Aircraft Materials & Processes PDF

AIRCRAFT MATERIALS & PROCESSES Ferrous & Non-Ferous Metals Types of ferrous metal Non-ferrous aircraft metal Aluminum and aluminum alloys Wrought aluminum Effects of alloying elements ICE BREAKER THORWUG NIRO WROUGHT IRON ISSORERCINON TREISTAN CORROSION RESISTANT URBIDALTIY DURABI...

AIRCRAFT MATERIALS & PROCESSES Ferrous & Non-Ferous Metals Types of ferrous metal Non-ferrous aircraft metal Aluminum and aluminum alloys Wrought aluminum Effects of alloying elements ICE BREAKER THORWUG NIRO WROUGHT IRON ISSORERCINON TREISTAN CORROSION RESISTANT URBIDALTIY DURABILITY YALLUIN ALLOM ALUMINUM ALLOY FEMETALRROUS FERROUS METAL  FERROUS METALS Ferrous metals contain iron, Ferrous metals are also often alloys, meaning they are made of several different metals and other elements. Because they have iron, ferrous metals are magnetic.  FERROUS METALS Cast Iron Wrought Iron Carbon Steel Iron-Based Superalloys  FERROUS AIRCRAFT METAL KEY CHARACTERISTICS Magnetic Strong and durable Can be brittle if thin Can be hardened and strengthened through alloying with other elements  NON-FERROUS METAL Non-ferrous metals do not contain iron, making them different from ferrous metals. They resist rust, lighter, good conductors of electricity and heat, and are non-magnetic.  NON-FERROUS METAL Aluminum Copper Zinc Titanium TABLE OF FERROUS METAL NON-FERROUS AIRCRAFT METAL Non-ferrous metals are metals that do not contain significant amounts of iron. In the context of aircraft, these metals are valued for their lightweight, resistance to corrosion, and ability to withstand extreme temperatures.  NON-FERROUS AIRCRAFT METAL KEY CHARACTERISTICS Lightweight: Non-ferrous metals are generally lighter than ferrous metals, which helps improve fuel efficiency and overall performance in aircraft. Corrosion Resistance: Many non-ferrous metals naturally resist corrosion, making them suitable for harsh environments.  NON-FERROUS AIRCRAFT METAL KEY CHARACTERISTICS Conductivity: Some non-ferrous metals, like aluminum and copper, have good electrical and thermal conductivity. Malleability and Ductility: These metals can be easily shaped and formed, allowing for complex designs in aircraft components.  NON-FERROUS AIRCRAFT METAL COMMON NON-FERROUS METALS IN AVIATION 1. Aluminum: - Widely used due to its excellent strength- to-weight ratio. - Commonly found in aircraft structures and skin. 2. Titanium: - Known for its high strength and corrosion resistance. - Used in critical components like engine parts and airframes.  NON-FERROUS AIRCRAFT METAL COMMON NON-FERROUS METALS IN AVIATION 3. Magnesium: One of the lightest structural metals. - Used in components where weight savings are crucial. 4. Copper: Excellent electrical conductivity. - Used in wiring and electronic components.  NON-FERROUS AIRCRAFT METAL COMMON NON-FERROUS METALS IN AVIATION 5. Nickel Alloys: High strength and heat resistance. Commonly used in turbine engines.  NON-FERROUS AIRCRAFT METAL APPLICATIONS IN AIRCRAFT: Structural Components: Fuselage, wings, and tail assemblies often utilize aluminum and titanium.  NON-FERROUS AIRCRAFT METAL APPLICATIONS IN AIRCRAFT: Engine Parts: Nickel alloys and titanium are critical in components that endure high temperatures and stresses.  NON-FERROUS AIRCRAFT METAL APPLICATIONS IN AIRCRAFT: Electrical Systems: Copper is used extensively in wiring due to its conductivity.  NON-FERROUS AIRCRAFT METAL ADVANTAGES OF NON-FERROUS METALS: Performance: Enhance overall aircraft performance through weight reduction. Durability: Improve longevity and reliability in various operating conditions. Safety: Contribute to the structural integrity of aircraft, ensuring passenger safety. NON-FERROUS AIRCRAFT METAL Non-ferrous metals play a vital role in modern aviation, providing the necessary strength, weight savings, and durability required for efficient and safe flight.  ALUMINUM IT IS LIGHTWEIGHT. ALUMINUM'S VERSATILITY IT IS EXTREMELY MAKES IT IN THE AIRCRAFT ALL ALUMINUM INDUSTRY, AS IT ALLOWS RESISTANT TO FOR THE CONSTRUCTION IS NOT THE CORROSION. SAME. OF MORE RELIABLE AND IT IS STRONG. LESS COSTLY AIRCRAFT.  ALUMINUM ALLOYS Lightweight Early 20th century Corrosion Resistant -began developing aluminum alloys “A mixture of aluminum and High Strength-to- to enhance the metal’s strength and other elements” other properties. Weight Ratio Formability  WROUGHT ALUMINUM Wrought aluminum refers to aluminum that has been mechanically worked or shaped into a desired form, such as sheets, plates, bars, tubes, or other structural components. Unlike cast aluminum, which is shaped by pouring molten aluminum into molds, wrought aluminum is processed through techniques like rolling, extruding, forging, or drawing to create different shapes and sizes. KEY CHARACTERISTICS OF WROUGHT ALUMINUM High Ductility: Wrought aluminum alloys are more ductile, meaning they can be easily formed or worked into complex shapes without breaking. This makes them ideal for applications requiring precise, custom shapes. Strength and Toughness: Wrought aluminum alloys generally exhibit better mechanical properties, including strength and toughness, compared to cast aluminum. Many wrought aluminum alloys can also be heat-treated to further improve their strength. KEY CHARACTERISTICS OF WROUGHT ALUMINUM Lightweight: Like other aluminum products, wrought aluminum is lightweight, which is especially advantageous in industries like aerospace and transportation where weight reduction is important. KEY CHARACTERISTICS OF WROUGHT ALUMINUM Corrosion Resistance: Many wrought aluminum alloys offer good resistance to corrosion, particularly those that belong to the 1xxx, 5xxx, and 6xxx series. KEY POINTS IN ALUMINUM ALLOY SERIES 1xxx Series: Best for electrical and thermal applications, but low strength limits its use in load-bearing structures. 2xxx Series: Excellent strength, especially in aerospace, but needs protection against corrosion. 5xxx Series: Ideal for marine environments due to its superior corrosion resistance. 6xxx Series: A versatile alloy with good strength and workability, commonly used in construction and automotive industries, as well as non-critical aerospace applications.  COMMON PROCESSING METHODS FOR WROUGHT ALUMINUM Rolling: This process involves passing aluminum through rollers to reduce thickness and create sheets, plates, or foils. Forging: In this process, aluminum is heated and shaped using compressive forces, resulting in high-strength components. Drawing: This technique involves pulling aluminum through a die to create wires or tubes with specific dimensions.  Applications of Wrought Aluminum in Aerospace Aircraft Component Description Benefits of Aluminum Lightweight and formable, contributing to fuel Fuselage Panels Form the curved outer shell of the aircraft. efficiency and design flexibility. Includes external panels and internal supports (spars High strength and low weight optimize lift-to- Wing Structures and ribs). drag ratio and bear loads during flight. Landing Gear Can handle heavy loads during takeoff and Lightweight parts like struts and frames. Components landing without adding unnecessary weight. Internal Structural Frames, bulkheads, and beams that reinforce the Provides rigidity and stability during flight. Components fuselage and distribute stress. The outermost layer that protects internal Distributes stress, resists corrosion, and protects Aircraft Skins components and contributes to aerodynamics. against environmental factors. Certain parts of the engine that require heat Improves engine performance and efficiency Engine Components dissipation. due to low weight. EFFECTS OF ALLOYING ELEMENTS GENERAL SPECIFIC EFFECTS BASED EFFECTS: ELEMENT TYPE: Toughness Carbon Machinability Titanium Fatigue Resistance Chromium Corrosion Resistance Aluminum EFFECTS OF ALLOYING ELEMENTS It increases malleability, ductility, & mechanical resistance. In addition it improves various properties such as strength, hardness, resistance to high temperature, & toughness. EFFECTS OF ALLOYING ELEMENTS 1000 Series (soft alloys) has a minimum of 99% aluminum with no major alloying additions. These compositions are characterized by excellent corrosion resistance, high thermal and electrical conductivity, low mechanical properties, and excellent workability. These alloys are non-heat treatable. EFFECTS OF ALLOYING ELEMENTS 2000 Siries (hard alloys) series grades are known as the copper grades of aluminum, as copper is the main alloying element. The addition of copper increases the alloy's strength and hardness, which in turn improves its machinability. THANK YOU FOR LISTENING