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Year 12 Engineering 2024 > Materials Combined Deck > Flashcards

Materials Combined Deck Flashcards

1
Q

How does pitting corrosion occur in aircraft structures?

A

Pitting occurs from small, localized breakdowns in the protective layer, forming deep pits.

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2
Q

What are some common corrosion mechanisms in aircraft structures?

A

Uniform corrosion, pitting, crevice corrosion, intergranular corrosion, exfoliation, and stress corrosion cracking.

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3
Q

What is stress corrosion cracking and its impact on aircraft safety?

A

SCC is brittle cracking due to tensile stress and a corrosive environment, potentially leading to sudden structural failures.

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4
Q

What preventive measures are used to prevent corrosion in aircraft?

A

Use of corrosion-resistant materials, protective coatings, regular cleaning and maintenance, sealants, and corrosion inhibitors.

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5
Q

How is corrosion detected in aircraft maintenance?

A

Through visual inspections, robotic inspections, infrared thermography and other non-destructive testing methods.

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6
Q

How does crevice corrosion occur in aircraft structures?

A

Crevice corrosion occurs in confined spaces, where stagnant moisture and contaminants cause localised attack.

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7
Q

What are the primary advantages of using aluminium-silicon alloys in aircraft manufacturing?

A

Aluminium-silicon alloys are highly valued in aircraft manufacturing for their excellent cast ability, high corrosion resistance, and good strength-to-weight ratio.

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8
Q

How does the addition of magnesium to aluminium-silicon alloys impact their mechanical properties for aerospace applications?

A

Adding magnesium to aluminium-silicon alloys enhances their mechanical properties, such as increasing their strength and hardness, making them more suitable for structural applications in aerospace.

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9
Q

What specific properties make aluminium-copper alloys particularly suitable for use in aircraft structures?

A

Aluminium-copper alloys are known for their high strength and excellent fatigue resistance, which are crucial for the structural integrity of aircraft.

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10
Q

In what ways does aluminium-silicon-magnesium alloy improve the overall performance and durability of aircraft components compared to pure aluminium?

A

The aluminium-silicon-magnesium alloy improves overall performance and durability by offering superior strength, better wear resistance, and enhanced thermal stability compared to pure aluminium.

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11
Q

Can you explain how aluminium alloys contribute to the reduction of aircraft weight and fuel consumption?

A

Aluminium alloys contribute to reducing aircraft weight due to their high strength-to-weight ratio, which in turn leads to lower fuel consumption and improved efficiency.

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12
Q

How does the microstructure of aluminum-silicon alloys influence their mechanical properties?

A

Finer silicon particles generally lead to increased strength and improved wear resistance.

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13
Q

What role does the macrostructure of aluminum-copper alloys play in their fatigue resistance?

A

A refined grain structure can enhance fatigue resistance by reducing stress concentrations and crack initiation sites.

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14
Q

What effect does the addition of magnesium to aluminium-silicon alloys, have on their properties?

A

This results in improved strength and hardness due to precipitation hardening.

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15
Q

In what way does the heat treatment process affect the macrostructure of aluminium-copper alloys and their resultant properties?

A

By promoting the formation of fine precipitates within the grains. This enhances their strength and hardness while maintaining good ductility.

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16
Q

What does CNC stand for in terms of materials for the aerospace industry?

A

Ceramic and carbon matrix composites

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17
Q

why would powder forming be used for the production of many automotive vehicle parts?

A

powder forming is used for the production of many parts of cars including gears and camshafts. it results in a homogenous microstructure, which has better overall strength due to its uniformity.

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18
Q

Why is extrusion used in the production of bumpers and impact beams?

A

extrusion is used for this purpose for its properties of grain flow alignment, in which the grains are deformed and elongated towards the extrusion direction.

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19
Q

Why is forging used for the manufacturing of crankshafts in automotive vehicles?

A

Forging is used for how it manipulates the grain structure of metals, in the case of crankshafts it is used for its aligned grain low which enhances strength and fatigue resistance, it also reduces porosity, meaning it reduces the amount of voids in the metal, additionally reducing the chance of manufacturing defects.

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20
Q

why is MIG welding and TIG welding used in the production of train cars?

A

MIG welding (metal inert gas) is used for Its ability to be used on a variety of steel thicknesses, making it ideal for welding different parts of the train car, including thin sheet metal and thick structural components. TIG (Tungsten inert gas) welding is used for producing high-quality welds with excellent appearance and strength, which is integral for the structural integrity of train car components that are made of aluminium.

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21
Q

why isn’t hot rolling used to create steel body panels?

A

During hot rolling, the steel undergoes significant deformation, resulting in a recrystallized microstructure with larger grains. This process is faster and more cost-effective for shaping steel compared to cold rolling. However, it can also result in less precise dimensions and surface finish, and the final product may require additional processing to achieve the desired properties.

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22
Q

why is cold rolling used to create steel body panels?

A

cold rolling involves passing the steel through rollers at room temperature or slightly above room temperature. This process is used to produce thinner and precise steel sheets with better surface finish and dimensional accuracy.

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23
Q

Briefly Describe a thermo -softening

A

A thermo softening polymer is** a polymer that can be repeatedly melted and solidified without changing its properties**

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24
Q

Describe the stucture of a thermo softening polymer

A

have a linear strcuture (long, straight chains of repeating units connected end-to-end) or branch structure (a main chain with various side chains or branches extending from it)

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25
Q

Describe engineering Textiles,
Provide examples and properites

A

Engineering textiles are specialised fabrics designed for specific technical applications,

Propeties:
* high strength,
* durability,
* heat resistance, or
* chemical resistance,

** usally woven or knitten threads of fabrics.**

examples:
* kelvar -
* gore tex
* Geotextiles (used in roads)

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26
Q

Explain the process of Blow moulding and injection moulding.

A

Blow Moulding - Produces hollow parts. material is melted and formed into a parison, which is clamped into a mould. Air is blown , expanding the material to the mould’s shape. .

**Injection Moulding: **Produces solid parts with complex shapes, The material is melted and injected under high pressure into a mould, shaping the plastic. High pressure ensures the mould is completely filled.

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27
Q

Desribe the process of Extrusion of polymers

A

Extrusion is used to create objects with a fixed cross-sectional profile, like:
* pipes
* containers/ straws
* window and door frames
* Construction - like decking, and fencing.

Plastic granules are fed into an extruder, where they are heated and melted. A screw then pushes the molten plastic through a die to form the desired shape.

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28
Q

What is a thermo setting polymer?

A

type of polymer that irreversibly hardens when heated or cured.
they cannot be remelted or reshaped once set.

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29
Q

Describe the structure of a thermo setting polymer.

A

have a** cross linked ** structure which feaures many links betwteen each molecule.

This structure creates a network of bonds that are difficult to break. Explaining why they cannot be reshaped with heat.

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30
Q

How are thermo setting polymers modified for use on Aricraft?

A

Materials are modified to withstand aerospace conditions like: extreme heats, exposure to chemicals and extra mehanical stresses.

done by:
* adding re-enforcement fibres (like carbon
* adding high perfomance fillers - like Resins with Fire Retardant Additives
* Resins with Toughening Agents

31
Q

Explain the Process of compression moulding and what materials are amde by it?

A

involves pre-heating the mould, placing the material in the bottom half, closing the mould, and applying high pressure and holding at high temps to shape.

Things made:
* automotive parts
* plants and bowls
* Sports helmets and pads

32
Q

Why are composites materials often used in aerospace?

A

thye have high strength-to-weight ratio compared to other materials and usally have **better corrosion resistance. **

contribute to better performance, reduced maintenance, and overall cost savings.

33
Q

What is reinforced glass fibre (fibre glass) ?and what are its applications in aircraft?

A

is a composite material made of glass fibres in a resin matrix. The glass fibres provide strength and rigidity, while the resin binds them,

**Applications: **
* combined with alluminuim to be used in fuselage, wings and tail
* cabin interiors (panels & seats)
* fairings and engine cowlings

34
Q

What is Fibre metal laminate (FML) ?and what are its applications in aircraft?

A

(FML) is a composite material made of **alternating layers of metal sheets and fibre-reinforced polymers. ** This combo enhances strength, durability, and resistance to fatigue

Applications:
*Fuselage Panels
* wings and tail compoents
* cargo doors

35
Q

What is Kevlar? and what are its applications in aircraft?

A

Kevlar is a, synthetic aramid fibre is 5x stronger than steel by weight, lightweight, flexible, tough, good heat resistance as well.

**Appilcations: **
* fuel tanks - inner walls coated in kelvar
* can be intregated into wings and fuselage
* inside the engine cowl

36
Q

What is Carbon fibre? and what are its applications in aircraft?

A

is a high-strength, lightweight material made from thin strands of carbon atoms bonded in a crystalline structure, excellent strength-to-weight ratio and rigidity.

** Applications: **
* Tail: vertical and horizontal stabilisers
* wing and Fuselage
* Interior Components - cabin linings & seats

37
Q

What is the principle of heat treatment?

A

changes the metal’s properties to the specific needs of the use. This is done by heating to a temp range, and hold for a cetian time. Then cooling in air,water or oil.

38
Q

What is the Rockwell Hardness Test?

A

Rockwell hardness test measures the the max amount of damage that occurs under a large load by the form of an indent.

39
Q

How is the Brinell Hardness Test conducted?

A

In the Brinell Hardness Test, a hard steel or carbide ball is pressed into the material, and then you measure the diameter of the indentation it leaves behind.

40
Q

What distinguishes the Vickers Hardness Test?

A

Vickers hardness test uses a diamond pyramid indent and measures the length of the indent.

41
Q

What does the Charpy Impact Test evaluate?

A

This message the energy absorbed by the material when a fracture by a swinging pendulum.

42
Q

What is the Drop Weight Impact Test?

A

This test is demonstrated by dropping the item from a known height and it demonstrates the impacts.

43
Q

What is annealing in the context of heat treatment for ferrous metals?

A

Annealing involves heating ferrous metals to a precise temperature and holding the temperature for a set amount of time then cooling it down slowly in a contorlled temp in a furnance

44
Q

How does normalizing differ from annealing for ferrous metals?

A

annealing allows the material to cool at a controlled rate in a furnace.

Normalizing allows material to cool by placing it in a room temperature environment

45
Q

What is hardening? (ferrous metals)

A

Hardening is heating the the metal to a high temperature (in the range 760-1300 C) then rapidly cooling in water or oil.

46
Q

How do temperature changes during heat treatment affect the properties of ferrous metals?

A

significantly alter the properties of ferrous metals - like latering tougness, hardness, ductility, and grian strcure size and shape

47
Q

What is the purpose of heat treatment for alloys

A

to achieve the desired characteristics such as strength, hardness, durability. This is done by altering grain structure and size.

48
Q

What is the process of solution heat treatment for alloys?

A

This treatment involves heating the metal up until it’s in a solid solution and then rapidly cooling it.

49
Q

How does tempering effect alloys that have been hardened?

A

This involves heating a previously hardened alloyed to a temperature below the critical range then cooling it.

50
Q

What is normalizing for steel alloys?

A

Normalizing steel alloys involves heating them above their critical temperature and then cooling them slowly in air.

51
Q

What is the process of tempering?

A

tempering is the process of heat treating a material again but at a lower temp range (usally 80-500 degress c) holding for a low time then cooling slowly in air.

52
Q

What can Aluminium be alloyed with?

A

Copper, being primarily used for aircraft structures. Because of the high tensile strength,
Also can be combined with Magnesium and silicon used in bicycles frames, truck and marine structures.

53
Q

How does Precipitation Hardening effect the microstructure of non-ferrous metals?

A

The results are a hard and brittle intermetallic compound.

54
Q

What is the point Dye Penetrant Inspection?

A

To detect surface-breaking defects in metals.

55
Q

How does ultrasound inspection work?

A

Ultrasound inspection works by introducing high-frequency sound waves into the material. These sound waves travel through the material and reflect off any internal flaws differently than they do from the surrounding material. The reflections are then analyzed to interpret and locate the size and where it is.

56
Q

What is the point of NTD (non-destructive testing) on aircraft

A

To ensure the safety of passengers, to ensure the longevity of the parts and performance.

57
Q

What does annealing do to the microstructure of non-ferrous metals?

A

The result is an equiaxed grain structure.

58
Q

What are the different types of heat treatments for non-ferrous metals.

A

Annealing, and precipitation hardening, alloying, solid solution hardening

59
Q

What are the applications of alloys in the aerospace industry.

A

Aluminum alloys are extensively used for structural components due to their high strength-to-weight ratio and thus helping with fuel efficiency

60
Q

How does Annealing effect non-ferrous metals?

A

Annealing primarily aims to make a metal softer and more ductile, facilitating easier fabrication or machining. It also helps in removing residual stresses induced during forming or machining, thus improving the material’s overall stability and performance.

61
Q

How does Solid solution hardening effect non-ferrous metals?

A

This process is used to enhance the strength and hardness of a metal through the addition of alloying elements that form a homogeneous solid solution with the base metal.

62
Q

What defines macrostructure and microstructure in non-ferrous metals?

A

Macrostructure refers to the large-scale structure of a metal including features like grain boundaries, phases, and defects such as cracks. Microstructure, involves the structure at a microscopic level, revealing details such as the arrangement of atoms, grain size, phase distribution.

63
Q

How do microstructural changes impact the mechanical properties of non-ferrous metals?

A

Microstructural changes, like grain refinement and precipitate formation, can increase strength and hardness.

64
Q

How does smaller grain size impact the yield strength of non-ferrous metals?

A

Smaller grain size increases the yield strength of non-ferrous metals by creating more grain boundaries, which makes the metal stronger but very brittle.

65
Q

When is Gamma Ray Inspection preferred over X-ray Inspection?

A

Gamma Ray Inspection is preferred over X-ray Inspection for thicker sections of metal, such as engine blocks and critical structural elements, because gamma rays have deeper penetration capabilities.

66
Q

Why is NDT important for quality control in the manufacturing of aircraft components?

A

NDT is important for quality control in manufacturing because it ensures that components meet strict quality standards, are defect-free.

67
Q

why would quenching be used for the production of the chassis of a vehicle?

A

quenching is used to harden the steel to make the supporting members stronger and more impact resistant.

68
Q

why would hardening be used in the production of transmission systems in vehicles

A

hardening would be used in transmission systems to prevent various damaged that come with wear that include chipping, bending and breaking.

69
Q

why is normalizing used in part of the production of structurally supporting components in aircraft?

A

Normalizing is used to undo the stress applied by work done on the planes parts so they are more resilient to impact and cyclically applied loads.

70
Q

why are suspension springs in the automotive industry tempered?

A

Suspension springs are tempered to influence them to hold their shape, which is what the function of the spring is to do. it rebounds when force is applied.

71
Q

what properties do ceramics have that makes them ideal for engine parts such as spark plugs?

A

ceramics are used for components like spark plugs for their insulating properties and replicability.

72
Q

what process do windshields go under to prevent shattering when impacted?

A

windshields are laminated to prevent shattering from most impacts. this process is when a sheet of plastic is put in between two window panes which gets the properties of the plastic with he stiffness of glass.

73
Q

Manufacturing processes for ferrous metals (powder forming)

A

Powder forming is the process of creating metal powders and then blending and compacting the mixture in a die. They are then pressed into the mould to form the shape required and the shapes are then heated and sintered in an atmosphere. During sintering, the pressed powder particles fuse together, forming metallurgical bonds. After the item is sintered at a temperature to allow atoms to diffuse between grains, producing a homogeneous grain structure.

Year 12 Engineering 2024 (25 decks)

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