ASSIGNMENT- FERROUS ALLOY

The approximate percentage of the above alloying agents to

achieve the desired properties of the steel are Carbon (low,
medium and high carbon steels) (0.10 - 0.30%), (0.30 - 0.50%)
0.50 - 1.05%).Silicon is (0.2 -2 .0%) Phosphorus is (0.05%).Nickel
is (0.3%).Chromium is (3 - 5%) and chrome-molybdenum 0.4 -
1.10% Cr 0.08 - 0.35% Mo. Nickel/Chromium is (1.25 - 3.5% Ni 0.8
- 1.5% Cr).Molybdenum (0.2-5%).Vanadium is (0.2%) and
Tungsten is (Up to 18%).

Carbon is classified in 3 which is low carbon steel, medium

carbon steel and high carbon steel. Low carbon steel Used in
safety wire, cable bushings and threaded rod ends. Easily welded
and machined but does not easily accept heat treatment.Medium
carbon steel Improved heat treatment capabilites while retaining
ductility.High carbon steels are very hard steel, used in springs,
files and cutting tools

Silicon Increases strength, Magnetism and used for spring

steels.Phosphorus raises yield strength and improves resistance to
corrosion.Nickel is used in SAE 2330 steel contains 3 percent
nickel and 0.03 percent carbon, and is used in producing aircraft
hardware such as bolts, nuts, rod ends and pins.Chromium used in
balls and rollers of antifriction bearings.Chrome-molybdenum is
used in terms of toughness and wear resistance make it a good
material for engine cylinders and other highly stressed
parts.Nickel/Chromium used for forged or machined parts requiring
high strength, ductility, shock resistance and
toughness. Molybdenum used in high strength structural members
and cylinder barrels..Vanadium
Uses in most wrenches and ball bearings are made of chrome-
vanadium steel.Last but not lease,Tungsten are typically used for
breaker contacts in magnetos and for high speed cutting tools.
ASSIGNMENT 2- NON FERROUS METAL

Pure aluminium while being exceptionally light , lacks sufficent

strength for aircraft structural applications, but when it is alloyed
with other compatible metals it gains considerable strength while
retaining it low weight and some of its corrosion resistant
properties carries over to the newly formed alloy. When aluminium
is mixed with copper or zinc, the resultant alloy is strong as steel
with only one third the weight.

Clad aluminium is a new corrosion resistant aluminum

product which is markedly superior to the present strong alloys. Its
use should result in greatly increased life of a structural part.
Alclad is a heat-treated aluminum, copper, manganese,
magnesium alloy that has the corrosion resistance of pure metal at
the surface and the strength of the strong alloy underneath. The
clad surface protects the underlying aluminium alloy from corrosive
attack, however if it is scratched it loses this protective property.
The thickness of the pure aluminium layer is approximately 5% of
the alloys total thickness.

Magnesium and Dow metal alloys Magnesium alloy is one of

the lightest metals with sufficient strength to be used in aircraft
structures. It is typically alloyed with the following elements such
as, Zinc,Aluminium,Thorium, Zirconium,Manganese
Magnesium has some serious drawbacks as an aircraft alloy.
Magnesium is highly reactive and readily corrodes as well as being
prone to cracking. This limits magnesium alloy use in thin sheet
metal and metal forming and is the reason why most magnesium
components are cast. Magnesium also burns readily, and caution
must be taken when grinding or machining. If a fire does occur, dry
powder fire extinguishers must be used as putting water on a
magnesium fire only intensifies the blaze. .DOW METAL is
trademark name applied to any of various magnesium alloys
containing more than 85 percent magnesium, characterized by
extreme lightness.
Titanium falls between aluminium and stainless steel in terms of
elasticity, density, and elevated temperature strength. It has a
melting point of from 1500 °C to 1735 °C, low thermal conductivity,
and a low coefficient of expansion. It is light, strong, and resistant
to stress corrosion cracking. Titanium is approximately 60 percent
heavier than aluminium and about 50 percent lighter than stainless
steel.

• A (alpha) — all around performance; good weldability; tough and

strong both cold and hot,

and resistant to oxidation. 

• B (beta)—bendability; excellent bend ductility; strong both cold

and hot, but vulnerable to

contamination. 

• C (combined alpha and beta for compromise performances) —

strong when cold and warm, but weak when hot; good bendability;
moderate contamination resistance; excellent forgeability.

Nickel adds strength and hardness to steel and increases its yield
strength. It also slows the rate of hardening when steel is heat-
treated, which increases the depth of hardening and produces a
finer grain structure. The finer grain structure reduces steel's
tendency to warp and scale when heat-treated. SAE 2330 steel
contains 3 percent nickel and 0.03 percent carbon, and is used in
producing aircraft hardware such as bolts, nuts, rod ends and pins.
 Monel is a trademark of Special Metals Corporation for a series of
nickel alloys, primarily composed of nickel (up to 67%) and copper,
with some iron and other trace elements. In the 1960s, Monel
metal found bulk uses in aircraft construction, especially in making
the frames and skins of experimental rocket planes, such as the
North American X-15, to resist the great heat generated by
aerodynamic friction during extremely high speed flight. Monel
metal retains its strength at very high temperatures, allowing it to
maintain its shape at high atmospheric flight speeds, a trade off
against the increased weight of the parts due to Monel's high
density.

Inconel is a registered trademark of Special Metals Corporation

that refers to a family of austenitic nickel-chromium-based
superalloys. Inconel alloys are typically used in high temperature
applications. Inconel is often encountered in extreme
environments. It is common in gas turbine blades, seals and
combustors as well as turbocharger rotors and seals because of
their ability to maintain strength and corrosion resistance under
extremely high temperature conditions. Inconel contains
approximately 80 percent nickel and 14 percent chromium and
small amounts of iron and other elements.

luminium bronze is a type of bronze in which aluminium is the

main alloying metal added to copper. A variety of aluminium
bronzes of differing compositions have found industrial use, with
most ranging from 5% to 11% aluminium by weight, the remaining
mass being copper; other alloying agents such as iron, nickel,
manganese, and silicon are also sometimes added to aluminium
bronzes. Aluminium bronzes have good tearing qualities, great
strength, hardness and resistance to both shock and fatigue.
Because of these properties they are used for diaphragms, gears
and pumps. These alloys are useful in areas exposed to salt water
and corrosive gasses.
Muntz metal is a form of alpha-beta brass with about 60% copper,
40% zinc and a trace of iron. It is named after George Fredrick
Muntz who commercialised the alloy following his patent of 1832.
The alloy must be worked hot and is used today for corrosion
resistant machine parts.

Copper tubing was once used extensively in aircraft fluid lines but
because of its weight and tendency to become brittle when
subjected to vibration it has been almost entirely replace with
aluminium alloy. Brass fittings for fluid lines have also been
replaced either aluminium or steel fittings.

TIn , this silvery, malleable other metal is not easily oxidized in air
and is used to coat other metals to prevent corrosion. The first
alloy, used in large scale since 3000 BC, was bronze, an alloy of
tin and copper. After 600 BC pure metallic tin was produced.
Pewter, which is an alloy of 85-90% tin with the remainder
commonly consisting of copper, antimony and lead, was used for
flatware from the Bronze Age until the 20th century. In modern
times tin is used in many alloys, most notably tin/lead soft solders,
typically containing 60% or more of tin.

Zinc is hard and brittle at most temperatures but becomes

malleable between 100 and 150 C. Above 210 C, the metal
becomes brittle again and can be pulverized by beating. Zinc is a
fair conductor of electricity. For a metal, zinc has relatively low
melting (419.5 C) and boiling points (907 C).

A widely used alloy which contains zinc is brass, in which copper is

alloyed with anywhere from 3% to 45% zinc, depending upon the
type of brass.

Brass is generally more ductile and stronger than copper and has
superior corrosion resistance.

Zinc is most commonly used as an anti-corrosion agent.

Galvanization, which is the coating of iron or steel to protect the
metals against corrosion.

The 7xxx series aluminium alloys are made harder and stronger
with the addition of zinc. Some widely used forms of zinc
aluminium alloys are 7075 and 7178

ASSIGNMENT 3 - NON FERROUS METAL PART 2

Most external aircraft surfaces are made of clad aluminium.

ALCLAD consists of a pure aluminium coating rolled onto the
surface of heat-treated aluminium alloy. The thickness of this
coating is approximately 5 percent of the alloys thickness on each
side. For example, if an ALCLAD sheet of aluminium is .040 inch
thick, then 5%, or 0.020 inches of pure aluminium is applied to
each side. This results in an alloy thickness of 0.036 inch.

This clad surface greatly increases the corrosion resistance of an

aluminium alloy. However if it is penetrated, corrosion agents can
attack the alloy within. For this reason sheet metal must be
protected from scratches and abrasions. In addition to providing a
starting point for corrosion abrasions create potential stress points.

Precautions when handling and storing ALCLAD:

Sheets stored on edge in rack

Do not remove protective paper
Don't cut off corner ID markings
Keep work area clean
Have assistance when handling large sheets
Aluminium sheets are identified across the sheet in rows as follows

Four digit designation e.g. 2024

Federal specification no e.g. QQ-A-50/5
Military specification e.g. MIL-A-8902
Aeronautical material spec e.g. AMS 4049
Material thickness e.g. .032

the relative disadvantages of titanium when subjected to very

high temperatures is because of the high melting point of titanium,
high temperature properties are disappointing. The ultimate yield
strength of titanium drops rapidly above 425°C. The absorption of
oxygen and nitrogen from the air at temperatures above 530°C
makes the metal brittle on long exposure that it soon becomes
worthless. However titanium does have some merit for short time
exposure up to 1650°C where strength is not important. Aircraft
firewalls demand this requirement.

ASSIGNMENT 4- Aluminium Alloying Metals

Copper Alloys with the 2xxx series utilise copper as the

principal alloying agent. When aluminium is mixed with copper
certain metallic changes take place in the resultant alloy's grain
structure, these changes are beneficial and produce greater
strength. A major drawback to aluminium-copper alloys is their
susceptibility to inter-granular corrosion when improperly heat-
treated. Most aluminium alloy used in aircraft structures is
aluminium-copper alloy. Two of the most commonly used in the
construction of skins and rivets are 2017 and 2024.

Manganese alloys with the 3xxx series utilise manganese as the

principal alloying agent, and are generally considered non heat-
treatable. The most common variation is 3003 which offers
moderate strength and has good working characteristics.

Silicon alloys with the 4xxx series utilise silicon which lowers a
metals melting temperature. This results in an alloy that works well
for welding and brazing.

Magnesium is used to produce 5xxx series alloys. These alloys

possess good welding characteristics and corrosion resistance. If
the metal is exposed to high temperature or excessive cold
working its susceptibility to corrosion increases.

Magnesium and Silicon are added to aluminium the resultant alloy

carries the 6xxx series designation. in these alloys the silicon and
manganese form magnesium silicide which makes the alloy heat-
treatable. The 6xxx series has medium strength and good forming
and corrosion resistance properties.
Zinc is added to aluminium alloy to produce 7xxx series alloys
making it harder and stronger. Some widely used zinc-aluminium
alloys are 7075 and 7178. The aluminium-zinc alloy 7075 has a
tensile of 77 KSI and a bearing strength of 139 KSI. However the
alloy is very difficult to bend. An even stronger zinc alloy is 7178
which has a tensile strength of 84 KSI and a bearing strength of
151 KSI.