Comparison with one-inch rule	122	(1)
HAZ at TIG welds	123	(2)
Difference between TIG and MIG welding	123	(1)
Severity of softening with TIG welding	124	(1)
Extent of softened zone for TIG welding	125	(1)
HAZ at friction-stir welds	125	(1)
Plate elements in compression	126	(22)
General description	126	(2)
Local buckling	126	(1)
Types of plate element	126	(1)
Plate slenderness parameter	127	(1)
Element classification (compact or slender)	127	(1)
Treatment of slender elements	128	(1)
Plain flat elements in uniform compression	128	(7)
Local buckling behaviour	128	(2)
Limiting values of plate slenderness	130	(1)
Slender internal elements	130	(1)
Slender outstands	131	(3)
Very slender outstands	134	(1)
Plain flat elements under strain gradient	135	(6)
Internal elements under strain gradient, general description	135	(1)
Internal elements under strain gradient, classification	136	(2)
Slender internal elements under strain gradient	138	(1)
Outstands under strain gradient, general description	139	(1)
Outstands under strain gradient, case T	140	(1)
Outstands under strain gradient, case R	140	(1)
Reinforced elements	141	(7)
General description	141	(1)
Limitations on stiffener geometry	142	(1)
`Standard' reinforcement	143	(1)
Location of the stiffener	143	(1)
Modified slenderness parameter	144	(1)
Classification	145	(1)
Slender reinforced elements	146	(2)
Beams	148	(33)
General approach	148	(1)
Moment resistance of the cross-section	149	(8)
Moment--curvature relation	149	(1)
Section classification	150	(1)
Uniaxial moment, basic formulae	150	(1)
Effective section	151	(1)
Hybrid sections	152	(1)
Use of interpolation for semi-compact sections	152	(1)
Semi-compact section with tongue plates	153	(1)
Local buckling in an under-stressed compression flange	154	(1)
Biaxial moment	154	(3)
Shear force resistance	157	(6)
Necessary checks	157	(1)
Shear yielding of webs, method 1	157	(1)
Shear yielding of webs, method 2	157	(3)
Shear resistance of bars and outstands	160	(1)
Web buckling, simple method	160	(1)
Web buckling, tension-field action	161	(2)
Inclined webs	163	(1)
Combined moment and shear	163	(1)
Low shear	163	(1)
High shear, method A	164	(1)
High shear, method B	164	(1)
Web crushing	164	(2)
Webs with bearing stiffeners	164	(1)
Crushing of unstiffened webs	165	(1)
Web reinforcement	166	(4)
Types of reinforcement	166	(1)
Tongue plates	166	(1)
Transverse stiffeners	167	(1)
End-posts	168	(2)
Lateral-torsional buckling	170	(9)
General description	170	(1)
Basic check	171	(1)
Equivalent uniform moment	171	(1)
Limiting stress for LT buckling	172	(1)
Slenderness parameter	173	(3)
Beams with very slender compression flanges	176	(1)
Effective length for LT buckling	176	(2)
Beams of varying cross-section	178	(1)
Effect of simultaneous side moment	179	(1)
Beam deflection	179	(2)
Basic calculation	179	(1)
Beam of slender section	179	(2)
Tension and compression members	181	(26)
General approach	181	(1)
Modes of failure	181	(1)
Classification of the cross-section (compression members)	182	(1)
Effective section	182	(2)
General idea	182	(1)
Allowance for HAZ softening	182	(1)
Allowance for local buckling	183	(1)
Allowance for holes	183	(1)
Localized failure of the cross-section	184	(1)
General yielding along the length	184	(1)
Column buckling	185	(3)
Basic calculation	185	(1)
Column buckling stress	185	(2)
Column buckling slenderness	187	(1)
Column buckling of struts containing very slender outstands	188	(1)
Torsional buckling	188	(11)
General description	188	(1)
Interaction with flexure	189	(1)
`Type-R' sections	190	(1)
Sections exempt from torsional buckling	190	(1)
Basic calculation	191	(1)
Torsional buckling stress	191	(2)
Torsional buckling slenderness	193	(1)
Interaction factor	193	(1)
Torsional buckling of struts containing very slender outstands	194	(1)
Empirical slenderness formulae	195	(4)
Torsional buckling of certain standardized sections	199	(1)
Combined axial force and moment	199	(8)
The problem	199	(1)
Secondary bending in trusses	200	(1)
Section classification	200	(1)
Interaction formulae (P + uniaxial M)	201	(2)
Alternative treatment (P + uniaxial M)	203	(1)
Interaction formulae (P + biaxial M)	203	(1)
Alternative treatment (P + biaxial M)	204	(1)
Treatment of local buckling	205	(1)
Eccentrically connected angles, channels and tees	205	(2)
Calculation of section properties	207	(28)
Summary of section properties used	207	(1)
Plastic section modulus	207	(5)
Symmetrical bending	207	(1)
Unsymmetrical bending	208	(2)
Bending with axial force	210	(1)
Plastic modulus of the effective section	211	(1)
Elastic flexural properties	212	(5)
Inertia of a section having an axis of symmetry	212	(1)
Inertias for a section with no axis of symmetry	213	(3)
Product of inertia	216	(1)
Inertia of the effective section	216	(1)
Elastic section modulus	217	(1)
Radius of gyration	217	(1)
Torsional section properties	217	(8)
The torque--twist relation	217	(1)
Torsion constant, basic calculation	218	(1)
Torsion constant for section containing `lumps'	219	(2)
Polar inertia	221	(1)
Warping factor	222	(1)
Special LT buckling factor	222	(3)
Warping calculations	225	(10)
Coverage	225	(1)
Numbering the elements	225	(1)
Evaluation of warping	226	(1)
Formula for the warping factor	227	(1)
Bisymmetric and radial-symmetric sections	228	(1)
Skew-symmetric sections	229	(1)
Monosymmetric sections, type 1	229	(1)
Monosymmetric sections, type 2	230	(2)
Asymmetric sections	232	(3)
Joints	235	(33)
Mechanical joints (non-torqued)	235	(8)
Types of fastener	235	(1)
Basic checking procedure	236	(1)
Joints in shear, fastener force arising	237	(1)
Joints in shear, fastener resistance	238	(2)
Joints in shear, member failure	240	(1)
Joints in tension, fastener force arising	240	(1)
Joints in tension, fastener resistance	240	(1)
Interaction of shear and tension	241	(1)
Comparisons	241	(2)
Joints made with proprietary fasteners	243	(1)
Mechanical joints (friction-grip)	243	(4)
General description	243	(1)
Bolt material	244	(1)
Ultimate limit state (shear loading)	244	(1)
Serviceability limit state (shear loading)	244	(1)
Bolt tension and reaction force	245	(1)
Slip factor	246	(1)
Serviceability factor	247	(1)
Welded joints	247	(8)
General description	247	(1)
Basic checking procedure	248	(1)
Weld force arising	249	(1)
Calculated resistance, weld-metal failure	250	(2)
Calculated resistance, fusion-boundary failure	252	(1)
Welded joints carrying axial moment	253	(1)
Welds under combined loading	254	(1)
Friction-stir welds	255	(1)
Bonded joints	255	(13)
General description	255	(1)
Specification of the adhesive	256	(1)
Surface preparation	257	(1)
Effect of moisture	257	(1)
Factors affecting choice of adhesive	258	(1)
Creep	259	(1)
Peeling	259	(1)
Mechanical testing of adhesives	259	(1)
Glue-line thickness	260	(1)
Properties of some selected adhesives	261	(4)
Resistance calculations for bonded joints	265	(2)
Testing of prototype joints	267	(1)
Fatigue	268	(18)
General description	268	(2)
Possible ways of handling fatigue	270	(1)
Checking procedure (safe life)	271	(3)
Constant amplitude loading	271	(1)
Variable amplitude loading	272	(1)
Design life	272	(1)
Stress range	272	(1)
Stress-range spectrum	273	(1)
Representative stress	274	(3)
Method A	274	(2)
Method B	276	(1)
Classification of details	277	(2)
The BS.8118 classification	277	(1)
Friction-stir welds	278	(1)
Bonded joints	278	(1)
Endurance curves	279	(1)
Instructions to fabricator	280	(1)
Improvement measures	281	(2)
Fatigue of bolts	283	(3)
Basic approach	283	(1)
Endurance curves for steel bolts	283	(1)
Variation of bolt tension	284	(2)
References	286	(2)
Index	288