AIRCRAFT MATERIALS

AND PROCESSES
AMT 611
 Ever since the Wright brothers built their Flyer back in 1903 ,
the materials used in airplane design have been constantly evolving.

The original Wright Flyer was comprised primarily of spruce and ash wood with
muslin covering the wings, while today’s airliners are made mostly of aluminum with
some structure made from steel.
 History of Materials Science
• materials closely connected
our culture
• the development and
advancement of societies are
dependent on the available
materials and their use
• early civilizations designated
by level of materials
development
• initially natural materials
• develop techniques to
produce materials with
superior qualities (heat
treatments and addition of
other substances)

MATERIALS SELECTION!
 Materials Tetrahedron
structure • arrangement of internal components
• subatomic
• atomic
• microscopic
• macroscopic (bulk)

characterization
processing properties
• material characteristic
• method of preparing
• response to external
material
stimulus
• mechanical, electrical,
performance thermal, magnetic,
• behavior in a optical, deteriorative
particular application
 Classification of Materials
Metals Ceramics & Glasses Polymers
• good conductors of • thermally and • very large molecules
electricity and heat electrically insulating • low density, low weight
• lustrous appearance • resistant to high • maybe extremely
• susceptible to temperatures and flexible
corrosion harsh environments
• strong, but • hard, but brittle
deformable
 Classification of Materials: A Few Additional Catagories

Biomaterials Semiconductors Composites

• implanted in human • electrical properties • consist of more than
body between conductors one material type
• compatible with and insulators • designed to display
body tissues • electrical properties a combination of
can be precisely properties of each
controlled component

Intel Pentium 4 fiberglass surfboards

hip replacement
 Choice of Medium

structure

processing properties

performance
 TYPES OF STRUCTURE
• Metals Properties • Polymers Properties
• good conductors of • very large molecules
electricity and heat • low density, light
• lustrous appearance weight materials
• susceptible to • maybe extremely
corrosion flexible
• strong, but
deformable

• Ceramics and Properties

Glasses • thermally and
electrically insulating
• resistant to high
temperatures and
harsh environments
• hard, but brittle
Atomic Arrangement: Ordered vs. Disordered
Crystalline:
atoms are arranged in a 3D, periodic array giving the material “long range order”

• stacking can effect

properties (i.e.
ductility)
• anisotropic materials

hexagonal close-packed

Non-crystalline or amorphous:
atoms only have short-range, nearest neighbor order
• viscous materials (generally complex formulas) or rapid
cooling
• isotropic materials
 Microstructure
Single Crystal
• the periodic arrangement of
atoms extends throughout the
entire sample
• difficult to grow, environment must
be tightly controlled
• anisotropic materials
Polycrystalline
• many small crystals or grains
• small crystals misoriented with
respect to on another
• several crystals are initiated and
grow towards each other
• anisotropic or isotropic materials
 Bulk Properties
Mechanical: Electrical:
elastic modulus conductivity
shear modulus resistivity
hardness capacitance

+ -

Thermal:
Optical: thermal expansion
reflectivity heat capacity
absorbance thermal conductivity
emission
Processing Structure Properties Performance
Performance Goal: increased strength from a metallic material
In actuality, crystals are NOT perfect. There are defects!
In metals, strength is determined by how easily defects can move!
OFF

slow cooling

quenching
 Aluminum Oxide (Al2O3)

single-crystal polycrystalline, polycrystalline,

(transparent) fully dense 5% porosity
(translucent) (opaque)
 PROPERTIES OF MATERIALS
• Hardness - refers to the ability of a material to resist
abrasion, penetration, cutting action, or permanent
distortion.
• Strength - one of the most important properties of a
material is strength. Strength is the ability of a material to
resist deformation. Strength is also the ability of a material
to resist stress without breaking.
The type of load or stress on the material affects the strength
it exhibits.
• Density - Is the material’s mass per unit volume.
• Malleability - is the ability to be bent or molded into different
forms.
A metal which can be hammered, rolled, or pressed into various
shapes without cracking, breaking, or leaving some other
detrimental effect, is said to be malleable.
• Ductility - is the property of a metal which permits it to be
permanently drawn, bent, or twisted into various shapes without
breaking.
This property is essential for metals used in making wire and
tubing. ; the ability to be drawn out into a thin wire form.
• Elasticity - is the property that enables a metal to return to
its original size and shape when the force which causes the
change of shape is removed.
• Toughness -a material which possesses toughness will
withstand tearing or shearing and breaking.
• Brittleness- describes a material's tendency to break or
shatter when exposed to stress.
Because structural metals are often subjected to shock loads,
brittleness is not a very desirable property. Cast iron, cast aluminum,
and very hard steel are examples of brittle metals.
• Fusibility - is the ability of a metal to become liquid by the
application of heat.
Metals are fused in welding. Steels fuse around 2,600 °F and
aluminum alloys at approximately 1,100 °F.
• Thermal Expansion - refers to contraction and expansion that
are reactions produced in metals as the result of heating or
cooling.
Cooling and heating affect the design of welding jigs, castings,
and tolerances necessary for hot rolled material.
• Conductivity - is the property which enables a metal to carry
heat or electricity.
The heat conductivity of a metal is especially important in
welding because it governs the amount of heat that will be
required for proper fusion.
CLASSIFICATIONS OF METAL
 Metals

Ferrous Non Ferrous

Pure Non Non
Ferrous Ferrous
Pure Ferrous
Metals Alloys
Ferrous Alloys
Metals
Copper Alum. Brass Bronze Solder
Steel
Iron Zinc Tin Copper Copper Lead
+ + +
High Zinc Tin Tin
Speed Lead Silver
Steel Alloying.

High Speed Steel Cutting Gold Mercury

Tools

Mercury is the only non

ferrous metal that is liquid
at room temperature.
 Much of the metal used on today's aircraft contains no iron.
It does not rust in the same way when exposed to moisture.
Aluminum, Copper, Titanium, and Magnesium are some of the most
common nonferrous metals used in aircraft construction and repair.
Other examples : Zinc, Tin, Lead, Silver and Gold
Aluminum alloys
The Aluminum Association Alloy
and Temper Designation System
Temper designation system
 * For 1xxx series, the last two digits indicates
hundredths above 1 percent of pure aluminum.
 Application of
Aluminum Alloys
 List of most generally used alloy types for aircraft
structural aluminum:
• Alloy 1100
-Is a low strength, commercially pure aluminum that can be only be used in
non-structural applications where strength is not important.
• Alloy 2024
-Is the most popular structural aluminum alloy. Its strength is equivalent to the
mild steel, but its susceptible to corrosion.
• Alloy 3003
- It is similar to 1100 and is used for the same types of applications. It is non-
heat treatable but it can be hardened by cold working.
• Alloy 5052
- Is used for welded applications such as fuel tanks and for rigid fluid lines.
• Alloy 6061
- Used in applications where heat treatability, ease forming, medium strength,
and good corrosion resistance are needed.
• Alloy 7075
- Used for high strength structural requirements.
Clad Aluminum
- An aluminum alloy sheet that has a coating of pure aluminum rolled onto its
surface.
- The pure aluminum cladding protects the core alloy sheet from corrosion.
 Other alloys
• Magnesium Alloy
- Is the lightest structural metal, weighing only about two thirds as much as
aluminum.
• Copper Alloy
-high electrical and heat conductivity.
• Titanium Alloy
- Has high structural strength which it retains to high temperature. It is used in
turbine engines, and for aircraft skins in areas where the temperature is high.
Titanium Designation
1. A (alpha) - all around performance, good weldability
2. B (beta) – bendable, excellent bend ductility
3. C ( alpha beta) – combination of alpha and beta.
 1.
Any alloy containing iron as its chief constituent is
called a ferrous metal. Ferrous metals mainly consist of metals
which have a magnetic effect to it. Prone to rust if exposed to moisture.
The most common ferrous metal in aircraft structures is steel.
This steel and iron is composed of carbon.
Other examples : Mild Steel, Cast Iron, High Carbon Steel, High
Speed Steel, and Stainless Steel
 Ferrous Metals
Metal Type. Metal Uses. Melting Point.

Mild Steel.
A ductile and malleable metal. Mild Used as Nuts and 1600°C
steel will rust quickly if it is in frequent bolts, Building girders,
contact with water. car bodies, gates, etc.
 Ferrous Metals
Metal Type. Metal Uses. Melting Point.

Cast Iron.
Is a very strong metal when it is in Used as car Brake 1200°C
compression and is also very brittle. It discs, car cylinders,
consists of 93% iron and 4% carbon metalwork vices,
plus other elements. manhole covers,
machinery bases eg:
The pillar drill.
 Ferrous Metals
Metal Type. Metal Uses. Melting Point.

High Carbon Steel .

It is a very strong and very hard steel Used for hand tools 1800°C
that has a high resistance to abrasion. such as screwdrivers,
Properties – Up to 1.5% carbon hammers, chisels, saws,
content. Very tough. springs and garden
tools.
 Ferrous Metals
Metal Type. Metal Uses. Melting Point.

High Speed Steel.

HSS is a metal containing a high Used for drill bits and 1400°C
content of tungsten, chromium and lathe cutting tools. It is
vanadium. However it is very brittle used where high
but is also very resistant to wear. speeds and high
temperatures are
created.
 Ferrous Metals
Metal Type. Metal Uses. Melting Point.

Stainless Steel.
Stainless steel is very resistant to wear Used for kitchen sinks, 1400°C
and water corrosion and rust. cutlery, teapots,
Properties – It is an alloy of iron with a cookware and surgical
typical 18% chromium 8% nickel and instruments.
8% magnesium content.
Revision Work/Metals.
 Metal Shapes
Metal can be provided in various shapes and sizes.
Some examples of these are shown below.

Round Solid. Square Solid. Hexagonal Solid. Angle Iron

Solid.

Round Hollow. Square Hollow.

(Tube) Hexagonal Hollow. Angle Iron
(Box Iron)
Hollow.
Some Specifications Applicable To Steel Products
And Other Metals
Specifications
SAE-AISI Society of Automotive Engineers – American
Iron and Steel Institute
ASTM American Society for Testing and Materials
(UNS) (www.astm.org)
ASME American Society of Mechanical Engineers
MIL U.S. Department of Defense
AMS Aerospace Materials Specification
BS British Standards Institution
(http://www.bsi-global.com/index.xalter)
EN European Committee for Standardization
(http://www.cenorm.be)
The Most Widely Used System for Designating Steels SAE-AISI
Tool Steel Categories
Stainless Steel Family
 Most Commonly Used Aluminium Alloys
Wrought alloys Sand Cast
• 1100 (pure Al) • 355.0*
• 2024*
• 3003 Die Cast
• 5052 • 380.0
• 6061*
• 6063*
• 7075*
*: can be age hardened
Blue shaded: mainly for aerospace applications
Most Frequently Used Carbon and Alloy Steels in the US

• SAE 1010: formed sheet-metal parts

• SAE 1020: general machine applications
• SAE 1040: flame- or induction-hardened parts
• ASTM A36: structural steel
• SAE 4140: high-strength machine parts
• SAE 4340: high-strength machine parts
• SAE 8620: carburized wear parts