Aluminium Design and Construction

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ISBN: 9780419157106 | 0419157107
Cover: Hardcover
Copyright: 4/8/1999

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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.

Preface

xiv

Acknowledgements

List of symbols and conversion factors

xvi

About aluminium

(22)

General description

(2)

The element

(1)

The name

(1)

The industrial metal

(1)

Alloys

(1)

Castings

(1)

Supposed health risk

(1)

Supposed fire risk

(1)

Physical properties

(2)

Comparison with steel

(3)

The good points about aluminium

(1)

The bad points

(2)

History

(3)

The precious metal stage

(1)

The big breakthrough

(1)

Early applications

(1)

Establishment of the alloys

(1)

The first major market

(1)

Aluminium since 1945

(5)

Growth in output

(1)

New technology

(1)

Structural engineering

(1)

Architecture

(1)

Land transport

(1)

Marine usage

(1)

Sources of information

(7)

Manufacture

(17)

Production of aluminium metal

(1)

Primary production

(1)

Secondary metal

(1)

Flat products

(3)

Rolling mill practice

(1)

Plate

(1)

Sheet

(1)

Tolerance on thickness

(1)

Special forms of flat product

(1)

Extruded sections

(11)

Extrusion process

(1)

Heat-treatment of extrusions

(1)

Correction

(1)

Dies

(2)

Hollow sections

(2)

Extrudability of different alloys

(1)

Size and thickness limits

(1)

Tolerances

(1)

Design possibilities with extrusions

(2)

Tubes

(2)

Extruded tube

(1)

Drawn tube

(1)

Welded tube

(1)

Fabrication

(19)

Preparation of material

(2)

Storage

(1)

Cutting

(1)

Holing

(1)

Forming

(1)

Machining

(1)

Mechanical joints

(4)

Bolting and screwing

(2)

Friction-grip bolting

(1)

Riveting

(2)

Arc welding

(4)

Use of arc welding

(1)

MIG welding

(1)

TIG welding

(1)

Filler metal

(1)

Weld inspection

(1)

Friction-stir welding

(3)

The process

(2)

Features of FS welding

(1)

Limitations

(1)

Applications

(1)

Other welding processes

(1)

Adhesive bonding

(3)

Use of bonding

(1)

Surface preparation

(1)

Two-component adhesives

(1)

One-component adhesives

(1)

Applying the adhesive

(1)

Clamping

(1)

Curing

(1)

Protection and finishing

(3)

General description

(1)

Pretreatment

(1)

Anodizing

(1)

Painting

(1)

Contact with other materials

(1)

Aluminium alloys and their properties

(28)

Numbering system for wrought alloys

(5)

Basic system

(1)

Standardization of alloys

(1)

Work hardening

(1)

The O and F conditions

(1)

Relation between temper and tensile strength

(1)

Availability of different tempers

(1)

Heat-treated material

(1)

Characteristics of the different alloy types

(4)

Non-heat-treatable alloys

(2)

Heat-treatable alloys

(1)

Data on selected wrought alloys

(10)

How mechanical properties are specified

(1)

Specific alloys and their properties

(1)

Comments on certain alloys

(4)

Minimum bend radius

(1)

Strength variation with temperature

(1)

Properties of forgings

(2)

Stress--strain curves

(2)

Empirical stress--strain relation

(1)

Stress--strain curve for minimum strength material

(1)

Casting alloys

(2)

Numbering system

(1)

Three useful casting alloys

(1)

Alloys used in joints

(1)

Fastener materials

(1)

Weld filler wire

(1)

Corrosion

(5)

Corrosion of exposed surfaces

(2)

When to protect against corrosion

(1)

Bimetallic corrosion

(2)

Limit state design and limiting stresses

(15)

Limit state design

(7)

General description

(1)

Definitions

(2)

Limit state of static strength

(3)

Serviceability limit state

(1)

Limit state of fatigue

(1)

The use of limiting stresses

(1)

Limiting stresses based on material properties

(4)

Derivation

(2)

Procedure in absence of specified properties

(1)

Listed values

(1)

Limiting stresses based on buckling

(4)

General form of buckling curves

(1)

Construction of the design curves

(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

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Aluminium Design and Construction

Summary

Table of Contents

Supplemental Materials