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Universidad Carlos III de Madrid www.uc3m.es

AEROSPACE MATERIALS I

TOPIC 0. FAMILIES OF MATERIALS, APPLICATIONS AND INTRODUCTION TO AEROSPACE MATERIALS • Historic evolution of Materials Science and Engineering • The Science and Engineering of Materials • Materials Classification • General properties of Materials • From structure to properties • Introduction to Aerospace Materials • Evolution of main aerospace materials • Materials in the global aerospace industry • Materials requirements in structures and engines

Dpt. Materials Sci. and Eng. and Chemical Eng.

UC3M

Aerospace Materials I

Stone age

Paleolithic: woo od, ston ne, bon nes

Bronze age

Neolithic, clays, N wood, worked ston ne, Metals (Au, A Ag, skins, M Cu, Sn, ...)

UC3M

Si lk, transpare ent bronze (Cu-S Sn) glass, b Irron Blown gla ass 0

Pap per Surface processiing

Porcela ain

Iron age

AD

Aerospace Materials I

Industtrial Revolutiion Aluminiium (Mét. Ha all) Polyme ers Synthetic Fibe ers Mag gnetic Supports

HISTORIC EVOLUTION OF MATERIALS

5000

Topic 0: Families of materials, applications and introduction to aerospace materials.

BC

Dpt. Materials Sci. and Eng. and Chem. Eng.

7000

Topic 0: Families of materials, applications and introduction to aerospace materials.

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

2000

1990

1980

1970

1960

1950

1940

1930

1920

1910

1900

1890

1890

MILESTONES IN AEROSPACE MATERIALS

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

20

19

1980

1970

1960

1950

1940

1930

1920

1910

1900

1890

1890

MILESTONES IN AEROSPACE MATERIALS

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

2000

1990

1980

1970

1960

1950

1940

1930

1920

1910

1900

1890

1890

MILESTONES IN AEROSPACE MATERIALS

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

MATERIALS SCIENCE AND ENGINEERING Materials Science: basic knowledge about the internal structure, properties and processing of materials. Materials Engineering: fundamental knowledge applied to materials in order to transform them into useful products required by the society. society

MATERIALS SCIENCE AND ENGINEERING

Composition Atomic bonding Crystal structure Defect structure Microstructure Macrostructure

Dpt. Materials Sci. and Eng. and Chem. Eng.

MS

Materials properties

UC3M

ME

Density Stiffness Strength Fatigue Toughness Corrosion High temperature

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

MATERIALS SCIENCE AND ENGINEERING

Applications

Properties

Structure

Processing

Application of the tetrahedron of materials science and engineering to sheet steel for automotive chassis. The composition-microstructure and synthesis-processing are all interconnected and affect the performance-to-cost ratio. Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

CLASSIFICATION OF MATERIALS

Metals

Composites C Ceramics i

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

P l Polymers

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

CLASSIFICATION OF MATERIALS

Material

Composition

Structure

Properties

Metals

Metals

Crystalline

 e, σ σ  t, R 

Polymers

Chains of organic molecules

Semi crystalline or amorphous

σe,σt, ρ

Metals + no metals

Crystalline or amorphous

hardness, Rq, brittleness

Ceramics

Composite materials: system or results from the union (not chemical, chemical or more components, creating a new and characteristics, with properties materials .

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

combination of materials that insoluble between them) of two material with specific properties different from the constituent

Aerospace Materials11I

Topic 0: Families of materials, applications and introduction to aerospace materials.

CLASSIFICATION OF MATERIALS

Functional classification : 

Aerospace



Biomedical



Electronic Materials



Energy Technology and Environment



Magnetic Materials



Optical and Photonic Materials



“Smart” Materials



Structural Materials

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

GENERAL PROPERTIES OF MATERIALS

Nature of bonding  properties  type of materials Type of material

Character of bonding

Examples

Metal

Metallic

Fe steels Fe,

Ceramic and glasses

Ionic/ covalent

Silica (SiO2)

Polymers

Covalent and secondary

Polyethylene –(CH2)-

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

GENERAL PROPERTIES OF MATERIALS

Metals and Metallic alloys - Characteristic shine - Electrical and thermal conductivity - Workability - Ductility Alloys of Mg, Ti y Ni

Prosthesis of Knee and hip

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

GENERAL PROPERTIES OF MATERIALS

Polymers - Principally based on chains of carbon atoms joined by covalent bonds. - Thermoplastics - Thermostable - Elastomers - Thermal and electric insulators - Good specific properties - Low working temperature

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

GENERAL PROPERTIES OF MATERIALS

Ceramics - High hardness - Brittleness - Electric and thermal insulators - Workability - Good thermal and chemical stability.

http://perso.wanadoo.es/chyryes/glosario/cer_fun.htm Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

GENERAL PROPERTIES OF MATERIALS

Composite Materials - Great range of properties - Depend on the constituent materials - General classification as a function of the matrix and the reinforcement - Ceramic matrix - Metallic matrix - Polymeric matrix

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

GENERAL PROPERTIES OF MATERIALS Case Study – Material Selection

Problem: Select suitable material for bicycle frame and fork.

Steel and alloys

Low cost but Heavy. Less Corrosion resistance

Wood

Carbon fiber Reinforced plastic

Aluminum alloys

Light and strong. But Cannot be shaped

Very light and strong. No corrosion. Very expensive

Light, moderately Light Strong. Corrosion Resistance. expensive

Ti and Mg alloys

Slightly better Than Al alloys. But expensive

Cost important? Select steel Properties important? Select CFRP Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

Structure: • Distributi Di t ib ti on off e- a ffects ff t the th electric l t i , magnetic, ti thermal th l , optical ti l behaviour, and the corrosion resistance. • Bonding determines the type of material • The positioning of atoms in space  crystalline structure  influences mechanical properties Properties • Mech M hanical i l (Rmecanical, ductility, d tilit Rimpact...) • Physico-chemical ( Corrosion resistance, electrical, magnetic, optical…) Processing • Casting • Plastic deformation process • Joini J i ing process • Mechanical working process

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

Structure, Properties and Processing

Transparent Single crystal without defects

Opaque Polycrystalline Grain boundaries + pores

Translucent Polycrystalline Grain boundaries

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

Structure, Properties and Processing Atomic Scale Al alloys: ductile Mg alloys: relatively brittle J.F. Shackelford, Introduction to Materials Science and Engineering for Engineers; Prentice Hall.

• planes and directions of high atomic density • easily deformed mechanically • Ductility

Al: 12 planes and directions  major capacity for de deformation Mg: 3 planes and directions Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

STRUCTURAL FACTORS AT DIFFERENT SIZES AFFECT THE PROPERTIES OF METALS

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

STRUCTURAL FACTORS AT DIFFERENT SIZES AFFECT THE PROPERTIES OF FIBRE-POLYMER COMPOSITES

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

FROM STRUCTURE TO PROPERTIES

Example of application

P Properties ti

Metals and alloys Foundry products

Automotive motors

Castable , absorber of vibrations

Ceramics and glasses SiO2-Na2O-CaO

Windows

Optically transparent, thermal insulators

Polymers Polyethylene

Packaging and bags

Easily processed in thin layers , flexible and hermetic

Semiconductors Silicon

Transistors and intergraded circuits

Unique electrical properties

Composite C i Materials M i l WC-Co

Cutting and forming tools

Elevated hardness and relatively good impact resistance

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

INTRODUCTION TO AEROSPACE MATERIALS

Fatigue Light materials

E t Extreme temperatures t t Atmosphere

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

INTRODUCTION TO AEROSPACE MATERIALS The importance of aerospace materials

Materials affect virtually every aspect of the aircraft, including the: • Purchase cost of a new aircraft • Cost of structural upgrades to existing aircraft • Design options for the airframe, structural components and engines • Fuel consumption of the aircraft (light-weighting) • Operational performance of the aircraft (speed, range and payload) • Power and fuel efficiency of the engines • In-service maintenance (inspection and repair) of the airframe and engines Safety reliability and operational life of the airframe and engines • Safety, • Disposal and recycling of the aircraft and the end-of-life

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

INTRODUCTION TO AEROSPACE MATERIALS The importance of aerospace materials: selection factors for aerospace structural materials.

• The choice of aerospace materials is governed by the design, function, loads, and environmental service conditions of the structure. t t • Exist “safety-critical structures”, those structures that can result in loss of the aircraft when they fail: fuselage, wings, landing gear, empennage, gas turbine engines (blades, discs,…). – Most of the safety-critical structures requires a combination of high stiffness, strength, fracture toughness, fatigue endurance and corrosion resistance, and…. • Damage tolerant and durable over the aircraft design life – Military fighter aircraft: 8000-14000 fligth hours -15-40 years– Large commercial airliner: 30000-60000 fligth hours -25-30 years-

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

INTRODUCTION TO AEROSPACE MATERIALS The importance of aerospace materials: selection factors for aerospace structural materials.

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

INTRODUCTION TO AEROSPACE MATERIALS The importance of aerospace materials: selection factors for aerospace structural materials.

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

INTRODUCTION TO AEROSPACE MATERIALS The importance of aerospace materials: selection factors for aerospace structural materials.

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

HISTORICAL TIMELINE INDICATIONG WHEN KEY CRITERIA FOR MATERIALS SELECTION WERE INTRODUCED INTO AIRCRAFT DESIGN

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

HISTORICAL TIMELINE INDICATIONG THE APPROXIMATE YEAR WHEN THE MAIN TYPES OF MATERIALS WERE FIRST USED IN AIRCRAFT

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

PLOT OF WING PRESSURE LOAD AGAINST YEAR OF INTRODUCTION FOR DIFFERENT FIGHTERS, BOMBERS AND AIRLINERS Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

YIELD STRENGTH OF ALUMINIUM ALLOYS AND THE YEAR OF INTRODUCTION INTO SERVICE Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

DECLINE IN USE OF ALUMINIUM IN PASSANGER AIRCRAFT

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

DECLINE IN USE OF MAGNESIUM WITH SUCCESIVE VERSIONS OF TUPOLEV AIRCRAFTS SINCE 1960’s Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

AMOUNT OF TITANIUM USED IN AIRCRAFTS

Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

IMPROVEMENT IN THE TEMPERATURE CAPABILITY OF NICKEL SUPERALLOYS USED IN JET ENGINES Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

Skin operationg temerpatures for aircraft have increaed with the development of improved materails Dpt. Materials Sci. and Eng. and Chem. Eng.

UC3M

Aerospace Materials I

Topic 0: Families of materials, applications and introduction to aerospace materials.

EVOLUTION OF MAIN AEROSPACE MATERIALS

REDUCTIONS IN THE ENGINE FUEL CONSUMTION AND AIRCRAFT FUEL BURN PER SEAT BASED ON THE CORNET 4 AIRCRAFT Dpt. Materials Sci. and Eng. and Chem. Eng.

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