Aluminium Design and Construction
By John Dwight (1999)
Get the fundamentals on Aluminium Design from John Dwight. Learn about alloys, castings, fire risks and more in his comprehensive study!
BRIEF CONTENTS
About aluminium
- General description
- The element
- The name
- The industrial metal
- Alloys
- Castings
- Supposed health risk
- Supposed fire risk
- Physical properties
- Comparison with steel
- The good points about aluminium
- The bad points
- History
- The precious metal stage
- The big breakthrough
- Early applications
- Establishment of the alloys
- The first major market
- Aluminium since 1945
- Growth in output
- New technology
- Structural engineering
- Architecture
- Land transport
- Marine usage
Manufacture
- Production of aluminium metal
- Primary production
- Secondary metal
- Flat products
- Rolling mill practice
- Plate
- Sheet
- Tolerance on thickness
- Special forms of flat product
- Extruded sections
- Extrusion process
- Heat-treatment of extrusions
- Correction
- Dies
- Hollow sections
- Extrudability of different alloys
- Size and thickness limits
- Tolerances
- Design possibilities with extrusions
- Tubes
- Extruded tube
- Drawn tube
- Welded tube
Fabrication
- Preparation of material
- Storage
- Cutting
- Holing
- Forming
- Machining
- Mechanical joints
- Bolting and screwing
- Friction-grip bolting
- Riveting
- Arc welding
- Use of arc welding
- MIG welding
- TIG welding
- Filler metal
- Weld inspection
- Friction-stir welding
- The process
- Features of FS welding
- Limitations
- Applications
- Other welding processes
- Adhesive bonding
- Use of bonding
- Surface preparation
- Two-component adhesives
- One-component adhesives
- Applying the adhesive
- Clamping
- Curing
- Protection and finishing
- General description
- Pretreatment
- Anodizing
- Painting
- Contact with other materials
Aluminium alloys and their properties
- Numbering system for wrought alloys
- Basic system
- Standardization of alloys
- Work hardening
- The O and F conditions
- Relation between temper and tensile strength
- Availability of different tempers
- Heat-treated material
- Characteristics of the different alloy types
- Non-heat-treatable alloys
- Heat-treatable alloys
- Data on selected wrought alloys
- How mechanical properties are specified
- Specific alloys and their properties
- Comments on certain alloys
- Minimum bend radius
- Strength variation with temperature
- Properties of forgings
- Stress-strain curves
- Empirical stress-strain relation
- Stress-strain curve for minimum strength material
- Casting alloys
- Numbering system
- Three useful casting alloys
- Alloys used in joints
- Fastener materials
- Weld filler wire
- Corrosion
- Corrosion of exposed surfaces
- When to protect against corrosion
- Bimetallic corrosion
Limit state design and limiting stresses
- Limit state design
- General description
- Definitions
- Limit state of static strength
- Serviceability limit state
- Limit state of fatigue
- The use of limiting stresses
- Limiting stresses based on material properties
- Derivation
- Procedure in absence of specified properties
- Listed values
- Limiting stresses based on buckling
- General form of buckling curves
- Construction of the design curves
- The design curves
Heat-affected zone softening at welds
- General description
- Thermal control
- Patterns of softening
- Heat-treated material
- Work-hardened material
- Stress-strain curve of HAZ material
- Multi-pass welds
- Recovery time
- Severity of HAZ softening
- Softening factor
- Heat-treated material
- Work-hardened material
- Extent of the softened zone
- General considerations
- Nominal HAZ
- One-inch rule
- RD method
- Weld geometry
- Single straight MIG weld
- Variation of HAZ extent with weld size
- Overlapping HAZs
- Attachment welds
- Definition of an isolated weld (10A-rule)
- RD method, summary
- Application of HAZ data to design
- Design of members
- Design of joints
- Comparison with one-inch rule
- HAZ at TIG welds
- Difference between TIG and MIG welding
- Severity of softening with TIG welding
- Extent of softened zone for TIG welding
- HAZ at friction-stir welds
Plate elements in compression
- General description
- Local buckling
- Types of plate element
- Plate slenderness parameter
- Element classification (compact or slender)
- Treatment of slender elements
- Plain flat elements in uniform compression
- Local buckling behaviour
- Limiting values of plate slenderness
- Slender internal elements
- Slender outstands
- Very slender outstands
- Plain flat elements under strain gradient
- Internal elements under strain gradient, general description
- Internal elements under strain gradient, classification
- Slender internal elements under strain gradient
- Outstands under strain gradient, general description
- Outstands under strain gradient, case T
- Outstands under strain gradient, case R
- Reinforced elements
- General description
- Limitations on stiffener geometry
- ‘Standard’ reinforcement
- Location of the stiffener
- Modified slenderness parameter
- Classification
- Slender reinforced elements
Beams
- General approach
- Moment resistance of the cross-section
- Moment-curvature relation
- Section classification
- Uniaxial moment, basic formulae
- Effective section
- Hybrid sections
- Use of interpolation for semi-compact sections
- Semi-compact section with tongue plates
- Local buckling in an under-stressed compression flange
- Biaxial moment
- Shear force resistance
- Necessary checks
- Shear yielding of webs, method 1
- Shear yielding of webs, method 2
- Shear resistance of bars and outstands
- Web buckling, simple method
- Web buckling, tension-field action
- Inclined webs
- Combined moment and shear
- Low shear
- High shear, method A
- High shear, method B
- Web crushing
- Webs with bearing stiffeners
- Crushing of unstiffened webs
- Web reinforcement
- Types of reinforcement
- Tongue plates
- Transverse stiffeners
- End-posts
- Lateral-torsional buckling
- General description
- Basic check
- Equivalent uniform moment
- Limiting stress for LT buckling
- Slenderness parameter
- Beams with very slender compression flanges
- Effective length for LT buckling
- Beams of varying cross-section
- Effect of simultaneous side moment
- Beam deflection
- Basic calculation
- Beam of slender section
Tension and compression members
- General approach
- Modes of failure
- Classification of the cross-section (compression members)
- Effective section
- General idea
- Allowance for HAZ softening
- Allowance for local buckling
- Allowance for holes
- Localized failure of the cross-section
- General yielding along the length
- Column buckling
- Basic calculation
- Column buckling stress
- Column buckling slenderness
- Column buckling of struts containing very slender outstands
- Torsional buckling
- General description
- Interaction with flexure
- ‘Type-R’ sections
- Sections exempt from torsional buckling
- Basic calculation
- Torsional buckling stress
- Torsional buckling slenderness
- Interaction factor
- Torsional buckling of struts containing very slender outstands
- Empirical slenderness formulae
- Torsional buckling of certain standardized sections
- Combined axial force and moment
- The problem
- Secondary bending in trusses
- Section classification
- Interaction formulae (P+uniaxial M)
- Alternative treatment (P+uniaxial M)
- Interaction formulae (P+biaxial M)
- Alternative treatment (P+biaxial M)
- Treatment of local buckling
- Eccentrically connected angles, channels and tees
Calculation of section properties
- Summary of section properties used
- Plastic section modulus
- Symmetrical bending
- Unsymmetrical bending
- Bending with axial force
- Plastic modulus of the effective section
- Elastic flexural properties
- Inertia of a section having an axis of symmetry
- Inertias for a section with no axis of symmetry
- Product of inertia
- Inertia of the effective section
- Elastic section modulus
- Radius of gyration
- Torsional section properties
- The torque-twist relation
- Torsion constant, basic calculation
- Torsion constant for section containing ‘lumps’
- Polar inertia
- Warping factor
- Special LT buckling factor
- Warping calculations
- Coverage
- Numbering the elements
- Evaluation of warping
- Formula for the warping factor
- Bisymmetric and radial-symmetric sections
- Skew-symmetric sections
- Monosymmetric sections, type 1
- Monosymmetric sections, type 2
- Asymmetric sections
Joints
- Mechanical joints (non-torqued)
- Types of fastener
- Basic checking procedure
- Joints in shear, fastener force arising
- Joints in shear, fastener resistance
- Joints in shear, member failure
- Joints in tension, fastener force arising
- Joints in tension, fastener resistance
- Interaction of shear and tension
- Comparisons
- Joints made with proprietary fasteners
- Mechanical joints (friction-grip)
- General description
- Bolt material
- Ultimate limit state (shear loading)
- Serviceability limit state (shear loading)
- Bolt tension and reaction force
- Slip factor
- Serviceability factor
- Welded joints
- General description
- Basic checking procedure
- Weld force arising
- Calculated resistance, weld-metal failure
- Calculated resistance, fusion-boundary failure
- Welded joints carrying axial moment
- Welds under combined loading
- Friction-stir welds
- Bonded joints
- General description
- Specification of the adhesive
- Surface preparation
- Effect of moisture
- Factors affecting choice of adhesive
- Creep
- Peeling
- Mechanical testing of adhesives
- Glue-line thickness
- Properties of some selected adhesives
- Resistance calculations for bonded joints
- Testing of prototype joints
Fatigue
- General description
- Possible ways of handling fatigue
- Checking procedure (safe life)
- Constant amplitude loading
- Variable amplitude loading
- Design life
- Stress range
- Stress-range spectrum
- Representative stress
- Method A
- Method B
- Classification of details
- The BS.8118 classification
- Friction-stir welds
- Bonded joints
- Endurance curves
- Instructions to fabricator
- Improvement measures
- Fatigue of bolts
- Basic approach
- Endurance curves for steel
- Variation of bolt tension
