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The materials used in aircraft should The materials used in aircraft should posses properties, which permit them to posses properties, which permit them to perform the intended functions successfully, perform the intended functions successfully, while in use. The objective is to achieve while in use. The objective is to achieve complete structural integrity at minimum complete structural integrity at minimum structural weight and minimum cost. structural weight and minimum cost.

Modern high-speed aircrafts demand:Modern high-speed aircrafts demand:

              Highest safetyHighest safety

              Reliability of performanceReliability of performance

              Complete structural controlComplete structural control

              Minimum structural weight andMinimum structural weight and

              Minimum costMinimum cost

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In aircraft manufacturing unique application ofIn aircraft manufacturing unique application of

                  Metallic materialsMetallic materials

                  Non-metallic materials andNon-metallic materials and

                  Composites are employed.Composites are employed.

Hence, Hence, aircraft materials should posses aircraft materials should posses

  Quality Quality Highest importance. Materials free Highest importance. Materials free from internal from internal defects and gases. Measured defects and gases. Measured by cleanliness and by cleanliness and soundness.soundness.

  Structural efficiencyStructural efficiency Ratio of strength to Ratio of strength to weight/density, weight/density, UTS, YS, %E,UTS, YS, %E,%RA.%RA.

Fatigue strength Fatigue strength Resistance to cyclic Resistance to cyclic loads. Materials should loads. Materials should posses high endurance posses high endurance limit to take full advantage of limit to take full advantage of ultimate ultimate strength.      strength.      

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Fracture toughness Fracture toughness Resistance to crack Resistance to crack formation and formation and crack crack propagation. Tough propagation. Tough materials are materials are required.required.

Corrosion resistance Corrosion resistance High resistance to High resistance to general corrosion and stress general corrosion and stress corrosion. corrosion.

Materials which can with stand service Materials which can with stand service conditions conditions Materials should withstand rapid Materials should withstand rapid and gradual changes in climatic, static and and gradual changes in climatic, static and dynamic loads dynamic loads without affecting physical without affecting physical and mechanical properties. and mechanical properties.

Cost of material and fabricationCost of material and fabrication Lower Lower initial cost, initial cost, easy availability, economical to easy availability, economical to fabricate, durable and minimum overall cost.fabricate, durable and minimum overall cost.

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Metallic materials find the highest application Metallic materials find the highest application in construction of airframes.in construction of airframes.

MiG-27MiG-27 MiG-29MiG-29 SU-30SU-30

· Aluminium alloys% 52.0· Aluminium alloys% 52.0 53.553.5 61.561.5

· Ferrous alloys % 43.5· Ferrous alloys % 43.5 31.531.5 15.015.0

· Magnesium alloys % 2.8· Magnesium alloys % 2.8 1.01.0 2.22.2

· Titanium alloys % 1.0· Titanium alloys % 1.0 9.09.0 18.118.1

· Others· Others % 0.7 % 0.7 5.05.0 3.23.2

Metallic materials are classified into Metallic materials are classified into

   WROUGHT ALLOYSWROUGHT ALLOYS

CAST ALLOYS ANDCAST ALLOYS AND

POWDER METALS.POWDER METALS.

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WROUGHT ALLOYS can be processed to any desired shapes by cold or hot working methods. Sheets, rods, extrusions, profiles, forgings are example. They posses good workability in hot and cold condition. Desired mechanical properties can be achieved by suitable heat treatment. Highly stressed components are fabricated by using wrought alloys.

CAST ALLOYS have good cast ability. Hence, intricate shapes can be made. In case of investment castings minimum or no machining is required. Castings can also be heat treated to achieve desired mechanical properties. Considerable numbers of castings are used in airframes.

POWDER METALPOWDER METAL products like brake pads, carbon brush, and sintered parts are produced when the alloys are difficult to melt by conventional process and when conventional methods are not possible.

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AEROSPACE MATERIAL STANDARDSAEROSPACE MATERIAL STANDARDS

RUSSIA RUSSIA GOST GOST GOsudarstvennyj STandartovGOsudarstvennyj STandartov

INDIA INDIA IS IS Indian StandardsIndian Standards

UK UK DTD Directorate of Materials research DTD Directorate of Materials research and and DevelopmentDevelopment

BS British Standards InstituteBS British Standards Institute

(Aerospace Series) (Aerospace Series)

US US AMS Aerospace Material AMS Aerospace Material SpecificationSpecification

ASM American Society for MetalsASM American Society for Metals

AISI American Iron and Steel InstituteAISI American Iron and Steel Institute

GERMAN GERMAN DIN DIN Deutsches Institut Fur NormungDeutsches Institut Fur Normung

FRANCE FRANCE AFNOR Aerospatiale Technical AFNOR Aerospatiale Technical Management Management standard standard

AIR French Air ministry StandardAIR French Air ministry Standard

MIL MIL Army, Navy & Air force Military Army, Navy & Air force Military standardsstandards

 

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METALLIC materials, based on chemistry are METALLIC materials, based on chemistry are classified as classified as FERROUS ALLOYSFERROUS ALLOYS and and NON- FERROUSNON- FERROUS ALLOYSALLOYS..

NOTATION FOR FERROUS ALLOYSNOTATION FOR FERROUS ALLOYS

Russian English Element  Russian English Russian English Element  Russian English ElementElement

YY UU CarbonCarbon TT T T TitaniumTitanium

ГГ GG ManganeseManganese ДД D Copper D Copper

CC S S Silicon Silicon KK K Cobalt K Cobalt

XX KHKH Chromium Chromium Ю Ю YU YU Aluminium Aluminium

HH NN Nickel ФNickel Ф F F Vanadium Vanadium

MM M M Molybdenum B V Molybdenum B V TungstenTungsten

Beginning with: S-steel, SH- bearingBeginning with: S-steel, SH- bearing

Ending with: A-high quality, SEnding with: A-high quality, SSHSH- ESR Quality, GK- hot - ESR Quality, GK- hot rolledrolled

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FERROUS ALLOYSFERROUS ALLOYS have high load bearing have high load bearing capacity. Alloy of iron and carbon is called steel capacity. Alloy of iron and carbon is called steel and is a ferrous alloy. Addition of elements like and is a ferrous alloy. Addition of elements like chromium, manganese, silicon, nickel, titanium, chromium, manganese, silicon, nickel, titanium, molybdenum, etc. makes alloy steels.molybdenum, etc. makes alloy steels.

Ferrous alloys are further classifies asFerrous alloys are further classifies as

CARBON STEELSCARBON STEELS Low Carbon SteelLow Carbon Steel %C 0.10-0.30 %C 0.10-0.30 S10, S20, A12, A20, A30S10, S20, A12, A20, A30 Medium Carbon SteelMedium Carbon Steel % C 0.30-0.70 % C 0.30-0.70 S45, S50, S70S45, S50, S70 High Carbon SteelHigh Carbon Steel % C 0.70-2.0 % C 0.70-2.0 U7, U8, U9AU7, U8, U9A These are used as machined components, These are used as machined components, fasteners, clamps, brackets, pins, rivets, sheet fasteners, clamps, brackets, pins, rivets, sheet springs, Lever.springs, Lever.

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 ALLOY STEELSALLOY STEELS MEDIUM ALLOY.MEDIUM ALLOY. Alloying elements <10 Alloying elements <10 percentage * Excellent static and dynamic percentage * Excellent static and dynamic strength. Good weld ability. strength. Good weld ability. ChromansilChromansil steel 30 steel 30KHKHGSA for welded and GSA for welded and machined parts, air bottles, structural parts, machined parts, air bottles, structural parts, standard parts, eye bolts, cylinders, stay rods.standard parts, eye bolts, cylinders, stay rods.

ChromansilChromansil with nickelwith nickel 30 30KHKHGSN2A-VD Landing GSN2A-VD Landing gear, gear, high strength parts and bolts.high strength parts and bolts.4040KHKHN2SVA (AE643)N2SVA (AE643) u/c brace bolt, wing shaft u/c brace bolt, wing shaft pin.pin. Spring steelsSpring steels 50 50KHKHFA, 65S2VA flat and helical FA, 65S2VA flat and helical springs, AFU & after burner springs. springs, AFU & after burner springs. Steel fastenersSteel fasteners 16 16KHKHSN, 20G2A rivets, SN, 20G2A rivets, screws, anchor nuts, nuts, screws, anchor nuts, nuts, 40 40 KHKH for crank shaft, for crank shaft, 1212KHKHN4AN4A for gears, shafts, pins, axles for gears, shafts, pins, axles

Bearing steel SH KH15 for bearings,

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HIGH ALLOYHIGH ALLOY Alloying elements > Alloying elements > 10percentage * these are 10percentage * these are corrosion resistant corrosion resistant and heat resistant steelsand heat resistant steels and are called stainless and are called stainless steels. Classified further as steels. Classified further as

AUSTENITIC, AUSTENITIC,

FERRITIC and FERRITIC and

MARTENSITIC STAINLESS STEELS. MARTENSITIC STAINLESS STEELS.

AUSTENITIC (AUSTENITIC (high % Cr & Ni)high % Cr & Ni) are non-magnetic, are non-magnetic, ductile, can be cold formed. High corrosion ductile, can be cold formed. High corrosion resistance. Hardened by cold working only. resistance. Hardened by cold working only.

Ex: 12Ex: 12KHKH18N10T18N10T Engine shrouds, ss Engine shrouds, ss pipes, ss pipes, ss standard parts, ss locking wires, ss standard parts, ss locking wires, ss balls, clamps, balls, clamps, straps.straps. KHKHN38VT (AE703)N38VT (AE703) tail cone, tail cone,

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FERRITIC (12 to 14% Cr)FERRITIC (12 to 14% Cr) are of low nickel and are of low nickel and extremely low carbon content. Magnetic, ductile, extremely low carbon content. Magnetic, ductile, cold formable, heat resistant and non-heat cold formable, heat resistant and non-heat treatable.treatable.

0808KHKH13, 1313, 13KHKH13 axle, bush13 axle, bush

1010KHKH12S12SYUYU, 10, 10KHKH17NT bearing17NT bearing

MARTENSITICMARTENSITIC steels are magnetic, corrosion steels are magnetic, corrosion resistant and heat treatable.resistant and heat treatable.

2020KHKH13, 1413, 14KHKH17N217N2 are used for bolts, are used for bolts, nuts nuts and valves. and valves.

VNS2 (08VNS2 (08KHKH15N5D2T)15N5D2T) used for welded used for welded fuel tanks, fuel tanks, gun chute, frames, profilesgun chute, frames, profiles

EP310(EP310(VNS5)VNS5)(13(13KHKH15N4AM3) 15N4AM3) 0606KHKH14N6D2MBT are used in SU3014N6D2MBT are used in SU30

FERROUS CAST ALLOYSFERROUS CAST ALLOYS: 45L, 35: 45L, 35KHKHGSL for GSL for bushes NLG link, door bracket and VNL-3 bushes NLG link, door bracket and VNL-3 (08(08KHKH14N5M2D) for tie pieces and coupling of 14N5M2D) for tie pieces and coupling of air intake channel.air intake channel.

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NON-FERROUS ALLOYSNON-FERROUS ALLOYS

NOTATION FOR NON FERROUS ALLOYSNOTATION FOR NON FERROUS ALLOYS

RUSSIANRUSSIAN ENGLISH ELEMENT RUSSIAN ENGLISH ELEMENT RUSSIAN ENGLISH ENGLISH

ELEMENTELEMENT

AA A A Aluminium Aluminium Б Б BB BerylliumBeryllium

MM M M Copper Copper Ж Ж ZHZH IronIron

CC S S Lead Lead H H NN NickelNickel

MЦMЦ M MTSTS Manganese Manganese MГ MГ MG MG MagnesiumMagnesium

OO O O Tin Tin K K KK SiliconSilicon

ЩЩ T TSHSH Zinc Zinc X X KHKHChromiumChromium

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ALUMINIUM BASE ALLOYSALUMINIUM BASE ALLOYS

Aluminium base alloys are major airframe Aluminium base alloys are major airframe material. High strength to weight ratio, easy to material. High strength to weight ratio, easy to fabricate, available in various desired shapes, fabricate, available in various desired shapes, reasonably good corrosion resistance and weld reasonably good corrosion resistance and weld ability, high electrical conductivity and high ability, high electrical conductivity and high thermal conductivity are advantages of these thermal conductivity are advantages of these alloys.alloys.

HEAT TREATABLE ALUMINIUM ALLOYSHEAT TREATABLE ALUMINIUM ALLOYS

DURALUMINDURALUMIN (Al-Cu-Mg) D1, D16, D19, D20, used (Al-Cu-Mg) D1, D16, D19, D20, used for skin, body, rivets, tank 1 profile, stabilizer for skin, body, rivets, tank 1 profile, stabilizer panels.panels.D16 & D19 are not weld able, D20 is weld able, D16 & D19 are not weld able, D20 is weld able, and D19P is for heat resistant rivets. Sheets of and D19P is for heat resistant rivets. Sheets of D16 and D19 are protected from corrosion by D16 and D19 are protected from corrosion by cladding with pure Aluminium. Other products are cladding with pure Aluminium. Other products are protected by anodizing and painting.protected by anodizing and painting.

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•HIGH STRENGTH ALLOYHIGH STRENGTH ALLOY

•(Al-Zn-Cu-Mg) V93, V95 used for aircraft (Al-Zn-Cu-Mg) V93, V95 used for aircraft structural parts like wing spar, under structural parts like wing spar, under carriage beam, ejection seat rails, wing carriage beam, ejection seat rails, wing panels, engine mounting bkt, flap bkt, bell panels, engine mounting bkt, flap bkt, bell cranks. cranks.

•ALUMINIUM FORGING ALLOYALUMINIUM FORGING ALLOY

•(Al-Cu-Mg-Fe-Ni) AK4, AK4-1, (Al-Si-Mg) AK6, (Al-Cu-Mg-Fe-Ni) AK4, AK4-1, (Al-Si-Mg) AK6, AK8 use as bell cranks, piston forgings, AK8 use as bell cranks, piston forgings, crankcases, wheel hub, NLG bkt.crankcases, wheel hub, NLG bkt.

•ALUMINUM-LITHIUM ALLOYSALUMINUM-LITHIUM ALLOYS 0142001420 for for fairing, profiles and skin sheets (Li 1.5-2.6, fairing, profiles and skin sheets (Li 1.5-2.6, Mg 4.0-7.0, Mn 0.24-0.4, Ti 0.1-0.2%)Mg 4.0-7.0, Mn 0.24-0.4, Ti 0.1-0.2%)

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NON-HEAT TREATABLE ALLOYSNON-HEAT TREATABLE ALLOYS

These are of low strength. Mechanical properties These are of low strength. Mechanical properties cannot be improved by heat treatment. Excellent for cannot be improved by heat treatment. Excellent for weld able structures.weld able structures.

•MagnaliumMagnalium (Al-Mg) AMG2, AMG3, AMG5, AMG5P, (Al-Mg) AMG2, AMG3, AMG5, AMG5P, AMG6AMG6

Finds application in drop tanks, oil pipe lines, Finds application in drop tanks, oil pipe lines, hydraulic tanks,hydraulic tanks,

AMG2N AMG2N is used as honeycomb foils inside control is used as honeycomb foils inside control surface parts.surface parts.

Cast alloysCast alloys

AL19AL19 (Al-Cu-Mn-Ti) for parts working at (Al-Cu-Mn-Ti) for parts working at 175-175- 30030000C, impeller pump housing. C, impeller pump housing. (HT)(HT)

AL9AL9 (Al-Si-Mg) complicated shaped castings, (Al-Si-Mg) complicated shaped castings, control stick handle body control stick handle body (NHT)(NHT)

VAL10VAL10 (Al-Cu-Mg-Be) ejection seat parts, bell (Al-Cu-Mg-Be) ejection seat parts, bell cranks. cranks. (HT).(HT).

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MAGNESIUM BASE ALLOYSMAGNESIUM BASE ALLOYS

Lightest engineering alloy used in Lightest engineering alloy used in airframe with strength of 20 to 35 kg/mmairframe with strength of 20 to 35 kg/mm22. . Poor corrosion resistance, poor toughness, Poor corrosion resistance, poor toughness, high notch sensitivity in fatigue. Magnesium high notch sensitivity in fatigue. Magnesium alloys are potential weight saver in alloys are potential weight saver in airframes. Principal alloying elements are airframes. Principal alloying elements are Aluminium, zinc and manganese. Corrosion Aluminium, zinc and manganese. Corrosion resistance can be improved by surface resistance can be improved by surface oxidation treatment.oxidation treatment.

MA8MA8 (Mn2-Ce0.2) for frames, floor beams and (Mn2-Ce0.2) for frames, floor beams and trim tabs, profiles, cover skins.trim tabs, profiles, cover skins.

BM65-1BM65-1 (Zn5-Zr0.5) for flap bracket (Zn5-Zr0.5) for flap bracket

ML5ML5 (Al8MnBeZn) for leading edges, LG hubs, (Al8MnBeZn) for leading edges, LG hubs, Control column body, wheel flange, leading Control column body, wheel flange, leading edge. edge.

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TITANIUM ALLOYSTITANIUM ALLOYS

High mechanical properties (50 to 90 High mechanical properties (50 to 90 kg/mmkg/mm22 UTS) , low specific weight (4.5 UTS) , low specific weight (4.5 gm/cmgm/cm33), outstanding corrosion resistance ), outstanding corrosion resistance and oxidation resistance up to 500and oxidation resistance up to 50000C have C have made titanium alloys increased use in air made titanium alloys increased use in air frames. Corrosion resistance of the alloys frames. Corrosion resistance of the alloys are reasonably good, especially in seawater are reasonably good, especially in seawater and against crevice attack.and against crevice attack.

OT4-1 OT4-1 (Ti-2.5Al-1.5Mn) tail cone, drag (Ti-2.5Al-1.5Mn) tail cone, drag chute doorchute door

VT22VT22 (Ti-5Al-1Cu-5Mo-5V) special (Ti-5Al-1Cu-5Mo-5V) special hydraulic tankshydraulic tanks

VT5-1VT5-1 (4-5.5Al-2-3Sn) Skin frames, (4-5.5Al-2-3Sn) Skin frames, guide guide units of compressor bodyunits of compressor body

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COPPER COPPER ANDAND COPPER ALLOYSCOPPER ALLOYS

Copper alloys have high thermal and Copper alloys have high thermal and electrical conductivity, high corrosion electrical conductivity, high corrosion resistance and high ductility.resistance and high ductility.

M1M1 (Cu99.9percentage), (Cu99.9percentage),

M2M2(Cu99.7percentage),(Cu99.7percentage),

M3M3 (Cu99.5percentage) (Cu99.5percentage)

are pure copper used in packing, sealing are pure copper used in packing, sealing rings, washers, rivets, fuel connecting rings, washers, rivets, fuel connecting pipes.pipes.

BrassBrass, , an alloy of copper with zinc is an alloy of copper with zinc is used for screws, pins, nozzles, bushes, used for screws, pins, nozzles, bushes, elbows and slide blocks. Notable areelbows and slide blocks. Notable are

L63 (Cu60.5-63.5 Zn rest) andL63 (Cu60.5-63.5 Zn rest) and

LS59-1(Cu57-60, Pb0.8-1.9, Zn rest)LS59-1(Cu57-60, Pb0.8-1.9, Zn rest)

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BronzesBronzes are alloys of copper with are alloys of copper with Aluminium (Al bronze), Nickel (Ni bronze), Aluminium (Al bronze), Nickel (Ni bronze), Manganese (Mn bronze), Beryllium (Be Manganese (Mn bronze), Beryllium (Be bronze), Titanium (Ti bronze)bronze), Titanium (Ti bronze)

Aluminium bronzeAluminium bronze grade BrA grade BrAZHZHN 10-4-4 N 10-4-4 and BrAand BrAZHZHMMTSTS 10-3-1.5 are used as 10-3-1.5 are used as antifriction bearing bushes in under antifriction bearing bushes in under carriage, flywheels, and nipples. The alloy carriage, flywheels, and nipples. The alloy is corrosion, shock and fatigue resistant. is corrosion, shock and fatigue resistant.

Beryllium bronzeBeryllium bronze BrB2 is used as leaf BrB2 is used as leaf springs, spring contacts, bellows, and springs, spring contacts, bellows, and radiator tubes.radiator tubes.

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COMPOSITE MATERIALS COMPOSITE MATERIALS

Bonded sandwich construction, Bonded sandwich construction, honey comb construction, provide light honey comb construction, provide light weight, thick sections and are used in weight, thick sections and are used in control surfaces of aircraft like wing flaps, control surfaces of aircraft like wing flaps, stabilizers,stabilizers, ailerons and rudder. Honeycomb ailerons and rudder. Honeycomb structure consists of a thick low-density structure consists of a thick low-density core of Aluminium alloy foil, AMG2N core of Aluminium alloy foil, AMG2N 0.030mm thickness and made up of 0.030mm thickness and made up of countless number of cells with close countless number of cells with close resemblance to a bee honeycomb. The core resemblance to a bee honeycomb. The core is bonded to the is bonded to the skin of duralumin D16/D19 skin of duralumin D16/D19 called facing sheets by structural adhesives called facing sheets by structural adhesives like redux or epoxy. Sandwich structures like redux or epoxy. Sandwich structures provide extremely lightweight and strong provide extremely lightweight and strong panels. They have properties like vibration panels. They have properties like vibration damping, thermal and acoustic insulation. damping, thermal and acoustic insulation.

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