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-Type of aircraft (pressurized or unpressurized)

Cessna 210-A or Boeing 727-200

-What is the difference between a firewall and bulkhead?

A Firewall is basically a separation between the engine compartment and the cabin or the
rest of the aircraft. Its function is to make sure that in the event of an engine fire the aircraft
structure and its occupants and protected from the heat and flames ling enough to execute
an emergency landing. Isolates the engine (s) from other parts of the aircraft structure. In
single-engine aircraft, that is the part of the fuselage that separates the engine compartment
from the cabin and a bulkhead This set is installed in the back of the plane, precisely in the
tail cone, which is the last section of the fuselage. It is part of the cabin pressurization

-What material would you use to make this bulkhead/firewall?

The following materials may be used in firewalls or shrouds without being tested as

*Stainless steel sheet

*Mild steel(coated with aluminium or otherwise protected against corrosion)
*Terne plate
*Monel metal
*Steel or cooper base alloy firewall fittings
*Titanium sheet

Metal Aircraft usually have the firewall sheet mounted directly onto the aircraft fuselage,
for example Cessna, Piper. But when you have a composite aircraft like a Pelican PL,
DynAero MCR then n extra sheet of fiberfrax high temperature ceramic blanket is installed
between the firewall sheet and the aircraft bulkhead.

Here is an overview of the bulkhead materials that are commonly available today:
Wood Pilings, Treated Lumber Sheeting, Steel Sheet Pilings, Vinyl Sheet Pilings,
Composite Sheet Pilings, Composite Pilings and Aluminum Sheet Pilings.

-What shape would you use to make the bulkhead/firewall?

The shape that I use to make a bulkhead/firewall are:

*Stainless steel sheet, 0.015 inch thick

*Mild steel(coated with aluminium or otherwise protected against corrosion) 0.018 inch
*Terne plate, 0.018 inch thick
*Monel metal, 0.018 inch thick
*Steel or cooper base alloy firewall fittings
*Titanium sheet, 0.016 inch thick
-What process(es) would you choose to make the bulkhead/firewall?

Bulk forming process because the material is usually processed at elevate temperatures, this
reduce the yield strees and therefore the required forces and increase the failure strain, so
more complex shapes can be made in one go.

Aluminium alloys melts about 600-650 Centigrades

Extrusion of Aluminum alloy take place between 350-500 Centigrades
Sheet metal forming, usually takes place at room temperature