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Part 1 Materials > 1 > Flashcards

1 Flashcards

1
Q

Why would I add nickel to anything?

A

Limits grain growth ?

Resistance to heating and corrosion

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2
Q

What steel has 36% nickel in it?

A

Invar steel, used for measuring instruments

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3
Q

What does chromium do?

A

Chromium enlarges grain growth.
Nickel and chrome are used to control grain growth

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4
Q

What is chromium used to make?

A

Ball and roller bearings

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5
Q

Low levels of nickel chrome would be used to make? (3% nickel / 1% chromium)

A

Piston engine components

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6
Q

High level nickel chromium steels would be used to make? (18% chromium/ 8% nickel)

A

STAINLESS STEELS, AUSTENTIC AT ROOM TEMPRETURE AND NON FERROUS

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7
Q

What does 0.3% molybdenum do?

A

Largely eliminates TEMPER BRITTLENESS producing NICKEL CHROME MOLY STEEL

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8
Q

What is vanadium used for?

A

The tools and springs

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9
Q

Cobalts used for?

A

High speed cutting tools and permanent magnets

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10
Q

Molybdenum gives?

A

A fine grain structure, makes it stronger without affecting ductility.

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11
Q

CHROME MOLYBDENUM STEEL is very suitable for what?

A

For welding and is used principally for welded structural parts

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12
Q

How much carbon in Maraging steel

A

0.03%

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13
Q

Why do we produce maraging steel? And what’s its advantages?

A

Marraging steel contains little to no carbon.

Simpler to weld

Simpler heat treatments are possible

Better resistance to stress corrosion and hydrogen embrittlement

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14
Q

What is carburising?

A

Add carbon to the outer surface of low carbon steel or low alloy steel.

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15
Q

When carburised steel is heat treated what happens?

A

The case is hardened while the core remains tough

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16
Q

Carburising using the box process what is needed?

A

Charred leather or charcoal, sodium
Carbonate and heated to 900 degrees

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17
Q

Cyanide hardening what is needed?

A

Molten salts, sodium carbonate and sodium cyanide. Heated to 900 degrees

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18
Q

What is gas carburising?

A

900 degrees for 3 hrs using methane and propane gases

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19
Q

Flame hardening

A

Flamed with oxy-acetylene and cooled by a water jet. Only steels with 0.4% carbon can be flame hardened

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20
Q

Induction hardening?

A

Eddy currents in the surface of the component, cooled by jets of water

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21
Q

American identification of steel has how many numbers?

A

4

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22
Q

The first digit identifies?

A

The principal alloying element

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23
Q

The second digit?

A

The percentage of this alloying element

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24
Q

The last 2 digits?

A

The percentage in hundredths of a percentage of the carbon in the steel

(Amount of carbon)

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25
Q

How is bauxite used to make aluminium?

A

Mixed with caustic soda to make an oxide. It’s an electrolytic process

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26
Q

Main advantage of pure aluminium?

Key disadvantage?

A

High corrosion resistance

Low strength

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27
Q

How can I protect aluminium alloys from corrosion?

A

Alclad or electrolytic process known as anodising

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28
Q

Soloution heat treatment is also known as?

A

Age hardening

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29
Q

If I solution heat treat something? How long have I got to work it?

A

2 HOURS
AFTER 2 HOURS DO IT AGAIN

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30
Q

How many times can a material be soloution heat treated?

A

3 time

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31
Q

After finishing working it, how long do I have to wait before riveting it?

A

24 hours

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32
Q

How long after that till aircraft can go flying

A

5 days

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33
Q

Pure aluminium is annealed by heating to a temperature of?

A

360 degrees followed by cooling in air

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34
Q

How can I delay the period of time for soloution heat treatment?

A

Refrigeration @ -20 degrees, soloution treated rivets may also be stored this way

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35
Q

Precipitation heat treatment is known as?

A

ARTIFICAL AGE HARDENING

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36
Q

How many times can ALCLAD be heat treated?

A

3 times as it decreases corrosion resistance

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37
Q

Age hardening of rivets can be delayed by?

A

Storing the rivets at a low temp immediately after quenching

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38
Q

If the rivets have not been used within 2 hours?

A

They may have to be heat treated again up
To a maximum of 3 times, further heat treatments would increase the grain size and result in low strength

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39
Q

Maximum time for quenching from furnace to quenching?

A

20 seconds, if not the grains grow to big causing hydrogen embrittlement

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40
Q

Salt bath fire extinguisher?

A

Dry sand

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41
Q

When should our identification of heat treatments be made?

A

Immediately after the heat treatment

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42
Q

ALUMINIUM ALLLOY IDENTIFICATION!

COPPER

MAGNESIUM

ZINC

A

COPPER 2000

MAGNESIUM 5000

ZINC 7000

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43
Q

ALUMINUM AND ITS ALLOYS ARE INTERNATIONALLY CLASSIFIED INTO ….. GROUPS, identified by a ……. Figure series number

A

8

4

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44
Q

In aluminium alloy identification such as 7075. The first digit indicates what?

A

The principal alloying element. So in this case ZINC

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45
Q

The second digit identifies?

A

THE ALLOY MODIFICATION STATE. 0 indicates that the alloy is original. 1 indicates that the alloy has been modified once.

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46
Q

THE THIRD AND FOURTH DIGITS IDENTIFY?

A

The specific aluminum alloy

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47
Q

What are the 2 divisions of aluminum alloys?

A

NON HEAT TREATABLE

AND HEAT TREATABLE

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48
Q

How are non heat treatable alloys strengthened

A

BY CONTROLLED WORKING OR COLD ROLLING

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49
Q

The 2000, 4000, 6000, 7000 and 8000 series alloys are strengthened by?

A

Soloution heat treatment followed by age hardening

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50
Q

The 1000, 3000, 5000 series alloys are what to increase there strength?

A

COLD WORKED

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51
Q

Non heat treatable aluminum alloys can be hardened by?

A

STRAIN HARDENING ALSO KNOWN AS COLD ROLLING

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52
Q

The cold worked temper of wrought alloys is indicated by the letter …….. followed by a number.

A

H

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53
Q

A second digit, 2,4,6 or 8 indicates what?

A

The final degree of hardness

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54
Q

The heat treated temper of aluminum alloys is indicated by the letter?

A

T. T showed the type of heat treatment

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55
Q

T3 means?

A

SOLUTION HEAT TREATED AND STRAIN HARDENED (COLD ROLLED)

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56
Q

T4 means?

A

SOLUTION HEAT TREATED THEN NATURALLY AGED

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57
Q

T42?

A

SOLUTION HEAT TREATED BY THE USER REGARDLESS OF THE PREVIOUS TEMPER

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58
Q

How to protect magnesium from corrosion?

A

CHROMATE IT

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59
Q

WHAT DOES TITANUIM LOOK LIKE AND WHATS IT GOT

A

GREYISH WHITE AND GOT A HIGH STRENGTH TO WEIGHT RATIO. HIGH RESISTENCE TO CREEP AND CORROSION

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60
Q

WHAT HAPPENS IF CADMIUM COMES INTO CONTACT WITH TITANIUM?

A

It will cause it to become embrittled

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61
Q

FINE TITANIUM SWARF OR POWDER IS FIRE RISK. IT SHOULD BE EXTINGUISHED USING?

A

DRY POWDER

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62
Q

What is inconel good for?

A

It’s quite tough at high temps and does not oxidise very much because of the protective film of chrome oxide which forms on the surface

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63
Q

A nimonic alloy?

A

High temps, gas turbine engines and resistance to creep

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64
Q

Monel metal is used for what?

A

Good resistance to corrosion and is used for rivets

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65
Q

What do we use copper for?

A

Electrical cables and equipment. Reddish brown in colour.

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66
Q

Brass is used for?

A

Pitot heads

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67
Q

Low tin bronzes are used for what?

A

Springs and instrument parts

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68
Q

High tin bronzes are used for what?

A

Bearings and bushes which are subjected to heavy loads

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69
Q

Tungum is good for what?

A

Good heat resistance and resistance to corrosion. Used to make hydraulic pipelines

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70
Q

Lead is used for what?

A

Lead is a major constituent of soft solder, mass balance weights and protection from x rays

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71
Q

CHAPTER 3:

What are the 2 forms of casting?

A

Sand casting

Die casting

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72
Q

What am I doing when casting?

A

pouring molten metals it into a mould.

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73
Q

What is sand casting?

A

Foundry sand is moulded around a suitable pattern in such a way that the pattern can be withdrawn to leave a cavity of the correct shape in the sand

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74
Q

What is DIE CASTING

A

In Die casting a permanent metal mould is used and the charge of the molten metal is usually forced in under pressure

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75
Q

What is forging?

A

The process of forming a product by hammering or pressing

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76
Q

What sort of process is drawing and What sort of components is made from drawing?

A

Drawing is exclusively a cold working process.

Rod wire and hollow tubes are produced by drawing them through a die

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77
Q

What is pressing?

A

A disc of metal is placed over a die then forced the metal disc through the die forming a cup shaped item.

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78
Q

Extrusion is the process of what?

A

The process of forcing metal in its plastic state through a die. This can produce complex cross sectional shapes required for aircraft construction

Aluminum alloy is heated between 350 degrees and 500 degrees

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79
Q

What is sintering?

A

Powder metallurgy where you have heat and pressure.

A pourus material made up by fusing powdered metal under heat and pressure.

80
Q

What is spinning?

A

Flat disc in a lathe and bend it using shapes

81
Q

CHAPTER 4 - what is a malleable metal?

A

One that can be deformed by a great deal of compression before it shows signs of cracking

82
Q

What is a ductile metal?

A

A ductile metal is one that can be deformed by a great deal of tension before it fractures

83
Q

What is a tough metal?

A

A tough metal can be bent many times before it breaks

84
Q

What is a tensile test?

A

Stretching until it breaks

85
Q

What is a compression test?

A

Measures the force required to compress or shorten a piece of metal until it breaks

86
Q

What is a toughness test?

A

The ability to resist mechanical shock

87
Q

How is the ductility of a material found?

A

A bend test

88
Q

What do we find out from a tensile test?

A

THE YIELD POINT

89
Q

If you go beyond the yield point what happens?

A

Permanent extension?

90
Q

How do I calculate the tensile strength of the material

A

MAXIMUM FORCE USED
/
Original cross sectional area

91
Q

What is proof stress?

A

Proof stress of an alloy is that stress which will produce a permanent extension off 0.1% in gauge length of the test piece

92
Q

When a metal is subjected to both tensile stress and high temperature of a long period continuous and permanent elongation takes place, this is known as creep. What is the final fracture called?

A

RUPTURE

93
Q

DEFINE HARDNESS?

A

RESISTANCE TO INDENTATION

94
Q

How does a brinell hardness tester work?

A

A steel ball bearing is pressed for 15 seconds. Then the diameter of the dent is measured.

95
Q

How does the vickers hardness tester work?

A

A diamond pressed for 15 seconds then the diameter is measured. Most accurate out of all.

96
Q

How does the Rockwell hardness tester work?

A

Uses 2 types of indenter a steel ball for for use with unhardened steel and soft metals .

And A SPHERICAL TIPPER DIAMOND CONE KNOWN AS THE BRALE INDENTER FOR USE WITH HARDER MATERIALS.

LARGE SCALE POINTER INDICATES HARDNESS

97
Q

What is the advantage of the shore scleroscope hardness test

A

ITS PORTABLE

98
Q

Impact tests measure what?

A

Resistance to shock - TOUGHNESS

99
Q

2 machines for measuring resistance to shock or toughness?

A

IZOD AND CHARPY TEST

100
Q

Which one is preferred for the extremes of temperatures?

A

CHARPY

101
Q

What is the striking energy of a izod test

A

160j through 60 degrees

102
Q

What is the striking energy of a CHARPY test

A

300j thought 160 degrees

103
Q

What is fatigue?

A

Fatigue is defined as the progressive deterioration of the strength of a material

104
Q

What is cyclic fatigue?

A

Caused by repeated fluctuating loads

105
Q

What is corrosion fatigue?

A

This is fatigue accelerated by surface corrosion.

106
Q

What is fretting fatigue?

A

This is caused by small scale rubbing movements is heavily loaded joints

107
Q

What is thermal fatigue?

A

Thermal cycles

108
Q

What is sonic fatigue caused by?

A

RESULT OF HIGH FREQ STRESS FLUCTUATIONS DUE TO VIBRATIONS CAUSE BY JETS KF PROPELLER NOISES

109
Q

What do I find out from a fatigue test?

A

FATIGUE OR ENDURANCE LIMIT /FINDING THE SAFE LIFE

110
Q

Does a polished test piece have a better endurance or fatigue limit?

A

YES

111
Q

What are the 2 groups of plastics?

A

THEROMOPLASTIC

AND

THERMOSETTING

112
Q

Thermoplastic materials can be what?

A

Become soft when heated and can be moulded again and again

113
Q

Thermosetting materials?

A

Become permanently hard during the moulding process and cannot be softened again

114
Q

How can we bend or shape plastics?

A

120 degrees in either glycerin or water

115
Q

Perspex or plexiglas should be stored how?

A

Vertically or 12 sheets can be stored flat with soft packing between each sheet

116
Q

Polyvinyl chloride PVC is often used to make?

A

Protective gloves and aprons or seat covers in light aircraft

117
Q

TUFNOL AND MICARTA ARE USED TO MAKE WHAT?

A

FAIRLEADS AND PULLEYS

118
Q

Perspex should be stored where?

A

In a cool, well ventilated place where it can not be affected by sunlight, direct heat or vapours dopes paints and solvents.

119
Q

If the aircraft is to be left out in strong sunlight it is advisable to?

A

Fit white cotton covers over the Perspex windscreens

120
Q

When cleaning and polishing Perspex application cloths are used …….. but polishing cloths may be …….

A

Once

Re used as long as they stay clean and soft

121
Q

what are the 2 components to a composite?

A

Matrix and the fibres or (reinforcing material)

122
Q

Define strength?

A

The ability to support a load without breaking

123
Q

Define stiffness?

A

Ability to support a load without bending

124
Q

Define impact resistance

A

The ability to withstand impact without shattering

125
Q

Freshly drawn fibres are very strong but not?

A

BRITTLE

126
Q

The fibres are drawn into bundles called rovings which can be further processed into?

A

Woven fabrics or chopped strands

127
Q

E GLASS?

A

An electrical grade with high resistivity

128
Q

S GLASS

A

High tensile glass fibre

129
Q

Glass fibre cloth is formed by?

A

Twisting together glass fibre strands or threads .

130
Q

How can a fibreglass or a glass fibre be recognised?

A

As a white gleaming cloth

131
Q

Kevlar is what? And has what properties

A

An aramid fibre. And has high strength and impact resistance

132
Q

Kevlar 49 is the grade used in aircraft composites? How much lighter is it than glass fibres?

A

40%

133
Q

What colour is Kevlar?

A

Yellow with black traces

134
Q

Carbon fibres are made from what?

A

Pure carbon and black in colour

135
Q

Kevlar threads are woven into cloth every 2 inches ……… and every 6 inches across ……

A

Along the weft

The warp

136
Q

Why is boron not commonly used in aviation??

A

Hazardous and very expensive

137
Q

What are the most used re-enforcing fibres?

A

Glass fibre, aramid and carbon/graphite

138
Q

Warp direction is designated at?

A

0 degrees

139
Q

The weft or fill is designated at

A

90 degrees

140
Q

Why is the Selvage edge removed?

A

Because the weave is different from the body of the fabric and would not give the same strength

141
Q

What is the bias?

A

The bias is when the weft threads are at 45degree angle to the warp threads

142
Q

Chopped glass fibres that are compressed together are known as?

A

MATS

143
Q

Plain weaves are the simplest form
Of weaves but?

A

It can be difficult to drape around complex shapes

144
Q

Twill weaves provide?

A

A superior wet out and drape properties.

145
Q

Satin weaves?

A

Are very flat and drape well, facilitate wetting out and have good mechanical properties.

146
Q

A rove or roving is formed by what?

A

Combining strands of fibre without twisting them to form mats

147
Q

What is the key to the strength of a composite?

A

It lies in the ability of the matrix to transfer stress to the re enforcing fibre

148
Q

Polyester resins are cured by the addition of what?

A

A catalyst

149
Q

What are catalysts known as?

A

Peroxides and are thin liquids

150
Q

What is added to a polyester resin to speed up the cross linking process?

A

Accelerator

151
Q

Epoxy resins are mixed with what to allow them to cure?

A

Hardner

152
Q

Epoxies have a very good resistance to what?

A

Chemicals

153
Q

Epoxy resins are more difficult to use than polyester resins and?

A

Are hazardous to health and expensive

154
Q

Curing a polymer from a thick liquid to a strong solid is a chemical process that may be brought around by?

A

Cold or hot curing

155
Q

Cold curing takes place at what temp?

A

Room temp (21) degrees

156
Q

In the cold curing process how long does it take for the resin to harden?

A

30 mins

157
Q

Hot curing cures at what temp?

A

200 degrees

158
Q

If too much resin is used, the composite will be..?

A

Weak

159
Q

If 3 layers of cloth are used, the fibre orientation should be?

A

0 45 and 90 degrees

160
Q

A better hot cure system uses an autoclave. How does an autoclave work?

A

Uses a vacuum to suck out the air and controlled heaters to cure the resin

161
Q

Pre pregs can only be used with what curing system?

A

Hot curing systems

162
Q

Pre pregs are stored how?

A

Stored in a sealed bag at -18 degrees

163
Q

What must be recorded when taking a pre preg out of the fridge?

A

Date and time and transfer of the material out of the fridge

164
Q

Who gives a the maximum out of freezer life?

A

The manufacturer

165
Q

2 main hazards when dealing with polyester and epoxies resins.

A

Skin contact and inhaling fumes

166
Q

Polymer resins are sticky liquids which is difficult to remove from?

A

The skin

167
Q

Dermatitis is an inflammation of the skin leading to

A

Sores, rashes and cracks in skin

168
Q

Accelerators are very reactive substances and must always be added to the resin before the?

A

Catalyst

169
Q

NEVER MIX A

A

CATALYST AND ACCELERATOR

170
Q

When machining composites wear eye protection conforming to

A

BS166

171
Q

In a sandwich construction the core is used to make a thick beam because?

A

The stiffness of the beam depends on its thickness

172
Q

Balsa wood is often used on?

A

A/c floors

173
Q

Three honeycomb materials most commonly used in aircraft is

A

Aluminium, glass fibre reinforced plastic and aramid fibre reinforced paper

174
Q

2 methods of honeycomb manufacture

A

Corrugation

And expansion

175
Q

The corrugation process is?

A

Sheets are cut to length and bonded together

176
Q

The expansion process is?

A

Known as the HOBE, sheets of the core material are coated with adhesive and stacked to form a hobe

177
Q

The three cell shapes are?

A

HEXAGONAL SHELL

OVER EXPANDED CELL - OXCORE

FLEXIBLE CORE OR FLEXI CORE

178
Q

Hexagonal shells are good for?

A

Flat panels

179
Q

OX CORE

A

Used for single curvature

180
Q

Flexi core?

A

Double curves

181
Q

If there is no lightning protection in the composite the lightning exits through it

A

Evaporating the resins leaving bare cloth

182
Q

What may be laminated under the top layer of fabric?

A

A fine aluminium mesh

183
Q

For lightining protection aluminium may also be?

A

Flame sprayed onto the component

184
Q

When honeycomb sandwich structures are damaged what effect does this have?

A

Separation of the honeycomb from the FRP skins

185
Q

Composites are more sensitive to compressive loading than

A

Tensile loading

186
Q

WHAT DO YOU DO TO FIND BVD

A

TAP TEST, X-RAYS CAN ALSO BE USED

187
Q

When drilling a composite what drill bit do we use?

A

Carbide drill bits with angles of 135 degrees

188
Q

Aluminum fasteners must not be used with carbon or graphite, why?

A

Because of their tendency to corrode the aluminum

189
Q

How can minor damage such as scratches pits and dents be normally repaired?

A

Mixing a small amount of resin and hardener and filling the area

190
Q

Blisters of less than one inch diameter can be repaired by?

A

Injecting mixed resin using a hypodermic syringe

191
Q

Small holes may be fixed by

A

Chopped glass fibres to fill the hole

192
Q

Vaccum baggin

How is the fibre/resin ratio controlled?

A

By emoting access resin

193
Q

What is the release film for?

A

The release film allows the vaccum bagging materials to be separated from the repair after curing

194
Q

What does the bleeder fabric do?

A

The bleeder fabric absorbs the resin bleeding out of the repair

195
Q

If the resin is heated to rapidly what happens?

A

It does not have time to flow before it gels

Part 1 Materials (4 decks)

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