Development of all-beryllium riveted structures

Results are presented of a development program aimed at making a full-scale, all-beryllium frustrum by riveted assembly methods. Included are descriptions of the sheet-metal fabrication practices and assembly plans. Results of extensive mechanical testing of both ingot- and powder-source beryllium products that are presented include tensile, notch-tensile, bearing, and shear tests. Although the full-size structure has not been built, examples are given of several conical and cylindrical structures that were made. The largest of these is a 20-in. diameter, 15-in. long cylinder that was roll-formed from one 0.050-in. thick ingot sheet and assembled with 60 countersunk rivets. Tensile testing of riveted flat coupons is also reported as is bulge testing of riveted cylindrical shells. A cost comparison of riveted deep-drawn and powder-source cylinders is made. Results show that when strength and dimensional tolerance requirements are not severe, a riveted assembly approach is warranted. 33 figures, 8 tables