关键词：新能源与高效节能；复合材料；能源效率；加工制造
摘 要：The current preferred method of making unitized aluminum aircraft structure is to machine it from a solid plate of material. This approach can be very wasteful in terms of material and energy, as much of the starting material is usually removed to create the final required part geometry. Nearer-net starting product forms, such as die forgings, require special dies, which have high costs, long lead times, and limited lifetimes. The forging process generally results in significant residual stresses in forgings, which can lead to production issues related to distortion when material is removed via machining to final part geometries. What is needed are ways to make tailored, near-net shape machining blanks, without expensive dies, and low residual stresses. A major objective of this project was to identify the energy benefits of combining a variety of solid state joining techniques, which are geometry independent, in order to produce high performance aluminum structures, while enabling the achievement of manufacturing benefits of lower-cost, faster cycle-time, and highly efficient joined structural assemblies. A further objective was to produce an energy consumption prediction model, which was capable of calculating the total energy consumption, solid waste burden, acidification potential, and CO2 burden in producing a starting product form, and then calculating the further energy consumption and environmental impacts of fabricating a final part configuration from the starting configuration. Yet another objective was to be able to utilize the model to compute and compare, on an individual part/geometry basis, multiple possible manufacturing pathways, to identify the best balance of energy consumption, environmental impact, and costs. Finally, another project goal was to help enable Solid State Joining (SSJ) technologies become better characterized, better utilized, and considered as mainstream processes, especially replacing/supplanting the energy intensive arc-welding/ fusion processes of joining such as gas-tungsten arc welding.