From WOOD, FABRIC and TWINE in 1903 with the Wright brothers’ forst sustained and controlled heavier-than-air powered flight to ALL METAL AIRCRAFT in WW1, to EXOTIC METALS and the use of COMPOSITE MATERIALS from 1940s onwards.

▪ SUSTAINABILITY ▪ ECONOMIC ▪ LEGISLATIVE DRIVERS (ENVIRONMENT) * demand materials with better performance and lighter in weight, and pressure was applied on aviation industry to do better*

CHEMICAL METALLURGY - is concerned with the extraction / separation of metals from their ores and with the refining of metals, compounding alloys. PHYSICAL METALLURGY - deals with the physical and mechanical properties of metals as affected by composition, mechanical working, and heat treatment.

- Ability of a material to resist abrasion, penetration, cutting action, or permanent distortion. Strength is increased by alloying, cold working, heat treatment. - High hardness metals will tend to be brittle and will have a high tensile strength

a metals ability to resist opposing forces. *scissors cutting or rivets holding two pieces together

a metals ability to resist penetration

the maximum limit of deformation before it breaks. used by engineers as a safety buffer

the ability to withstand tension is tensile strength, metal pulled from each end resulting in tension

•enables a metal to return to original size and shape when the force which causes the change of shape is removed •essential for parts used more than once

permanent distortion or change in shape of a metal without fracture under the action of a sustained force (elongated, compress, buckle, bend, twist) •above yield strength

deformation that is fully reversed or recovered when the load is removed

a metals ability to be bent, formed or shaped without cracking or breaking.

the property of a metal to be drawn into wire stock, extrusions or rods. •essential for making wire and tubing

Property of a metal’s tendency to break or shatter when exposed to stress

Materials ability to resist tearing or breaking when bent or stretched, stretched or otherwise deformed without breaking. Hammers and wrenches are examples of metals that must be both tough as well as hard is a desirable property.

Ability of a metal to be joined by heating and melting. Melting two or more compatible pieces of metals into one continuous part. Fusion joining or welding.

Mass per unit volume, metal selection, design, weight, and balance. Used to compare weights of metals (How tightly mat’l packed). Standard from which a metals density is determined is water.

o BRINELL o ROCKWELL o VICKERS o BARCOL

ROCKWELL TESTER directly measures the DEPTH OF PENETRATION

BRINELL TESTER is determined by forcing a penetrator into the material and measuring the DIAMETER OF THE RESULTING IMPRESSION

harder

3 readings

AREA WITHIN 3 DIAMETERS WILL GIVE AN INFLATED HARDNESS READING

HAND PRESSURE is used to exert pressure on a Barcol tester.

Wrought materials are formed by physically working the metal into shape by : o HAMMERING o OTHER FORMING TOOLS o HOT WORKING o COLDWORKING o EXTRUDING

smaller grain size

FERROUS METALS • Materials containing iron as chief constituent (base) is called ferrous • Most common is steel, alloy of iron with controlled amount of carbon added • Iron is fairly soft, malleable, ductile in pure form • Heavy, combines with oxygen to form iron oxide (Rust) • Usually mixed with carbon or other alloy agents to help with this • Iron poured from a furnace into molds is called cast iron, low strength to weight, few aircraft applications NON-FERROUS METALS • Term describing metals that don’t have “iron” as their base • All pure metals are non-ferrous elements, with exception of iron (Ferrite, ferromagnetic - materials science term used for iron) • Most non-ferrous metals are non-magnetic. • Aluminum, copper, titanium, magnesium most common in aircraft construction and repair • Others include nickel, platinum, palladium, gold, silver, cobalt, chromium, zinc, lead, bismuth, tin, tungsten, tantalum, niobium etc

YES - Most non-ferrous metals are non-magnetic.

•one of the most widely used metals on aircraft •Vital to aviation industry, high strength to weight ratio and ease of fabrication •2024 most common

•Used for castings, wrought form available in sheet, bar, tubing and extrusion • One of the lightest metals, 2/3 weight of aluminum • Pure state is not strong (like aluminum), stronger when alloyed with zinc, aluminum, thorium, zirconium or manganese •High strength to weight ratio •Highly susceptible to corrosion, tends to crack, form part while hot

•One of the most widely distributed metals and is reddish coloured metal • Not used as structural applications, is malleable, ductile (Heavy) •Corroded by salt water, not affected by fresh water

Lightweight, high in strength, high strength to weight ratio excellent corrosion resistance, particularly in salt water environment. Looks similar to stainless steel.

▪ Iron is fairly soft, malleable, ductile in pure form ▪ Heavy, combines with oxygen to form iron oxide (Rust)

• ALLOYING • COLD WORKING • HEAT TREATING

KSI

•LOW CARBON STEEL •MEDIUM CARBON STEEL •HIGH CARBON STEEL

• CORROSION RESISTANT • EASILY FORMED by rolling, drawing and bending • CONDUCTS HEAT • STRONG • TEMPERATURE RESISTANT • CAN BE USED FOR ALMOST ANY PART OF AN AIRCRAFT:

1. EXCELLENT MECHANICAL STRENGTH 2. RESISTANCE TO THERMAL CREEP DEFORMATION AT HIGH TEMPERATURES 3. CORROSION AND OXIDATION RESISTANCE *high temperatures too*

•a technique in which structural adhesives are mainly used to bond thin material lap joints, honeycomb structure, replacing rivets or spot welds that are generally used in these applications. •Metal bonding can be done either by explosion bonding or through the use of adhesives that eliminate the need for drilling holes.

Composite to composite, Metal to metal, Composite to metal

•Aging and fatigue - repeated loads, slow growth •Accidental damage, holes, punctures etc •Environmental degradation •Delamination, disbonds, impact damage

•Film adhesive “FREEZER STORAGE until they are to be used” •core adhesive “Requires elevated temperature cures”

•Film adhesive “The curing system is already incorporated into the adhesive” •Core adhesive “Requires elevated temperature cures”

200% during cure

• All adhesives should be handled with care • Avoid skin contact as some ingredients can cause skin irritation • The use of clean LINT FREE GLOVES is recommended when using film or core adhesive both from the hygienic standpoint and for the reliability of the repaired structure • Always wear PPE according to the WHMIS information • Check the manufacturer’s data sheet for the pot life (work life) of the mixed material

dry ice and heat