(937) 228 2148
Topic: Manage the
Impact of Bulk Residual Stress on the Design-Build-Sustain Process for Primary
Aircraft Structure
Meeting Schedule
Networking: 5:30 pm
Dinner: 6:00 pm
Talk: 7:00 pm
Cost: $25.00
Material Advantage Students: Free Food
BIO
Mark James is a Characterization Practice Lead in Alcoa's Product Design and
Development Division at the Alcoa Technical Center near Pittsburgh,
Pennsylvania. After finishing a Master's Degree in Mechanical Engineering with
a focus on numerical methods, Mark spent 5 years in industry working on
software such as the well known Franc2D/L finite element code. Mark's industry
experience led him to a PhD at Kansas State University focused on computation
methods for elastic-plastic fracture, followed by a National Research Council
Post-Doctoral Research Fellowship at NASA Langley Research Center. After an
additional three years at Langley as a contractor working on fatigue and
fracture projects, Mark joined Alcoa's Technical Center in 2005, where his
current responsibilities include managing Alcoa's "Residual Stress
Management for 3D Structures" program. He is also responsible for Alcoa's
part in a multi-year Metals Affordability program funded by AFRL. Mark is
active in the ASTM standardization process within Committee E8 on Fatigue and
Fracture and has particular interest in standardizing test methods to partition
residual stress from property data for fracture-mechanics-based testing.
ABSTRACT
Integrated product development teams and computational methods have received
significant attention in recent years as a means to reduce both time and cost
of new technology insertion. The holistic approach taken forms the basis for
the field of Integrated Computational Materials Engineering (ICME), which is
held up as an enabler for the community with benefits ranging from material
design through component design, manufacturing, and even sustainment. Recent
trade study results indicate that the benefit potential for sustainment is
substantial, provided that the up-front computational and material/design
integration aspects are in place to capture the cost saving and lifing benefits
downstream. Alcoa and Lockheed have made substantial progress towards
validating their respective visions of an ICME approach to manage bulk residual
stresses and consequences for large unitized structures, such as bulkheads and
wing spars, machined from large aluminum die-forgings. Recently they have
teamed to combine Alcoa's material and computational know-how with the
structural airframe design and sustainment capabilities of Lockheed. The
complementary capabilities and integrated approach enable a cradle-to-grave
approach to managing bulk residual stresses and their impact on primary
aircraft structure performance.