Professional Documents
Culture Documents
FY Part II 2012
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Structural Metals-Properties
Hardness
Ability to resist abrasion, penetration, cutting or permanent distortion
Brittleness
Property of metal that allows little bending or deformation without shattering
Malleable
A metal that can be hammered, rolled or pressed into various shapes without cracking or breaking
Ductility
Property of metal that allows it to be permanently drawn, bent, or twisted into various shapes without breaking
Elasticity
Property enables metal to return to its original shape when the force which causes the change of shape is removed
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Structural Metals-Properties
Toughness
A material that will withstand tearing or shearing and may be stretched without being deformed or breaking
Density
Weight of a unit volume of material
Fusibility
The ability of a metal to become liquid when heated (can be welded)
Conductivity
Property which enables a metal to carry heat or electricity
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Reliability
2 important factors are corrosion resistance and workability
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Metal Types
Ferrous Metals
Carbon Steel Nickel Steel Chromium Steel
Nonferrous Metals
Aluminum & Aluminum Alloys Alclad Aluminum Titanium & Titanium Alloys Copper & Copper Alloys Monel Magnesium & Magnesium Alloys
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Metalworking Processes
Hot working Cold Working Extruding Welding Brazing/Soldering
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Heat Treatment
Involves the heating and cooling of metals in the solid state Changes the mechanical properties so the metal can be more useful Metals can be made harder, stronger and more impact resistant or metals can be made softer and more ductile
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Case Hardening
STAGE ONE:
The steel is heated to red heat. It may only be necessary to harden one part of the steel and so heat can be concentrated in this area. (Select Slide
Show)
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Case Hardening
STAGE TWO: The steel is removed from the brazing hearth with blacksmiths tongs and plunged into case hardening compound and allowed to cool a little. The case hardening compound is high in carbon.
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Case Hardening
STAGE THREE: The steel is heated again to a red color, removed from the brazing hearth and plunged into cold, clean water. (Select Slide Show)
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Case Hardening
The steel rod should now have a hardened outer surface and a flexible, soft interior. The process can be repeated to increase the depth of the hardened surface.
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Aluminum alloys
Solution heat treatment Precipitation heat treatment
Magnesium alloys
Solution heat treatment Precipitation heat treatment
Titanium
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Metalworking Practices
Additional notes to remember when working with metals:
The material on the outside of a curve stretches, while the material on the inside of the curve compresses. There is a location near the middle of the metal thickness that neither shrinks nor stretches. This is called the neutral line, or the neutral axis, of the material.
Reference following slide for example of Pure Bending
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y Neutral Surface
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l y Neutral Surface
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Metalworking Practices
Cold working, strain hardening or work hardening of a metal is done by repeatedly applying a mechanical force to the metal. Material Properties & Cold Working
As the percent of Cold Working increases:
Tensile strength - increases Yield strength - increases Ductility - decreases Electrical conductivity decreases Corrosion resistance - decreases
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Metalworking Practices
A closed angle is and angle that has been bent beyond 90 degrees. For the greatest strength in a bent piece of material, the layout should always be made so that the bend will be perpendicular to the grain of the sheet Note that angle of bend is the angle through which the material has actually been bent. To illustrate, in Fig. 1, the angle on the drawing is 60 degrees, but the angle of bend A is 120 degrees (180 60 = 120); in Fig. 2, the angle of bend A is 60 degrees; in Fig. 3, angle A is 90 30 = 60 degrees.
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Corrosion - Classifications
Direct chemical attack
Battery acid, residual flux deposits, entrapped caustic cleaning solutions
Electrochemical attack
Requires a medium (usually water) that conducts tiny current of electricity More active metal becomes anodic & less active metal becomes cathodic The greater the difference in electrical potential (dissimilar metals) the greater the corrosion Most common cause of corrosion
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Corrosion
4 Conditions that must exists before corrosion can occur: (Select Slide Show)
The presence of a metal that will corrode (anode) The presence of dissimilar conductive materials (cathode) which has less tendency to corrode Presence of a conductive liquid (electrolyte) Electrical contact between the anode and cathode
Rust or corrosion that occurs with most metals is a result of the tendency for metals to return to their natural state. Nobel metals like gold and platinum do not corrode since they are chemically uncombined in their natural state. www.mit.asia
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Forms of Corrosion
Intergranular Corrosion
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Forms of Corrosion
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Forms of Corrosion
Uniform Corrosion
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Forms of Corrosion
Galvanic Corrosion
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Forms of Corrosion
Forms of Corrosion
Pitting Corrosion
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Forms of Corrosion
Crevice Corrosion
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Forms of Corrosion
Filiform Corrosion
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Forms of Corrosion
Forms of Corrosion
Corrosion Fatigue
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Forms of Corrosion
Fretting Corrosion
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Forms of Corrosion
Erosion Corrosion
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Forms of Corrosion
Dealloying
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Forms of Corrosion
Corrosion in Concrete
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Forms of Corrosion
Microbial Corrosion
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Corrosion-Preventive Maintenance
An adequate cleaning Detailed inspection for corrosion and failure of protective systems Prompt treatment of corrosion and touchup of damaged paint areas Keeping drain holes free of obstruction Daily wipe down of exposed critical areas Making maximum use of protective covers
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CorrosionPreventive Maintenance
Use of Chemical Cleaners When a structure is chemically cleaned the fayed surfaces should be protected to prevent corrosive materials from seeping between the lap joints. This would cause corrosion to form in an area where it is hard to detect. There are two parts to "sealing" faying surfaces: surfaces in contact edges where an electrolyte (chemical or water) could enter Lap joints - Many designs have lap joints in the fuselage skins. If the outside is to remain natural aluminum color, then mask the panel so you can put a chemical conversion coat where the panel is overlapped on the outside.
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Corrosion Removal
Complete corrosion treatment involves the following:
Cleaning and stripping of the corroded area Removing as much of the corrosion products as practicable Neutralizing any residual materials remaining in pits and crevices Restoring protective surface films Applying temporary or permanent coatings or paint finishes
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Composites-Wood Structure
Cellulose Strands Lignin Polymer
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Advantages of Composites
Stronger and stiffer than metals on a density basis Highly corrosion resistant Outstanding durability Low investment in fabrication equipment
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Advantages of Composites
Non-metallic materials, also known as composite materials, offer many advantages over other materials. Within aerospace markets, where exceptional performance is required but weight is critical, composites continue to grow in importance. Some of the many advantages of composites are: Stronger and stiffer than metals on a density basis Highly corrosion resistant Outstanding durability Low investment in fabrication equipment Illustration of the Delta 7425-9.5 rocket with CONTOUR spacecraft. Photo: Boeing
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Advantages of Composites
From virtual to real is the track that aircraft follow. Here, the Boeing 787 Dreamliner takes shape. Its fuselage, made of composites, consists of four cylindrical sections. Composites, because of their light weight and strength, are gaining favor as a material for aircraft. The Boeing Co.'s 787 Dreamliner, officially unveiled on July 8, 2007 has become the poster child for composites in aircraft design because the design uses the materials extensively. According to Boeing, composite materials constitute about 50 percent of the aircraft by weight.
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Composite Processes
Wet lay-up Prepreg lay-up Filament winding Press molding Resin Transfer Molding (RTM) Resin Infusion Chopper Gun sprayed materials
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Composite Processes
Wet Lay Up Process
Epoxy is applied to the carbon fiber. The finished panel will be cut into test samples.
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Composite Processes
BACKGROUND (PREPREG MANUFACTURE, LAY-UP AND CONSOLIDATION) Pre-pegs are thin sheets of fibres impregnated with resin. The most frequently used method of Pre-preg manufacture is the film route, which is illustrated schematically in figure1. Tows of fibre are pulled along a heated bed, where resin films are brought into contact with them on upper and lower surfaces. The thermal field is controlled so as to reduce the resin viscosity sufficiently to allow tow infiltration under the pressure applied via the consolidation rolls and to promote curing . Finally the pre-preg is backed with release film for storage until required for component manufacture.
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Composite Processes
BACKGROUND (PREPREG MANUFACTURE, LAY-UP AND CONSOLIDATION) Consolidation involves the cutting and stacking of pre-preg layers in a predetermined sequence of fibre orientations within a mould containing release agent and absorption layers. An upper plate is laid on top and this assembly is sealed in a vacuum bag, as shown in figure2. The matrix resin is cured by exposure to a defined combination of temperature and pressure. When the lay-up is heated, the constraint offered by the resin decreases as its viscosity falls. Application of pressure forces the fibres together. Therefore the temperature and pressure cycle affects, not only the fibre volume fraction and void content, but also the fibre distribution and alignment. The fibre alignment characterization technique presented here can be applied to fully cured composite components and to prepreg material.
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Composite Processes
Filament Winding: Process Technology To begin with, a large number of fibre rovings is pulled from series of creels into bath containing liquid resin, catalyst and other ingredients such as pigments and UV retardants. Fibre tension is controlled by the guides or scissor bars located between each creel and resin bath. Just before entering the resin bath, the rovings are usually gathered into a band by passing them through a textile thread board or stainless steel comb.
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Composite Processes
Press molding Press curing uses heated platens to apply both pressure and heat to the part. Presses, in general, operate at 20 - 1000 psi (140 - 7000 kPa) and up to 600F (320C). Press curing is very economical for flat parts and high production rates. Tooling requires matched die molds for contoured parts. The following steps are used in press molding:
1. Composite material is placed in the mold cavity. 2. Cure monitoring devices are installed. 3. Parts are placed into press and cured. Pressure, temperature, and time are monitored during the cure cycle to ensure curing parameters are met.
Press curing produces high quality parts with low void content.
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Composite Processes
Resin Transfer Molding (RTM) Resin Transfer Molding or RTM as it is commonly referred to is a Closed Mold Process in which reinforcement material is placed between two matching mold surfaces one being male and one being female. The matching mold set is then closed and clamped and a low-viscosity thermoset resin is injected under moderate pressures (50 100 psi typical) into the mold cavity through a port or series of ports within the mold. The resin is injected to fill all voids within the mold set and thus penetrates and wets out all surfaces of the reinforcing materials. The reinforcements may include a variety of fiber types, in various forms such as continuous fibers, mat or woven type construction as well as a hybrid of more that one fiber type. Vacuum is sometimes used to enhance the resin flow and reduce void formation. The part is typically cured with heat. In some applications, the exothermic reaction of the resin may be sufficient for proper cure.
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Composite Processes
Vacuum Infusion - The Equipment and Process of Resin Infusion The Vacuum Infusion Process (VIP) is a technique that uses vacuum pressure to drive resin into a laminate. Materials are laid dry into the mold and the vacuum is applied before resin is introduced. Once a complete vacuum is achieved, resin is literally sucked into the laminate via carefully placed tubing. This process is aided by an assortment of supplies and materials.
Vacuum infusion provides a number of improvements over traditionally vacuum bagged parts. These benefits include: Better fiber-to-resin ratio Less wasted resin Very consistent resin usage Unlimited set-up time Cleaner Reference following slide for example of this Vacuum equipment and process
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Composite Processes
In the following example, spiral tubing is used for both the resin feed and the vacuum line. Resin will enter on one side and fill the length of the tubing very quickly. At that point, resin will begin to flow across the laminate. While this approach is simpler to set up, the resin will need to travel across a longer distance. Depending on what materials and equipment are used, this distance becomes a significant factor. However, on the up-side, the inside surface texture of the finished part will be consistent.
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Composites-Boeing 777
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Fabrication
Types of materials Usage
Metal tubing is sized by its outside diameter and flexible hose by inside diameter on all aerospace vehicles. When installing metal tubing, tension is undesirable because pressurization will cause it to expand and shift www.mit.asia
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Fluid Lines
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