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CAT B- Mod 6 Materials and Hardware > 6.2- Aircraft Materials Non Ferrous > Flashcards

6.2- Aircraft Materials Non Ferrous Flashcards

1
Q

What is a non-ferrous metal?

A

One that does not contain iron as its base.

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2
Q

What ore does aluminium come from?

A

Bauxite

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3
Q

What are the most common alloying elements for aluminum?

A

Copper
Magnesium
Manganese
Zinc

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4
Q

Which alloying elements give aluminium the same strength as steel but third the weight?

A

Copper and zinc

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5
Q

What is the name of the standards that give aluminium alloys two classes?

A

H35.1 and H35.2 American national standards institute.

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6
Q

What are the two classes of aluminium alloys?

A

Wrought
Cast

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7
Q

What is a Wrought Aluminium alloy?

A

Compressed and tightened grain structure, used extensively in aircraft and can be heat treated.

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8
Q

What is cast aluminium alloy?

A

Brittle due to their coarse grain. Poured whilst molten for large components.

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9
Q

How are wrought aluminium’s designated?

A

4 digit system

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10
Q

What are the major wrought aluminium numbers?

A

1xxx Pure
2xxx Copper
8xxx Other elements
9xxx Unused

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11
Q

How does the 4 digit system break down?

A

1st Digit- Major element
2nd- Modifications
3/4th- Other elements

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12
Q

What are the two most common 4 digit alloys found on aircraft?

A

2024 and 7075

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13
Q

Can pure aluminium be strain hardened?

A

Yes

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14
Q

Where is pure aluminium used?

A

Electrical and chemical applications

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15
Q

What is the difference between pure aluminium 1100 and 1350?

A

Both are pure but 1100 is 99.00% aluminium and 1350 is 99.50%

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16
Q

What is the issue with 2xxx copper series?

A

Susceptible to intergranular corrosion when incorrectly heat treated.

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17
Q

What are the key characteristics of 3xxx manganese series?

A

Non heat treatable, moderate strength and good working.

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18
Q

What is the benefit to 4xxx silicon series?

A

Lowers a metals melting temp, ideal for welding?

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19
Q

What makes 5xxx magnesium series more susceptible to corrosion?

A

Excessive cold working or high temps

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20
Q

Whats different about 6xxx series?

A

They have two alloying elements, silicon and magnesium, they make magnesium silicide.

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21
Q

What series and alloying element is used when high strength and elasticity is needed?

A

8090, lithium.

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22
Q

What percentage of the thickness is cladding?

A

3-5%

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23
Q

How are clad sheets identified?

A

With the letters, A, AL-clad, Clad or ALC.

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24
Q

What is important about the direction of the al clad designation text?

A

Shows the direction of the grain.

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25
Q

What is the name of the most popular magnesium alloy?

A

AZ31

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26
Q

What are magnesium alloys used for?

A

Flat parts to be attached to the ribs or brackets.

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27
Q

What are the disadvantages of magnesium?

A

Highly susceptible to corrosion
Easily crack when formed

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28
Q

How are magnesium fires put out?

A

Smothered with dry sand.

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29
Q

What is pure titanium’s strength and weight compared to iron?

A

50% lighter same strength.

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30
Q

How does titanium become corrosion resistant?

A

It reacts with the oxygen to form titanium oxide on the surface.

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31
Q

How are titanium alloys classified?

A

Alpha
Alpha-beta
Beta

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32
Q

What is an alpha alloy?

A

Has medium strength and good elevated temp strength.

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33
Q

What is the standard ident for alpha alloy?

A

Ti-8Al-1Mo-1V

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34
Q

What is an alpha beta alloy?

A

Most versatile. Medium strength in the annealed condition and much higher strength when heat treated, not weldable.

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35
Q

What is a beta alloy?

A

Medium strength, excellent forming and contain large amounts of high density alloying elements.

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36
Q

What happens when titanium is added to high temp nickel-cobalt-chromium?

A

Produces a precipitation hardening reaction which provides strength at temps up to 815c.

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37
Q

What percentage of modern aircraft structures include titanium?

38
Q

What examples are uses for titanium in aircraft?

A

Bolts and fasteners
Flap tracks
Engine compressor blades
Firewalls
Hydraulic pipes in high temps

39
Q

What are the two most common nickel alloys?

A

Monel
Inconel

40
Q

What percentages are monel nickel alloys?

A

68% nickel and 29% copper with small amounts of iron and manganese.

41
Q

Where does monel work well?

A

Gears and parts where high strength and toughness and rivets.

42
Q

What percentages are in inconel?

A

80% nickel and 14% chromium.

43
Q

What are the most common copper base alloys?

A

Brass
Bronze
Beryllium

44
Q

What is brass?

A

Copper alloy used in bushings, fuel metering valves and electrical plugs.

45
Q

What is bronze?

A

Copper alloy containing tin.

46
Q

What are the two types of heat treatment on aluminium alloys?

A

Precipitation and Solution

47
Q

How are 2017 and 2024 treated?

A

Solution treated then 96 hours cooling/ageing at room temp.

48
Q

How does solution heat treatment work?

A

Heated in a salt bath or hot air furnace just below melting point. Held at temp then quenched in water.

49
Q

When solution heat treating what is the maximum time between removing from treatment and quenching?

A

10 seconds

50
Q

Why is quenching after solution heat treating always hot water?

A

Minimises distortion and alleviates cracking.

51
Q

Where can spray quenching not be used?

A

On bare 2017 or 2024.

52
Q

What is natural ageing?

A

When cooled at room temp.

53
Q

What percentage strength does copper ally 2024 have after 30 minutes of natural ageing?

54
Q

How can the ageing process be slowed down?

A

Storing at -20c

55
Q

How can the ageing process be sped up?

A

Reheating at 160-260c

56
Q

What are some the names for ageing that is not natural?

A

Artificial Age Hardening
Precipitation Hardening
Precipitation Heat Treatment

57
Q

What does annealing do?

A

Softens a metal and decreases internal stress.

58
Q

How is annealing carried out?

A

Heated and held at 415c then cooled to 260c at 25c an hour.

59
Q

What are the most common temper designations?

A

T- Solution
T3- Solution then strain hardened
T4- Solution then natural ageing
T6- Solution then Artificial aged

60
Q

What alloys are non heat treatable?

A

1xxx
3xxx
5xxx

61
Q

How can non heat treatable alloys be adjusted?

A

Cold work or cold rolling

62
Q

What is cold work or cold rolling also known as?

A

Strain hardening.

63
Q

What is the hardness designation F?

A

As fabricated

64
Q

What is the hardness designation O?

65
Q

What is the hardness designation H?

A

Strain hardened

66
Q

What is the hardness designation H1?

A

Strain hardened only

67
Q

What is the hardness designation H2?

A

Strain hardened and partially annealed.

68
Q

What is the hardness designation H3?

A

Strain hardened and stabilised.

69
Q

Temper designations- what do the digits after the designation (Hx2) represent?

A

The hardness.
2- Quarter hard
8- Full Hard

70
Q

What are the most frequently tested properties?

A

Hardness
Tensile Strength
Fatigue Strength
Impact Resistance

71
Q

What are the three common methods of hardness testing?

A

Brinell
Vickers
Rockwell

72
Q

What is the defined test specification for the brinell test?

73
Q

How does the brinell test work?

A

Hydraulic press with ball end, measure the indentation left behind.

74
Q

What is the Vickers test also known as?

A

Microhardness test.

75
Q

What are the advantages of the Vickers test?

A

Accuracy does not change with depth change
Only tiny idents made

76
Q

What are Vickers tests used for?

A

Small parts and thin sections.

77
Q

What is the most commonly used hardness test?

78
Q

What is the Rockwell test defined by?

79
Q

How is a Rockwell tester zeroed?

A

Minor load is applied (10kg)

80
Q

What three types of penetrators does a Rockwell tester use?

A

Conical diamond
1/16in ball
1/8in ball

81
Q

What are the three major loads of a Rockwell tester?

A

60, 100 and 150kg.

82
Q

What three brands of portable hardness tester can be found?

A

Barcol
Riehle
Ernst

83
Q

What is the Barcol tester for?

A

Testing hardness of Brass, Copper and aluminium.

84
Q

Where is the Barcol tester most commonly used?

A

Composites, to see if resins are cured?

85
Q

What is the tensile strength point where a material becomes plastic called?

A

Yield Tensile Strength.

86
Q

How is the elongation percentage worked out?

A

Increase in length divided by original length x 100

87
Q

What is the limit load?

A

Maximum load that an aircraft is expected to see at any point.

88
Q

What is the ultimate load?

A

Although never expected to be met it is the safety limit of loads an aircraft can take, approx. 1.5 times the load limit.

89
Q

What types of impact testers are there?

A

Charpy and Izod

90
Q

What is the difference between Charpy and Izod?

A

Charpy is 3 point and Izod is single.

91
Q

What is the most common impact tester?

A

Charpy V-notch.

CAT B- Mod 6 Materials and Hardware (14 decks)

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