40 Questions
What is the primary reason why copper is not used as a structural material in aircraft construction?
Low strength-to-weight ratio
Which alloy of copper is commonly used in electrical components due to its high conductivity?
Brass
What is the primary concern when working with beryllium copper alloys?
Grinding produces airborne contaminants
What is the primary benefit of using copper in electrical wiring?
Excellent electrical and thermal conductivity
What is the primary application of bronze in aircraft construction?
Bushings, bearings, and valve seats
What is the primary concern when working with copper alloys?
Risk of corrosion
What is the primary advantage of using beryllium copper alloys?
High precision and durability
What is the primary testing requirement for copper alloys?
All of the above
What is the primary purpose of alloying agents in steel?
To increase the strength of steel
What is the main difference between ferrous and non-ferrous metals?
Ferrous metals contain iron, while non-ferrous metals do not
What is the process of heating a metal to a high temperature and then rapidly cooling it?
Hardening
What is the primary purpose of heat treatment in aluminium alloys?
To increase the strength of the alloy
What is the term for the ability of a metal to resist cracking or breaking under stress?
Toughness
What is the term for the ability of a metal to be shaped without breaking?
Ductility
What is the term for the amount of force required to cause a material to bend or deform?
Yield strength
What is the term for the ability of a material to return to its original shape after being deformed?
Elasticity
What type of corrosion occurs when two dissimilar metals are in contact with each other in the presence of an electrolyte?
Galvanic corrosion
What is the primary purpose of a flared-tube fitting in a rigid line?
To provide a secure connection
What is the term for the process of inspecting a composite structure using a tapping sound to detect delamination or damage?
Tap testing
What type of rivet is commonly used in aircraft structural applications due to its high strength-to-weight ratio?
2024 Aluminium Alloy (DD) rivet
What is the term for the process of repairing a composite structure by filling a damaged area with a resin material?
Potted repairs
What type of corrosion occurs when a metal is subjected to repeated stress and corrosion, resulting in the formation of cracks?
Stress corrosion
What is the term for the process of inspecting a composite structure using high-frequency sound waves to detect delamination or damage?
Ultrasonic inspection
What type of rivet is commonly used in aircraft applications due to its high resistance to corrosion and high strength?
Corrosion-Resistant Steel (F) rivet
What is the primary reason iron is mixed with carbon and other alloying agents or impurities?
To reduce its corrosion rate
Which of the following is NOT a characteristic of iron in its pure form?
It is brittle
What is the main advantage of using cast iron in engines for items such as valve guides?
Its ability to hold a lubricant film
What is the term for the process of melting two or more compatible pieces of metal into one continuous part?
Fusion
Which of the following metals is NOT a ferrous metal?
Copper
What is the primary composition of steel?
Primarily iron
What is the term for the combination of iron and oxygen?
Iron oxide
What is the main reason cast iron is not commonly used in aircraft structures?
Its low strength-to-weight ratio
What is the primary purpose of annealing a metal?
To soften the metal for forming
Which property of a metal is its ability to resist cutting, penetration, or abrasion?
Hardness
What happens to a metal when it is work-hardened?
It becomes harder and more brittle
Which of the following is a characteristic of a malleable metal?
It is highly ductile and can be formed into thin sheets
What is the relationship between a metal's hardness and its tensile strength?
They are only related in some metals
What is the purpose of heat-treating a metal after it has been formed?
To increase its strength
What is the result of hammering and shaping a fully annealed metal?
It becomes harder and more brittle
Which of the following is a characteristic of a non-malleable metal?
It is brittle and prone to cracking
Study Notes
Composite Structure
- Composites are used in aircraft structures due to their high strength-to-weight ratio, corrosion resistance, and fatigue properties.
Composite Elements
- Composite elements consist of reinforcing fibers, matrices, and fillers.
- Reinforcing fibers include:
- Fiberglass (Glass Cloth)
- Aramid
- Carbon
- Ceramic Fibre
- Fibre science involves the study of fiber properties, manufacturing, and characterization.
Composite Fabrics
- Fabric orientation is crucial in composite manufacturing.
- Fabric styles include:
- Unidirectional
- Bidirectional
- Multidirectional
- Fabric weaves include:
- Plain weave
- Satin weave
Composite Bonding
- Matrix systems include:
- Resin matrix systems
- Adhesives (bonding agents)
- Pre-impregnated materials are used to improve bonding.
Working With Resins and Catalysts
- Resin and catalyst terminology is essential for understanding composite manufacturing.
- Disposing of resins requires proper handling and disposal procedures.
Aircraft Materials - Composite Maintenance, Inspection and Repairs
- Composite inspection methods include:
- Visual inspection
- Tap testing
- Ultrasonic inspection
- Radiographic inspection
- Thermography
- Composite defects and damage include:
- Cosmetic defects
- Impact damage
- Delamination
- Disbonds
- Cracks
- Resin matrix damage
- Water and aircraft fluid intrusion
- Hole damage
- Composite repairs involve:
- Potted repairs
- Injection repairs
- Laminate damage to one surface
- Laminate damage through the part
- Sandwich structure repairs
- Honeycomb core repairs
- Transparent plastic repair
Corrosion
- Chemical fundamentals of corrosion involve:
- Dry corrosion
- Wet corrosion
- Direct chemical attack
- Mercury
- Types of corrosion include:
- Electrochemical series
- Galvanic corrosion
- Stress corrosion
- Surface corrosion
- Pitting corrosion
- Intergranular corrosion
- Filiform corrosion
- Fretting corrosion
- Exfoliation corrosion
- Microbiological corrosion
- Material types and susceptibility to corrosion include:
- Metal corrosion susceptibility
- Aluminium
- Anodised Aluminium
- Magnesium
- Titanium
- Cadmium
- Chromium
- Nickel
- Copper and Copper Alloys
- Silver
- Gold
- Tin
Aircraft Rivets
- Rivet specifications and standards include:
- Rivet codes
- Rivet head design
- Rivet alloys
- 1100 Aluminium (A)
- 2117 Aluminium Alloy (AD)
- 5056 Aluminium Alloy (B)
- 2017 Aluminium Alloy (D)
- 2024 Aluminium Alloy (DD)
- 7050-T73 Aluminium Alloy (E)
- Corrosion-Resistant Steel (F)
- Monel (M)
- Rivet heat treatment is essential for durability.
- Special rivets and fasteners include:
- Special (Blind) Rivet Applications
- Friction-Lock Rivets
- Types of Mechanical-Lock Rivets
- Huck-Loks
- Olympic-LOKs
- CherryMAX
- Hi-Shear Rivets
- Special Fastener Applications
- Hi-Loks
- Jo-Bolt Fastener
Pipes, Hoses and Unions
-
Rigid lines are used for fluid transmission and have specific applications and size designations.
-
Rigid line fittings and unions include:
- Tube flaring
- Flared-tube fittings
- Flareless tube fittings
- Identification of flareless fittings
- Flareless fittings
- Universal Bulkhead Fittings
- Tapered Pipe Thread Fittings
- Banjo Fittings
- Quick-Disconnect Couplings
- Beading
-
Flexible fluid lines have specific applications and identification methods.
-
Flexible pipe fittings include:
- Swaged-end fittings
- Reusable fittings
- Blanks### Thermal Expansion
-
Thermal expansion refers to the ability of metal to be joined by heating and melting.
Fusibility
- Fusibility is the ability of metal to be joined by heating and melting.
- Fusing metal means to melt two or more compatible pieces of metal into one continuous part.
- The correct term is fusion joining or welding.
Ferrous Metals
- Ferrous metals are alloys containing iron as their chief constituent.
- Examples of ferrous metals include steel, cast iron, and titanium, as well as alloys of iron with other metals.
- The most common ferrous metal in aircraft structures is steel, an alloy of iron with a controlled amount of carbon added.
- Iron is a chemical element that is fairly soft, malleable, and ductile in its pure form.
- Iron combines readily with oxygen to form iron oxide, which is more commonly known as rust.
- Cast iron is iron poured from a furnace into molds, normally containing more than 2% carbon and some silicon.
- Cast iron has few aircraft applications because of its low strength-to-weight ratio.
Steel Composition
- Steel is a material composed primarily of iron.
Ferrous Metal Characteristics and Properties
- Strength: the ability of a material to withstand external forces without deformation or breaking.
- Metal loading forces: forces that act on a metal, causing it to deform or break.
- Hardness: a metal's ability to resist cutting, penetration, or abrasion.
- Malleability: a material's ability to be bent, formed, or shaped without cracking or breaking.
- Ductility: a material's ability to be stretched or deformed without breaking.
- Brittleness: the opposite of ductility, where a material breaks or cracks when deformed.
- Elasticity: a material's ability to return to its original shape after deformation.
- Toughness: a material's ability to absorb energy without breaking.
- Conductivity: the ability of a material to conduct heat or electricity.
- Thermal expansion: the ability of a material to expand or contract with temperature changes.
Identification of Steels
- Society of Automotive Engineers (SAE) steel numbering system is used to identify steels.
Alloying Agents in Steel
- Carbon: the most common alloying agent in steel, added to increase strength and hardness.
- Other alloying agents: silicon, manganese, chromium, and nickel, added to improve strength, corrosion resistance, and other properties.
Heat Treatment of Steel
- Purpose of heat treatment: to improve strength, hardness, and other properties of steel.
- Annealing: a process of heating and cooling steel to reduce hardness and improve ductility.
- Normalising: a process of heating and cooling steel to improve strength and hardness.
- Hardening: a process of heating and cooling steel to increase hardness.
- Tempering: a process of heating and cooling steel to reduce hardness and improve toughness.
Non-Ferrous Metals
- Non-ferrous metals are alloys that do not contain iron as their chief constituent.
- Examples of non-ferrous metals include copper, aluminum, magnesium, and titanium.
Properties of Non-Ferrous Metals
- Copper: a bright reddish metallic element with excellent electrical and thermal conductivity.
- Aluminum: a lightweight metal with high strength-to-weight ratio.
- Magnesium: a lightweight metal with high strength-to-weight ratio.
- Titanium: a strong and lightweight metal with high corrosion resistance.
Heat Treatment of Aluminium Alloys
- Purpose of heat treatment: to improve strength, hardness, and other properties of aluminum alloys.
- Solution heat treatment: a process of heating and cooling aluminum alloys to improve strength and hardness.
- Precipitation heat treatment: a process of heating and cooling aluminum alloys to improve strength and hardness.
- Annealing: a process of heating and cooling aluminum alloys to reduce hardness and improve ductility.
Aircraft Materials - Metallic Testing
- Testing of metallic materials is crucial to ensure their safety and performance in aircraft construction.
- Hardness testing: a method of measuring a material's resistance to scratching or abrasion.
- Tensile strength testing: a method of measuring a material's ability to withstand stretching or pulling forces.
- Fatigue strength testing: a method of measuring a material's ability to withstand repeated loading and unloading forces.
- Impact resistance testing: a method of measuring a material's ability to withstand sudden impacts or shocks.
This quiz covers composite structures, their applications, and materials used in them, including composite fibers and reinforcing fibers.
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