Materials Science and Engineering Quiz

Category B1 and B2 Licences

• The CASA B-06a module covers aircraft materials and corrosion for category B1 and B2 aircraft maintenance licenses.

Knowledge Levels

• The knowledge level indicators are defined as Level 1, Level 2, and Level 3.
• Level 1: Familiarity with basic elements of the subject, ability to give a simple description, and use typical terms.
• Level 2: General knowledge of theoretical and practical aspects, ability to apply knowledge, and use mathematical formulae.
• Level 3: Detailed knowledge of theoretical and practical aspects, ability to combine and apply knowledge, and understand interrelationships with other subjects.

Aircraft Materials - Ferrous (6.1.1)

• Ferrous metal characteristics and properties include strength, metal loading forces, hardness, malleability, ductility, brittleness, elasticity, toughness, conductivity, thermal expansion, and fusibility.
• Metal alloy steels include iron (ferrite) and steel composition.
• Identification of steels includes Society of Automotive Engineers (SAE) steel numbering system.
• Alloying agents in steel include carbon, other agents, and their purposes.
• Heat treatment of steel includes annealing, normalising, hardening, tempering, and case hardening.

Aircraft Materials - Non-Ferrous (6.2.1)

• Properties of non-ferrous metals include identifying aluminium, wrought aluminium alloys designation system, and aluminium and alloys series.
• Heat treatment of aluminium alloys includes solution heat treatment, precipitation heat treatment, annealing, and aluminium alloy temper designations.
• Other alloy types include magnesium, titanium, nickel, monel, copper, and their alloys.

Aircraft Materials - Metallic Testing (6.1.2 and 6.2.2)

• Testing of metallic materials includes metal testing, hardness testing, tensile strength testing, fatigue strength testing, airframe fatigue testing, and impact resistance testing.
• Hardness testing includes Brinell hardness tester and Rockwell hardness tester.

Aircraft Materials - Composite and Non-Metallic (6.3.1.1)

• Non-metallic structural materials include composite materials used in aircraft construction.
• Composite structures consist of a combination of materials.### Composite Structure
• Composites are used in aircraft structures due to their high strength-to-weight ratio
• Composite elements consist of reinforcing fibers, such as fiberglass, aramid, carbon, and ceramic fibers, embedded in a matrix material
• Fiberglass (glass cloth) is a common reinforcing fiber used in composites

Composite Fibers

• Reinforcing fibers include:
  • Fiberglass (glass cloth)
  • Aramid (e.g. Kevlar)
  • Carbon fibers
  • Ceramic fibers
• Fiber science is the study of the properties and behavior of fibers

Composite Fabrics

• Fabric orientation refers to the arrangement of fibers in a composite fabric
• Fabric styles include:
  • Plain weave
  • Satin weave
• Fabric weaves can affect the properties of the composite material

Composite Bonding

• Matrix systems include:
  • Resin matrix systems
  • Adhesives (bonding agents)
• Pre-impregnated materials are used to bond composite layers together
• Fillers can be added to the matrix material to improve its properties

Working with Resins and Catalysts

• Resin and catalyst terminology is important for understanding composite materials
• Disposing of resins requires special care due to their hazardous nature

Aircraft Materials - Composite Maintenance, Inspection, and Repairs

• Composite inspection methods include:
  • Visual inspection
  • Tap testing
  • Ultrasonic inspection
  • Radiographic inspection
  • Thermography
• Composites can be prone to defects and damage, including:
  • Cosmetic defects
  • Impact damage
  • Delamination
  • Disbonds
  • Cracks
  • Resin matrix damage
  • Water and aircraft fluid intrusion
  • Hole damage
• Composite repairs involve:
  • Damage assessment and repair process
  • Potted repairs
  • Injection repairs
  • Laminate damage to one surface
  • Laminate damage through the part
  • Sandwich structure repairs
  • Honeycomb core repairs
  • Transparent plastic repair
• Sealants are used to seal gaps and joints in composite materials

Corrosion

• Corrosion is a chemical reaction that occurs between a material and its environment
• Types of corrosion include:
  • Electrochemical series
  • Galvanic corrosion
  • Stress corrosion
  • Surface corrosion
  • Pitting corrosion
  • Intergranular corrosion
  • Filiform corrosion
  • Fretting corrosion
  • Exfoliation corrosion
  • Microbiological corrosion
• Materials can be susceptible to corrosion, including:
  • Metals (e.g. aluminum, magnesium, titanium, cadmium, chromium, nickel, copper, silver, gold, tin)
  • Effects of corrosion on metals

Aircraft Rivets

• Rivet specifications and standards include:
  • Rivet codes
  • Rivet head design
  • Rivet alloys (e.g. 1100 aluminum, 2117 aluminum alloy, 5056 aluminum alloy, 2024 aluminum alloy)
• Special rivets and fasteners include:
  • Friction-lock rivets
  • Mechanical-lock rivets (e.g. Huck-Loks, Olympic-LOKs, CherryMAX)
  • Hi-shear rivets
  • Special fastener applications (e.g. Hi-Loks, Jo-Bolt fasteners)
• Removal of special fasteners requires specialized techniques

Pipes, Hoses, and Unions

• Rigid lines and fittings are used in aircraft systems
• Flexible fluid lines and fittings are used in aircraft systems
• Identification of flexible hoses is critical for proper maintenance

Aircraft Materials - Ferrous (6.1.1)

• Ferrous metal characteristics and properties include:
  • Strength
  • Hardness
  • Malleability
  • Ductility
  • Brittleness
  • Conductivity
  • Expansion
  • Elasticity
  • Toughness
  • Fusibility
  • Density
• Metal alloy steels are used in aircraft construction
• Heat treatment of alloy steels can affect their properties

Metal Alloy Steels

• Metal characteristics and properties can be altered by adding small amounts of other materials
• Strength can be classified into different types, including:
  • Tensile strength
  • Compressive strength
  • Shear strength
  • Torsional strength
  • Bending strength
  • Fatigue strength
  • Impact strength (toughness)
• Metal loading forces include:
  • Tensile strength
  • Compressive strength
  • Shear strength
  • Torsional strength
  • Bending strength
  • Fatigue strength
  • Impact strength (toughness)

Strength

• Tensile strength is a measure of a metal's ability to withstand stress in tension
• Compressive strength is a metal's ability to withstand being pressed or squeezed
• Shear strength is a metal's ability to withstand shear stress
• Torsional strength is a metal's ability to resist rotational shear
• Bending strength is a metal's ability to resist bending
• Fatigue strength is a metal's ability to resist repeated loading
• Impact strength (toughness) is a metal's ability to resist shock

Metal Loading Forces

• The remaining four fundamental loading forces (excluding tension) are:
  • Compressive strength
  • Shear strength
  • Torsional strength
  • Bending strength
• Fundamental loading forces can affect the properties of metals

Fracture and Fatigue

• Fracture is a result of a metal's inability to withstand stress
• Fatigue strength is a metal's ability to resist repeated loading
• Impact strength (toughness) is a metal's ability to resist shock### Materials and Hardware

Metal Properties

• Metals can be hardened through heat-treating or work hardening, while others are softened by annealing.
• Hardness and malleability are generally considered opposite properties.
• Malleability is the ability of a material to be bent, formed, or shaped without cracking or breaking.
• Ductility is the ability of metal to be drawn into wire stock, extrusions, or rods.
• Brittleness is a material's tendency to break or shatter when exposed to stress.
• Elasticity is a metal's tendency to return to its original shape after normal stretching and bending.
• Toughness is a material's ability to resist tearing or breaking when it is bent or stretched.

Conductivity and Thermal Expansion

• Conductivity is the property that enables a metal to carry heat or electricity.
• Thermal expansion is the ability of a metal to expand when heated and shrink when cooled.
• Coefficient of expansion is the predictable amount of expansion or contraction at specific temperatures.

Ferrous Metals

• Ferrous metals contain iron as their chief constituent, including steel, cast iron, and titanium.
• Iron is a chemical element that is fairly soft, malleable, and ductile in its pure form.
• Cast iron has few aircraft applications due to its low strength-to-weight ratio.
• Steel is a material composed primarily of iron, with carbon as the second element.

Steel Composition

• The difference between steel, cast iron, and wrought iron is primarily based on carbon content.
• The Society of Automotive Engineers (SAE) uses a four-digit numerical index system to represent chemical composition standards for steel specifications.

Identification of Steels

• SAE designations for major classifications of steel include:
  • 1xxx – Carbon steels
  • 2xxx – Nickel steels
  • 3xxx – Nickel-chromium steels
  • 4xxx – Molybdenum steels
  • 5xxx – Chromium steels
  • 6xxx – Chromium-vanadium steels
  • 7xxx – Tungsten steels
  • 8xxx – Nickel-chromium-molybdenum steels
  • 9xxx – Silicon-manganese steels

Alloying Agents in Steel

• Carbon is the most common alloying element found in steel.
• Other alloying agents include:
  • Silicon
  • Manganese
  • Sulphur
  • Phosphorous
  • Nickel
  • Chromium
  • Molybdenum
  • Vanadium
  • Tungsten

Heat Treatment of Steel

• Heat treatment of steel is the process of heating and cooling carbon steel to change its physical and mechanical properties.
• Purpose of heat treatment is to increase strength, toughness, and ductility.
• Types of heat treatment include:
  • Annealing
  • Normalising
  • Hardening
  • Tempering

Category B1 and B2 Licences

• The CASA B-06a module covers aircraft materials and corrosion for category B1 and B2 aircraft maintenance licenses.

Knowledge Levels

• The knowledge level indicators are defined as Level 1, Level 2, and Level 3.
• Level 1: Familiarity with basic elements of the subject, ability to give a simple description, and use typical terms.
• Level 2: General knowledge of theoretical and practical aspects, ability to apply knowledge, and use mathematical formulae.
• Level 3: Detailed knowledge of theoretical and practical aspects, ability to combine and apply knowledge, and understand interrelationships with other subjects.

Aircraft Materials - Ferrous (6.1.1)

• Ferrous metal characteristics and properties include strength, metal loading forces, hardness, malleability, ductility, brittleness, elasticity, toughness, conductivity, thermal expansion, and fusibility.
• Metal alloy steels include iron (ferrite) and steel composition.
• Identification of steels includes Society of Automotive Engineers (SAE) steel numbering system.
• Alloying agents in steel include carbon, other agents, and their purposes.
• Heat treatment of steel includes annealing, normalising, hardening, tempering, and case hardening.

Aircraft Materials - Non-Ferrous (6.2.1)

• Properties of non-ferrous metals include identifying aluminium, wrought aluminium alloys designation system, and aluminium and alloys series.
• Heat treatment of aluminium alloys includes solution heat treatment, precipitation heat treatment, annealing, and aluminium alloy temper designations.
• Other alloy types include magnesium, titanium, nickel, monel, copper, and their alloys.

Aircraft Materials - Metallic Testing (6.1.2 and 6.2.2)

• Testing of metallic materials includes metal testing, hardness testing, tensile strength testing, fatigue strength testing, airframe fatigue testing, and impact resistance testing.
• Hardness testing includes Brinell hardness tester and Rockwell hardness tester.

Aircraft Materials - Composite and Non-Metallic (6.3.1.1)

• Non-metallic structural materials include composite materials used in aircraft construction.
• Composite structures consist of a combination of materials.### Composite Structure
• Composites are used in aircraft structures due to their high strength-to-weight ratio
• Composite elements consist of reinforcing fibers, such as fiberglass, aramid, carbon, and ceramic fibers, embedded in a matrix material
• Fiberglass (glass cloth) is a common reinforcing fiber used in composites

Composite Fibers

• Reinforcing fibers include:
  • Fiberglass (glass cloth)
  • Aramid (e.g. Kevlar)
  • Carbon fibers
  • Ceramic fibers
• Fiber science is the study of the properties and behavior of fibers

Composite Fabrics

• Fabric orientation refers to the arrangement of fibers in a composite fabric
• Fabric styles include:
  • Plain weave
  • Satin weave
• Fabric weaves can affect the properties of the composite material

Composite Bonding

• Matrix systems include:
  • Resin matrix systems
  • Adhesives (bonding agents)
• Pre-impregnated materials are used to bond composite layers together
• Fillers can be added to the matrix material to improve its properties

Working with Resins and Catalysts

• Resin and catalyst terminology is important for understanding composite materials
• Disposing of resins requires special care due to their hazardous nature

Aircraft Materials - Composite Maintenance, Inspection, and Repairs

• Composite inspection methods include:
  • Visual inspection
  • Tap testing
  • Ultrasonic inspection
  • Radiographic inspection
  • Thermography
• Composites can be prone to defects and damage, including:
  • Cosmetic defects
  • Impact damage
  • Delamination
  • Disbonds
  • Cracks
  • Resin matrix damage
  • Water and aircraft fluid intrusion
  • Hole damage
• Composite repairs involve:
  • Damage assessment and repair process
  • Potted repairs
  • Injection repairs
  • Laminate damage to one surface
  • Laminate damage through the part
  • Sandwich structure repairs
  • Honeycomb core repairs
  • Transparent plastic repair
• Sealants are used to seal gaps and joints in composite materials

Corrosion

• Corrosion is a chemical reaction that occurs between a material and its environment
• Types of corrosion include:
  • Electrochemical series
  • Galvanic corrosion
  • Stress corrosion
  • Surface corrosion
  • Pitting corrosion
  • Intergranular corrosion
  • Filiform corrosion
  • Fretting corrosion
  • Exfoliation corrosion
  • Microbiological corrosion
• Materials can be susceptible to corrosion, including:
  • Metals (e.g. aluminum, magnesium, titanium, cadmium, chromium, nickel, copper, silver, gold, tin)
  • Effects of corrosion on metals

Aircraft Rivets

• Rivet specifications and standards include:
  • Rivet codes
  • Rivet head design
  • Rivet alloys (e.g. 1100 aluminum, 2117 aluminum alloy, 5056 aluminum alloy, 2024 aluminum alloy)
• Special rivets and fasteners include:
  • Friction-lock rivets
  • Mechanical-lock rivets (e.g. Huck-Loks, Olympic-LOKs, CherryMAX)
  • Hi-shear rivets
  • Special fastener applications (e.g. Hi-Loks, Jo-Bolt fasteners)
• Removal of special fasteners requires specialized techniques

Pipes, Hoses, and Unions

• Rigid lines and fittings are used in aircraft systems
• Flexible fluid lines and fittings are used in aircraft systems
• Identification of flexible hoses is critical for proper maintenance

Aircraft Materials - Ferrous (6.1.1)

• Ferrous metal characteristics and properties include:
  • Strength
  • Hardness
  • Malleability
  • Ductility
  • Brittleness
  • Conductivity
  • Expansion
  • Elasticity
  • Toughness
  • Fusibility
  • Density
• Metal alloy steels are used in aircraft construction
• Heat treatment of alloy steels can affect their properties

Metal Alloy Steels

• Metal characteristics and properties can be altered by adding small amounts of other materials
• Strength can be classified into different types, including:
  • Tensile strength
  • Compressive strength
  • Shear strength
  • Torsional strength
  • Bending strength
  • Fatigue strength
  • Impact strength (toughness)
• Metal loading forces include:
  • Tensile strength
  • Compressive strength
  • Shear strength
  • Torsional strength
  • Bending strength
  • Fatigue strength
  • Impact strength (toughness)

Strength

• Tensile strength is a measure of a metal's ability to withstand stress in tension
• Compressive strength is a metal's ability to withstand being pressed or squeezed
• Shear strength is a metal's ability to withstand shear stress
• Torsional strength is a metal's ability to resist rotational shear
• Bending strength is a metal's ability to resist bending
• Fatigue strength is a metal's ability to resist repeated loading
• Impact strength (toughness) is a metal's ability to resist shock

Metal Loading Forces

• The remaining four fundamental loading forces (excluding tension) are:
  • Compressive strength
  • Shear strength
  • Torsional strength
  • Bending strength
• Fundamental loading forces can affect the properties of metals

Fracture and Fatigue

• Fracture is a result of a metal's inability to withstand stress
• Fatigue strength is a metal's ability to resist repeated loading
• Impact strength (toughness) is a metal's ability to resist shock### Materials and Hardware

Metal Properties

• Metals can be hardened through heat-treating or work hardening, while others are softened by annealing.
• Hardness and malleability are generally considered opposite properties.
• Malleability is the ability of a material to be bent, formed, or shaped without cracking or breaking.
• Ductility is the ability of metal to be drawn into wire stock, extrusions, or rods.
• Brittleness is a material's tendency to break or shatter when exposed to stress.
• Elasticity is a metal's tendency to return to its original shape after normal stretching and bending.
• Toughness is a material's ability to resist tearing or breaking when it is bent or stretched.

Conductivity and Thermal Expansion

• Conductivity is the property that enables a metal to carry heat or electricity.
• Thermal expansion is the ability of a metal to expand when heated and shrink when cooled.
• Coefficient of expansion is the predictable amount of expansion or contraction at specific temperatures.

Ferrous Metals

• Ferrous metals contain iron as their chief constituent, including steel, cast iron, and titanium.
• Iron is a chemical element that is fairly soft, malleable, and ductile in its pure form.
• Cast iron has few aircraft applications due to its low strength-to-weight ratio.
• Steel is a material composed primarily of iron, with carbon as the second element.

Steel Composition

• The difference between steel, cast iron, and wrought iron is primarily based on carbon content.
• The Society of Automotive Engineers (SAE) uses a four-digit numerical index system to represent chemical composition standards for steel specifications.

Identification of Steels

• SAE designations for major classifications of steel include:
  • 1xxx – Carbon steels
  • 2xxx – Nickel steels
  • 3xxx – Nickel-chromium steels
  • 4xxx – Molybdenum steels
  • 5xxx – Chromium steels
  • 6xxx – Chromium-vanadium steels
  • 7xxx – Tungsten steels
  • 8xxx – Nickel-chromium-molybdenum steels
  • 9xxx – Silicon-manganese steels

Alloying Agents in Steel

• Carbon is the most common alloying element found in steel.
• Other alloying agents include:
  • Silicon
  • Manganese
  • Sulphur
  • Phosphorous
  • Nickel
  • Chromium
  • Molybdenum
  • Vanadium
  • Tungsten

Heat Treatment of Steel

• Heat treatment of steel is the process of heating and cooling carbon steel to change its physical and mechanical properties.
• Purpose of heat treatment is to increase strength, toughness, and ductility.
• Types of heat treatment include:
  • Annealing
  • Normalising
  • Hardening
  • Tempering

Stress-Strain Curve

• The stress-strain curve for structural steel (tensile strength) shows the relationship between stress (σ) and strain (ε)
• The curve has four key points: yield strength, ultimate strength, necking, and fracture

Types of Strength

• Compressive strength: a metal's ability to withstand being pressed or squeezed
• Shear strength: a metal's ability to withstand shear stress
• Torsional strength: a metal's ability to resist rotational shear
• Bending strength: a metal's ability to resist bending

Additional Types of Strength

• Fatigue strength (endurance strength): a metal's ability to resist repeated loading
• Impact strength (toughness): a metal's ability to resist shock### Materials and Hardware
• Elasticity: A metal's tendency to return to its original shape after normal stretching and bending. Examples: spring steel used in landing gear, aircraft skins expanding and contracting when pressurized.
• Toughness: A material's ability to resist tearing or breaking when bent or stretched. Examples: hammer faces, wrenches.

Properties of Metals

• Conductivity: The ability of a metal to carry heat or electricity. Examples: thermal conductivity, electrical conductivity.
• Thermal Expansion: The ability of a metal to expand when heated and shrink when cooled. The amount of expansion or contraction is predictable at specific temperatures.
• Hardness: A metal's ability to resist cutting, penetration, or abrasion. Relates to tensile strength, but not always absolute. Examples: heat-treating, work hardening, annealing.
• Malleability: A material's ability to be bent, formed, or shaped without cracking or breaking. Examples: annealing, hammering, pressing, rolling into thin sheets.
• Ductility: The ability of metal to be drawn into wire stock, extrusions, or rods. Examples: control cables, ease of forming, resistance to failure under shock loads.
• Brittleness: A material's tendency to break or shatter when exposed to stress. Examples: cast iron, very hard steel, ductile fracture vs brittle fracture.

Composite Structures

• Composite Materials: A combination of materials with different properties to create a new material with unique properties.
• Fibres: Reinforcing materials used in composite structures. Examples: fibreglass, aramid, carbon, ceramic fibre.
• Fibre Science: The study of the properties and behaviour of fibres.
• Composite Bonding: The process of combining materials to create a composite structure. Examples: matrix systems, resin matrix systems, adhesives, pre-impregnated materials.

Corrosion

• Corrosion: The deterioration of materials due to chemical reactions with the environment. Examples: dry corrosion, wet corrosion, direct chemical attack, galvanic corrosion.
• Types of Corrosion: Electrochemical series, galvanic corrosion, stress corrosion, surface corrosion, pitting corrosion, intergranular corrosion.
• Material Susceptibility: The likelihood of a material to corrode. Examples: aluminium, magnesium, titanium, cadmium, chromium, nickel, copper, silver, gold, tin.

Aircraft Rivets

• Rivet Specifications: Standards and codes for rivets. Examples: solid-shank rivets, rivet codes, rivet head design, rivet alloys.
• Special Rivets: Blind rivets, friction-lock rivets, mechanical-lock rivets, Huck-Loks, Olympic-LOKs, CherryMAX.

Pipes, Hoses, and Unions

• Rigid Lines: Pipelines made of rigid materials. Examples: size designations, tube flaring, flared-tube fittings, flareless tube fittings.
• Flexible Fluid Lines: Pipelines made of flexible materials. Examples: outer cover, flexible line identification, types of flexible hose.
• Fittings and Unions: Connections and joints used in piping systems. Examples: swaged-end fittings, reusable fittings, blanks.

Stress-Strain Curve

• The stress-strain curve for structural steel (tensile strength) shows the relationship between stress (σ) and strain (ε)
• The curve has four key points: yield strength, ultimate strength, necking, and fracture

Types of Strength

• Compressive strength: a metal's ability to withstand being pressed or squeezed
• Shear strength: a metal's ability to withstand shear stress
• Torsional strength: a metal's ability to resist rotational shear
• Bending strength: a metal's ability to resist bending

Additional Types of Strength

• Fatigue strength (endurance strength): a metal's ability to resist repeated loading
• Impact strength (toughness): a metal's ability to resist shock### Materials and Hardware
• Elasticity: A metal's tendency to return to its original shape after normal stretching and bending. Examples: spring steel used in landing gear, aircraft skins expanding and contracting when pressurized.
• Toughness: A material's ability to resist tearing or breaking when bent or stretched. Examples: hammer faces, wrenches.

Properties of Metals

• Conductivity: The ability of a metal to carry heat or electricity. Examples: thermal conductivity, electrical conductivity.
• Thermal Expansion: The ability of a metal to expand when heated and shrink when cooled. The amount of expansion or contraction is predictable at specific temperatures.
• Hardness: A metal's ability to resist cutting, penetration, or abrasion. Relates to tensile strength, but not always absolute. Examples: heat-treating, work hardening, annealing.
• Malleability: A material's ability to be bent, formed, or shaped without cracking or breaking. Examples: annealing, hammering, pressing, rolling into thin sheets.
• Ductility: The ability of metal to be drawn into wire stock, extrusions, or rods. Examples: control cables, ease of forming, resistance to failure under shock loads.
• Brittleness: A material's tendency to break or shatter when exposed to stress. Examples: cast iron, very hard steel, ductile fracture vs brittle fracture.

Composite Structures

• Composite Materials: A combination of materials with different properties to create a new material with unique properties.
• Fibres: Reinforcing materials used in composite structures. Examples: fibreglass, aramid, carbon, ceramic fibre.
• Fibre Science: The study of the properties and behaviour of fibres.
• Composite Bonding: The process of combining materials to create a composite structure. Examples: matrix systems, resin matrix systems, adhesives, pre-impregnated materials.

Corrosion

• Corrosion: The deterioration of materials due to chemical reactions with the environment. Examples: dry corrosion, wet corrosion, direct chemical attack, galvanic corrosion.
• Types of Corrosion: Electrochemical series, galvanic corrosion, stress corrosion, surface corrosion, pitting corrosion, intergranular corrosion.
• Material Susceptibility: The likelihood of a material to corrode. Examples: aluminium, magnesium, titanium, cadmium, chromium, nickel, copper, silver, gold, tin.

Aircraft Rivets

• Rivet Specifications: Standards and codes for rivets. Examples: solid-shank rivets, rivet codes, rivet head design, rivet alloys.
• Special Rivets: Blind rivets, friction-lock rivets, mechanical-lock rivets, Huck-Loks, Olympic-LOKs, CherryMAX.

Pipes, Hoses, and Unions

• Rigid Lines: Pipelines made of rigid materials. Examples: size designations, tube flaring, flared-tube fittings, flareless tube fittings.
• Flexible Fluid Lines: Pipelines made of flexible materials. Examples: outer cover, flexible line identification, types of flexible hose.
• Fittings and Unions: Connections and joints used in piping systems. Examples: swaged-end fittings, reusable fittings, blanks.

Composite Structure

• Composites are used in aircraft structures due to their high strength-to-weight ratio, corrosion resistance, and fatigue life.
• Composite elements include fibers, fabrics, and bonding systems.

Composite Fibers

• Reinforcing fibers include fibreglass, aramid, carbon, and ceramic fibers.
• Fibreglass (glass cloth) is a popular choice for composites due to its low cost, high strength, and resistance to fatigue and corrosion.
• Aramid fibers have high strength, stiffness, and resistance to impact and fatigue, but are costly and difficult to process.
• Carbon fibers have high strength, stiffness, and resistance to fatigue, but are expensive and brittle.
• Ceramic fibers have high strength, stiffness, and resistance to heat, corrosion, and fatigue.

Composite Fabrics

• Fabric orientation is critical in composite design, as it affects the strength and stiffness of the material.
• Fabric styles include woven, knitted, and non-woven fabrics.
• Fabric weaves include plain, satin, and twill weaves, each with its own set of characteristics.

Composite Bonding

• Matrix systems include resin, adhesive, and filler materials.
• Resin matrix systems are commonly used in composites, with polymeric resins being the most popular choice.
• Adhesives (bonding agents) are used to bond composite materials together.
• Pre-impregnated materials (pre-pregs) are composite materials with pre-applied resin.

Aircraft Materials - Composite Maintenance, Inspection, and Repairs

• Composite inspection methods include visual, tap testing, ultrasonic, radiographic, and thermography.
• Composite defects and damage include cosmetic defects, impact damage, delamination, disbonds, cracks, and resin matrix damage.
• Composite repairs involve assessment and repair of damaged areas, with techniques including potted, injection, and laminate repairs.

Corrosion

• Corrosion is the deterioration of materials due to chemical reactions with the environment.
• Types of corrosion include electrochemical, galvanic, stress, surface, pitting, intergranular, filiform, fretting, exfoliation, and microbiological corrosion.
• Materials susceptible to corrosion include metals, with aluminium, magnesium, titanium, and copper being commonly used in aircraft.

Aircraft Rivets

• Rivets are used to fasten materials together, with specifications and standards governed by codes and regulations.
• Rivet types include solid-shank, blind, and special rivets, with different materials and alloys used depending on the application.
• Rivet heat treatment is used to increase strength and corrosion resistance.

Pipes, Hoses, and Unions

• Rigid lines include pipes and tubes, with size designations and fittings used to connect them.
• Flexible fluid lines include hoses, with identification and types of hose used depending on the application.
• Fittings and unions include flared, flaredless, and swaged-end fittings, with materials and alloys used depending on the application.

Aircraft Materials - Ferrous

• Ferrous metals include iron and its alloys, such as steel, cast iron, and stainless steel.

• Iron is a chemical element that is soft, malleable, and ductile, but prone to rust.

• Steel is an alloy of iron with a controlled amount of carbon, with different types and alloys used depending on the application.

• Alloying elements include chromium, nickel, molybdenum, vanadium, and tungsten, which add strength, toughness, and corrosion resistance to steel.### Magnesium Alloys

• Tendency to crack when formed, overcome by heating parts when forming, such as hot-dimpling thin material.

• Readiness to burn in a dust or small particle form, caution must be exercised when grinding and machining.

• Fire extinguished by smothering with dry sand or other dry material that excludes air and cools the surface.

• Water intensifies the fire.

Heat Treatment of Magnesium Alloys

• Solution heat treatment increases tensile strength, ductility, and resistance to shock.
• Artificially aging (precipitation heat-treated) after solution heat treatment increases hardness and yield strength.
• Solution heat treatment increases hardness of magnesium alloys used in gearbox and generator housings.

Titanium and Its Alloys

• Lightweight metals with high strength and excellent corrosion resistance characteristics.
• Sensitive to nitrogen and oxygen, must be converted to titanium dioxide with chlorine gas and a reducing agent before use.
• High strength-to-weight ratio, used extensively in civilian aerospace industry.

Carbon Steel Characteristics

• Silicon acts as a hardener, improves ductility in small quantities.
• Manganese improves anti-wear properties, non-magnetic, and resistant to abrasion.
• Sulphur is an undesirable impurity, causes brittleness, and must be removed in the refining process.
• Manganese counters sulphur's effects, improves forging characteristics, and makes metal less brittle.
• Sulphur improves machinability of steel in small amounts.
• Phosphorous raises yield strength, improves resistance to atmospheric corrosion.
• Nickel adds strength, hardness, and increases yield strength.

Composite Structure

• Composites are used in aircraft structures due to their high strength-to-weight ratio, corrosion resistance, and fatigue life.
• Composite elements include fibers, fabrics, and bonding systems.

Composite Fibers

• Reinforcing fibers include fibreglass, aramid, carbon, and ceramic fibers.
• Fibreglass (glass cloth) is a popular choice for composites due to its low cost, high strength, and resistance to fatigue and corrosion.
• Aramid fibers have high strength, stiffness, and resistance to impact and fatigue, but are costly and difficult to process.
• Carbon fibers have high strength, stiffness, and resistance to fatigue, but are expensive and brittle.
• Ceramic fibers have high strength, stiffness, and resistance to heat, corrosion, and fatigue.

Composite Fabrics

• Fabric orientation is critical in composite design, as it affects the strength and stiffness of the material.
• Fabric styles include woven, knitted, and non-woven fabrics.
• Fabric weaves include plain, satin, and twill weaves, each with its own set of characteristics.

Composite Bonding

• Matrix systems include resin, adhesive, and filler materials.
• Resin matrix systems are commonly used in composites, with polymeric resins being the most popular choice.
• Adhesives (bonding agents) are used to bond composite materials together.
• Pre-impregnated materials (pre-pregs) are composite materials with pre-applied resin.

Aircraft Materials - Composite Maintenance, Inspection, and Repairs

• Composite inspection methods include visual, tap testing, ultrasonic, radiographic, and thermography.
• Composite defects and damage include cosmetic defects, impact damage, delamination, disbonds, cracks, and resin matrix damage.
• Composite repairs involve assessment and repair of damaged areas, with techniques including potted, injection, and laminate repairs.

Corrosion

• Corrosion is the deterioration of materials due to chemical reactions with the environment.
• Types of corrosion include electrochemical, galvanic, stress, surface, pitting, intergranular, filiform, fretting, exfoliation, and microbiological corrosion.
• Materials susceptible to corrosion include metals, with aluminium, magnesium, titanium, and copper being commonly used in aircraft.

Aircraft Rivets

• Rivets are used to fasten materials together, with specifications and standards governed by codes and regulations.
• Rivet types include solid-shank, blind, and special rivets, with different materials and alloys used depending on the application.
• Rivet heat treatment is used to increase strength and corrosion resistance.

Pipes, Hoses, and Unions

• Rigid lines include pipes and tubes, with size designations and fittings used to connect them.
• Flexible fluid lines include hoses, with identification and types of hose used depending on the application.
• Fittings and unions include flared, flaredless, and swaged-end fittings, with materials and alloys used depending on the application.

Aircraft Materials - Ferrous

• Ferrous metals include iron and its alloys, such as steel, cast iron, and stainless steel.
• Iron is a chemical element that is soft, malleable, and ductile, but prone to rust.
• Steel is an alloy of iron with a controlled amount of carbon, with different types and alloys used depending on the application.
• Alloying elements include chromium, nickel, molybdenum, vanadium, and tungsten, which add strength, toughness, and corrosion resistance to steel.

Composite Structure

• Composites are used in aircraft structures due to their high strength-to-weight ratio, corrosion resistance, and fatigue life.
• Composite elements include fibers, fabrics, and bonding systems.

Composite Fibers

• Reinforcing fibers include fibreglass, aramid, carbon, and ceramic fibers.
• Fibreglass (glass cloth) is a popular choice for composites due to its low cost, high strength, and resistance to fatigue and corrosion.
• Aramid fibers have high strength, stiffness, and resistance to impact and fatigue, but are costly and difficult to process.
• Carbon fibers have high strength, stiffness, and resistance to fatigue, but are expensive and brittle.
• Ceramic fibers have high strength, stiffness, and resistance to heat, corrosion, and fatigue.

Composite Fabrics

• Fabric orientation is critical in composite design, as it affects the strength and stiffness of the material.
• Fabric styles include woven, knitted, and non-woven fabrics.
• Fabric weaves include plain, satin, and twill weaves, each with its own set of characteristics.

Composite Bonding

• Matrix systems include resin, adhesive, and filler materials.
• Resin matrix systems are commonly used in composites, with polymeric resins being the most popular choice.
• Adhesives (bonding agents) are used to bond composite materials together.
• Pre-impregnated materials (pre-pregs) are composite materials with pre-applied resin.

Aircraft Materials - Composite Maintenance, Inspection, and Repairs

• Composite inspection methods include visual, tap testing, ultrasonic, radiographic, and thermography.
• Composite defects and damage include cosmetic defects, impact damage, delamination, disbonds, cracks, and resin matrix damage.
• Composite repairs involve assessment and repair of damaged areas, with techniques including potted, injection, and laminate repairs.

Corrosion

• Corrosion is the deterioration of materials due to chemical reactions with the environment.
• Types of corrosion include electrochemical, galvanic, stress, surface, pitting, intergranular, filiform, fretting, exfoliation, and microbiological corrosion.
• Materials susceptible to corrosion include metals, with aluminium, magnesium, titanium, and copper being commonly used in aircraft.

Aircraft Rivets

• Rivets are used to fasten materials together, with specifications and standards governed by codes and regulations.
• Rivet types include solid-shank, blind, and special rivets, with different materials and alloys used depending on the application.
• Rivet heat treatment is used to increase strength and corrosion resistance.

Pipes, Hoses, and Unions

• Rigid lines include pipes and tubes, with size designations and fittings used to connect them.
• Flexible fluid lines include hoses, with identification and types of hose used depending on the application.
• Fittings and unions include flared, flaredless, and swaged-end fittings, with materials and alloys used depending on the application.

Aircraft Materials - Ferrous

• Ferrous metals include iron and its alloys, such as steel, cast iron, and stainless steel.
• Iron is a chemical element that is soft, malleable, and ductile, but prone to rust.
• Steel is an alloy of iron with a controlled amount of carbon, with different types and alloys used depending on the application.
• Alloying elements include chromium, nickel, molybdenum, vanadium, and tungsten, which add strength, toughness, and corrosion resistance to steel.