Appendix BAppendix BNOTE: Samples did not undergo HIP operation & thus Contained PorosityHeat TreatmentSimulated Sand Removal TreatmentSolution TreatmentQuenchAging TreatmentT6B1 Hour at 495C + Air Quench*8 Hours at 495CBoiling Water5 Hours at 190C

T7B1 Hour at 495C + Air Quench*8 Hours at 495CBoiling Water4 Hours at 260C

Note: Air quench had an Average cooling rate of 0.87C/second (between 480 and 216C)

Table B-1 Averaged Data From the Room Temperature Tensile Tests of the W319 Aluminum AlloyNOTE: Samples did not undergo HIP operation & thus Contained PorosityTensile Strengths(MPa)Elongation(%)Heat TreatmentAverage SDAS(m)Average Solid'n Time(min)Sample SourceNumber of Samples TestedUltimate0.2%YieldModulus(GPa)TotalElasticPlasticT6B230.7Wedge4Average425369674.10.83.3St.Dev.7972.30.12.3T6B7016.1Wedge6Average308297690.70.70.1St.Dev.111580.20.10.1T6B10043.4Wedge5Average232*---232700.40.40St.Dev.14*90.10.10T7B230.7Wedge4Average327223704.40.53.9St.Dev.5250.300.3T7B6010.9Wedge24Average264209751.70.31.3St.Dev.11530.300.3T7B6010.9EC**20Average215***215740.50.30.2St.Dev.9640.100.1T7B7016.1Wedge6Average225183681.30.50.8St.Dev.11320.300.3T7B10043.4Wedge5Average166151740.60.40.2St.Dev.7330.100.1*Samples failed prior to the 0.2% offset; a yield strength could not be calculated**Samples taken from 23 mm-thick engineered component***50% of the samples failed prior to 0.2% yield; Average UTS of samples with a 0.2% yield strength was 2219 Mpa

Appendix DAppendix DNOTE: Samples did not undergo HIP operation & thus Contained Porosity

Heat TreatmentSimulated Sand Removal TreatmentSolution TreatmentQuenchAging TreatmentT6B1 Hour at 495C + Air Quench*8 Hours at 495CBoiling Water5 Hours at 190C

T7B1 Hour at 495C + Air Quench*8 Hours at 495CBoiling Water4 Hours at 260C

Note: Air quench had an Average cooling rate of 0.87C/second (between 480 and 216C)

Table D-1 The Room Temperature Fatigue Data of the W319-T6B Aluminum AlloyID#Average SDAS(m)Average Solid'n Time(min)Sample SourceAlt. Stress (R=-1) (Mpa)Stress as a % of YSResultCycles?230.7Wedge82.722Run Out10,000,010?230.7Wedge82.722Run Out10,000,001?230.7Wedge89.624Run Out11899537?230.7Wedge89.624Run Out11866786?230.7Wedge96.526Run Out14072526?230.7Wedge96.526Run Out13766416?230.7Wedge96.526Run Out10345882?230.7Wedge96.526Run Out10000005?230.7Wedge96.526Failed1453109?230.7Wedge103.428Run Out24286620?230.7Wedge103.428Run Out14873452?230.7Wedge110.230Run Out12373260?230.7Wedge110.230Failed297342?230.7Wedge12434Failed580147?230.7Wedge137.837Failed5066736?230.7Wedge137.837Failed260067?230.7Wedge137.837Failed245644?230.7Wedge137.837Failed196820?230.7Wedge137.837Failed169251?230.7Wedge137.837Failed167292?230.7Wedge137.837Failed148186?230.7Wedge165.445Failed125530?230.7Wedge165.445Failed111302?230.7Wedge165.445Failed85481?230.7Wedge192.952Failed93677?7016.1Wedge41.314Run Out10000012?7016.1Wedge48.216Run Out10000002?7016.1Wedge55.119Failed2460662?7016.1Wedge55.119Failed2027535?7016.1Wedge55.119Failed354739?7016.1Wedge6221Failed1593606?7016.1Wedge68.923Failed1470939?7016.1Wedge68.923Failed592213?7016.1Wedge68.923Failed560327?7016.1Wedge68.923Failed488480?7016.1Wedge68.923Failed358881?7016.1Wedge96.53Failed277300?7016.1Wedge96.5232Failed241947?7016.1Wedge96.532Failed233762?7016.1Wedge96.532Failed159596?7016.1Wedge96.532Failed136101?7016.1Wedge110.237Failed78980?7016.1Wedge12442Failed25893?7016.1Wedge137.846Failed51648?7016.1Wedge137.846Failed50888?7016.1Wedge137.846Failed28358?7016.1Wedge137.846Failed18792?7016.1Wedge137.846Failed14883?10043.4Wedge3113Run Out10837350?10043.4Wedge34.515Failed3013038?10043.4Wedge37.916Run Out24131487?10043.4Wedge41.318Run Out14042947?10043.4Wedge41.318Run Out10000000?10043.4Wedge41.318Failed1596811?10043.4Wedge48.221Run Out12406892?10043.4Wedge55.124Failed1073590?10043.4Wedge55.124Failed787273?10043.4Wedge55.124Failed569868?10043.4Wedge55.124Failed306179?10043.4Wedge55.124Failed234354?10043.4Wedge68.930Failed2310259?10043.4Wedge68.930Failed647712?10043.4Wedge68.930Failed542576?10043.4Wedge68.930Failed169467?10043.4Wedge68.930Failed167213?10043.4Wedge82.736Failed174061?10043.4Wedge96.542Failed207697?10043.4Wedge96.542Failed162743?10043.4Wedge96.542Failed107310?10043.4Wedge96.542Failed103069?10043.4Wedge96.542Failed100847?10043.4Wedge110.248Failed54172?10043.4Wedge137.859Failed25209?10043.4Wedge137.859Failed24066?10043.4Wedge137.859Failed19730?10043.4Wedge137.859Failed8595?10043.4Wedge137.859Failed4459

Table D-2 The Room Temperature Fatigue Data of the W319-T7B Aluminum AlloyID#Average SDAS(m)Average Solid'n Time(min)Sample SourceAlt. Stress (R=-1) (Mpa)Stress as a % of YSResultCycles?230.7Wedge68.931Run Out10629484?230.7Wedge82.737Run Out20714016?230.7Wedge96.543Run Out13050004?230.7Wedge96.543Failed5399544?230.7Wedge96.543Failed1355784?230.7Wedge96.543Failed1014936?230.7Wedge96.543Failed714421?230.7Wedge96.543Failed537542?230.7Wedge96.543Failed426292?230.7Wedge96.543Failed409420?230.7Wedge96.543Failed242539?230.7Wedge110.249Failed603345?230.7Wedge110.249Failed392762?230.7Wedge110.249Failed164046?230.7Wedge12456Failed432450?230.7Wedge137.862Failed258384?230.7Wedge137.862Failed176945?230.7Wedge137.862Failed134424?230.7Wedge137.862Failed112470?230.7Wedge137.862Failed65264?230.7Wedge137.862Failed52236?230.7Wedge137.862Failed40607?230.7Wedge180.581Failed7429?230.7Wedge180.581Failed5710?230.7Wedge180.581Failed2198?6010.9Wedge55.126Run Out12000000?6010.9Wedge55.126Run Out12000000?6010.9Wedge68.933Run Out12000000?6010.9Wedge68.933Failed1068888?6010.9Wedge68.933Failed721381?6010.9Wedge68.933Failed546253?6010.9Wedge68.933Failed516720?6010.9Wedge96.546Failed225827?6010.9Wedge96.546Failed224401?6010.9Wedge96.546Failed151904?6010.9Wedge96.546Failed146992?6010.9Wedge96.546Failed117265?6010.9Wedge137.866Failed26472?6010.9Wedge137.866Failed16775?6010.9Wedge137.866Failed14062?6010.9Wedge137.866Failed7532?6010.9Wedge137.866Failed4897?6010.9EC*34.517Run Out12000000!?6010.9EC*37.918Run Out12000000?6010.9EC*41.320Run Out12000000?6010.9EC*41.320Run Out12000000?6010.9EC*41.320Failed2201901?6010.9EC*41.320Failed1979869?6010.9EC*44.821Run Out12000000?6010.9EC*44.821Run Out12000000?6010.9EC*55.126Failed1656791?6010.9EC*55.126Failed1306661?6010.9EC*55.126Failed1210245?6010.9EC*55.126Failed951826?6010.9EC*68.933Failed582905?6010.9EC*68.933Failed526387?6010.9EC*68.933Failed240137?6010.9EC*68.933Failed206300?6010.9EC*96.546Failed214068?6010.9EC*96.546Failed102361?6010.9EC*96.546Failed76874?6010.9EC*96.546Failed57514?6010.9EC*96.546Failed56842?6010.9EC*137.866Failed46451?6010.9EC*137.866Failed27123?6010.9EC*137.866Failed11621?7016.1Wedge48.226Run Out14109710?7016.1Wedge51.728Run Out15000009?7016.1Wedge55.130Run Out15000007?7016.1Wedge55.130Run Out14081685?7016.1Wedge55.130Failed4136743?7016.1Wedge55.130Run Out3392444?7016.1Wedge55.130Failed2504142?7016.1Wedge58.632Failed3396452?7016.1Wedge68.938Failed987904?7016.1Wedge82.745Failed378352?7016.1Wedge89.649Failed130235?7016.1Wedge89.649Failed98048?7016.1Wedge89.649Failed90074?7016.1Wedge96.553Failed264664?7016.1Wedge96.553Failed143549?7016.1Wedge96.553Failed127094?7016.1Wedge96.553Failed111094?7016.1Wedge96.553Failed92518?7016.1Wedge96.553Failed82391?7016.1Wedge137.875Failed12993?7016.1Wedge137.875Failed9079?7016.1Wedge137.875Failed8279?7016.1Wedge137.875Failed8112?7016.1Wedge137.875Failed4318?7016.1Wedge144.579Failed3899?7016.1Wedge144.579Failed1272?7016.1Wedge144.779Failed3252?10043.4Wedge3121Run Out13019256?10043.4Wedge41.327Run Out17240320?10043.4Wedge18.232Failed1117522?10043.4Wedge48.232Failed689061?10043.4Wedge48.232Failed4122503?10043.4Wedge55.137Failed1896922?10043.4Wedge55.137Failed1376901?10043.4Wedge55.137Failed1084440?10043.4Wedge55.137Failed691099?10043.4Wedge55.137Failed629789?10043.4Wedge68.946Failed378655?10043.4Wedge75.850Failed149458?10043.4Wedge75.850Failed40604?10043.4Wedge75.850Failed116651?10043.4Wedge82.755Failed124478?10043.4Wedge96.564Failed48499?10043.4Wedge96.564Failed37007?10043.4Wedge96.564Failed28438?10043.4Wedge96.564Failed25232?10043.4Wedge96.564Failed21721?10043.4Wedge120.680Failed6502?10043.4Wedge120.680Failed3194?10043.4Wedge120.680Failed3135?10043.4Wedge137.891Failed1515?10043.4Wedge137.891Failed659?10043.4Wedge137.891Failed642?10043.4Wedge137.891Failed366?10043.4Wedge137.891Failed130

(WO RO) W Dist. T6BAverage SDAS(m)Alt. Stress (R=-1) (Mpa)CyclesBasquin2396.514531091224363.22323899110.2297342474299.1930443031245801471631851.99942545137.82600671214933.87154951137.82456441147555.114424137.8196820919468.000931966137.8169251790676.143815345137.8167292781524.442698458137.8148186692268.495001038165.41255301410584.13901221165.41113021250703.70302189165.485481960552.40011872192.9936772205070.75806276137.85066736k=0.20823669858.861752

Average SDAS(m)Alt. Stress (R=-1) (Mpa)CyclesBasquin7055.12460662126837.87918256855.12027535104511.80997976555.135473918285.4623769315621593606147741.93731288868.91470939230523.48146681868.959221392810.784492020968.956032787813.655630762268.948848076553.895319188168.935888156243.323178114996.5277300232258.34603329396.5241947202647.71023338396.5233762195792.19432179896.5159596133672.92821323396.5136101113994.205385781110.278980128048.8871907891242589375503.4635960159137.851648254586.684746444137.850888250840.443257765137.828358139784.100178897137.81879292630.7500727072137.814883k=0.20173362.2527315933Average SDAS(m)Alt. Stress (R=-1) (Mpa)CyclesBasquin10034.5301303819434.518262596741.3159681124160.815025751955.1107359063689.63850697155.178727346704.172706804855.156986833806.841454084555.130617918163.758817077255.123435413902.813497389868.92310259395300.28305945468.9647712110827.71972363568.954257692838.268947882568.916946728996.901676061668.916721328611.22767240482.717406170750.958072327696.5207697175428.42127468996.5162743137458.64198089996.510731090637.919117690396.510306987055.81665773296.510084785179.0348454172110.25417285839.5910653314137.825209115213.804211564137.824066109989.900914574137.81973090172.8889322926137.8859539282.1074694909137.84459k=0.21120379.16430558

(W RO) W Ave. T6BAve. SDASStressResultsCyclesRankPln(-ln(1-P))ln(N)kScale factorexp(scale)Weibull averageAve YSAve %elon.2382.7Run Out10,000,0104,012,289,924150.6041666667-0.076058454315.20487268960.20814.44843928751,883,1181,670,006.713694.182.7Run Out10,000,0014,012,286,313140.5625-0.190339325515.204871789689.6Run Out11,899,5377,018,457,084170.68750.151132538215.764053963289.6Run Out11,866,7866,999,140,241160.64583333330.03728390315.761297876796.5Run Out14,072,52611,857,254,544210.85416666670.655077053416.28845043696.5Run Out13,766,41611,599,331,823200.81250.515201894116.26645805396.5Run Out10,345,8828,717,252,066190.77083333330.387508677515.980814616296.5Run Out10,000,0058,425,822,395180.72916666670.267161702515.9468116431103.4Run Out24,286,62028,521,828,238240.97916666671.353564797617.1661802552103.4Run Out14,873,45217,467,150,359220.89583333330.816144641216.6758325526110.2Run Out12,373,26019,736,960,246230.93751.019781440516.798003590596.5Failed1,453,1091,224,36390.3541666667-0.82733294414.017931449110.2Failed297,342474,29910.0208333333-3.860692774813.0695936105124Failed580,1471,631,852120.4791666667-0.427212089814.3052261238137.8Failed5,066,736ERROR:#N/AERROR:#N/AERROR:#N/A23.8874682977137.8Failed260,0671,214,93480.3125-0.981647055514.010200206623,669,858,862137.8Failed245,6441,147,55570.2708333333-1.152478523613.9531442498137.8Failed196,820919,46850.1875-1.571952527313.7315505219137.8Failed169,251790,67640.1458333333-1.847511462313.5806437366137.8Failed167,292781,52430.1041666667-2.207266774913.569001705137.8Failed148,186692,26820.0625-2.740493006513.4477291579165.4Failed125,5301,410,584110.4375-0.552752143114.1595144596165.4Failed111,3021,250,704100.3958333333-0.685367161714.0392169133165.4Failed85,481960,55260.2291666667-1.345985400813.7752638147192.9Failed93,6772,205,071130.5208333333-0.30692361614.6062701562

Ave. SDASStressResultsCyclesRankPln(-ln(1-P))ln(N)kScale factorexp(scale)Weibull averageAve YSAve %elon.7041.3Run Out10000012122,829,946220.93478260871.004312271311.71855612450.20112.0562956596172,180152,895.312970.748.2Run Out10000002264,923,010230.97826086961.342510013512.487194532955.1Failed2460662126,838110.4565217391-0.494680704511.750665008155.1Failed2027535104,51290.3695652174-0.773607914811.557055358255.1Failed35473918,28510.0217391304-3.81767207119.8138616175