Topic 1: Introduction to aerospace materials II.
Introduction to Aerospace Materials II
José Manuel Torralba
torralba@ing.uc3m.es
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Outline
Course Outline and Objectives
Classification: Engineering Metals
General Properties of Metals
Metallic Materials Today
Milestones in Metallic Materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2
Aerospace Materials
II
Topic 1: Introduction to aerospace materials II.
Aims and Objectives
• Understand: structure, composition,
processing, properties and performance
of different families of metallic materials
used in aerospace and relationship among
them.
• To know the more adequate standardized
tests to evaluate properties and
performance of metallic materials, and to
analyze the results.
• To be able to select metallic materials for
applications in different aerospace
engineering fields.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
3
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Course Outline
I.- Metallic Materials
1.
2.
3.
4.
Solidification of Metals
Processing I : Casting
Processing II: Metal Forming Fundamentals
Heat Treatments
II.- Materials Behaviour In-Service
5.
6.
7.
8.
Mechanisms of deformation and fracture I: Fracture
Mechanisms of deformation and fracture II: Fatigue
Thermomechanical behaviour: Creep
Corrosion and Wear
III.- Applications
9. Special Steels
10.Al-alloys
11.Ti-Alloys
12.Alloys for High Temperature Applications: Intermetallics
and Superalloys
13.Surface Treatments
14.Joining Methods
15.Non-destructive Testing Methods
4
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Classification of Materials
Aerospace Materials I
Aerospace Materials II
5
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Stages of manufacturing process
Raw materials
Casting methods
(gravity casting, die
casting etc.)
Deformation
processing
(rolling forging
extruding etc.)
Part 1. Metallic Materials
Molding (polymer
Powder methods
(pressing and sintering, hot
pressing, hot isostatic
pressing etc)
Material removal
molding, glass
molding)
Special methods
(composite layup,
chemical vapor
deposition,
electroforming etc.)
Aerospace materials I
(milling, grinding machining
etc)
Heat treating
(quenching and tempering,
age-hardening etc)
Joining
Part 3. Joining processes
and Surface Treatments
(welding, brazing,
fastening, adhesive
bonding etc.)
Finishing
(Cleaning, polishing,
painting etc)
Part 2. Behaviour inservice conditions
FAILURE IN
Part 3. Applications
Dpt. Materials Sci. and Eng. and Chem. Eng.
APPLICATIONS
UC3M
Useful life
SERVICE
CONDITIONS
6
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Evaluation
•
•
Continuous evaluation assessment:
- Exercises, tests, laboratory: 40%
End-of-term-examination: 60%
Continuous evaluation will consist of three parts:
•
•
•
•
•
•
(i) exercises and tests to be solved individually, during classes (3
activities 10% each) that will count 30% of the total mark
(ii) Presentations performed by students on the selected topics of the
course. Grade of the presentation will count 10% (it can replace one
mark of the tests)
(iii) Laboratory practices, that will be assessed with a questionnaire that
will be handed in at the end of each laboratory session, and that will count
10% of the total mark.
Help sessions and tutorial classes will be held prior to the final exam.
In order to pass, the final mark of the exam and the continuous evaluation
must be at least 5. (Minimum final-exam mark:4)
3 questions with a mark of 2 or less, transform the final exam mark
into 3.9
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
7
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Evaluation
Percentage of
final mark
Activity
Description
LABORATORY SESSIONS (10%)
10%
Laboratory Reports
Assessment of the methodology and
realization of the laboratory session as well
as the written report
CONTINIOUS EVALUATION (30%)
30%
10%
3 Exercises and Tests (10% each)
Presentations and reports
(= 1 test)
Exercises and test will be performed
individually during class and will be marked
Students will present in groups one of the
selected topics of the lecture course and
prepare a short handout with lecture notes
DEADLINE FOR SIGNING UP: 27/02/2023
FINAL EXAM (60%)
60%
Final exam for the lecture course. It will
contain problems and questions from the
whole lecture course.
Minimum mark to pass exam (in order
to count for the final grade with
continuous evaluation): 4
In order to pass the lecture course the total grade must be at least 5
Final Exam
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
8
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
https://doodle.com/meeting/
participate/id/egZR2Zrd
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
9
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Evaluation
Percentage of
final mark
Activity
Description
LABORATORY SESSIONS (10%)
10%
Laboratory Reports
Assessment of the methodology and
realization of the laboratory session as well
as the written report
CONTINIOUS EVALUATION (30%)
30%
10%
3 Exercises and Tests (10% each)
Presentations and reports
(= 1 test)
Exercises and test will be performed
individually during class and will be marked
Students will present in groups one of the
selected topics of the lecture course and
prepare a short handout with lecture notes
DEADLINE FOR SIGNING UP: 27/02/2023
FINAL EXAM (60%)
60%
Final exam for the lecture course. It will
contain problems and questions from the
whole lecture course.
Minimum mark to pass exam (in order
to count for the final grade with
continuous evaluation): 4
3 questions with a mark of 2 or less,
transform the final exam mark into 3.9
In order to pass the lecture course the total grade must be at least 5
Final Exam
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
10
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Evaluation
(ii) Presentations and reports:
OBJECTIVE: to develop soft-skills.
• Groups of 5-6 students
• Select one of the topics from the course marked for “presentation”
• Use the slides of the lecture course to give the presentation
• Each group will prepare either concept maps, mind maps, conceptual
diagrams, visual metaphors or comparison charts on all the topics
presented by their classmates. These works will count as reports.
• Reports will be corrected and used as studying material for all
students.
• Presentation and reports will be marked and the grade will
count 10% of the total mark. (self-evaluation, peerevaluation and evaluation by the teacher)
• Deadline for signing up for students presentation :
27/02/2023
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
11
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
(ii) Presentations Topics
Date
16 Mar
TOPIC
DESCRIPTION
Corrosion
23 Mar
Wear
13 Apr
Ti alloys
Corrosion. Basic electrochemical corrosion. Types of
corrosion. Corrosion control and prevention. High
temperature corrosion
Friction. Wear. Friction and wear tests. Lubricants. Wear
and friction in metal-working processes. Materials
selection for tribological system.
Production processes and manufacturing. Phase
transformations in Ti alloys.
Characteristics of Ti alloys. Heat Treatments for Ti alloys.
Applications of Ti in aerospace
20 Apr
Al- alloys
27 Apr
Surface Treatments
4 May
Non-detructive
testing
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Non Heat treatable Wrought Aluminium Alloys
Heat treatable Wrought Aluminium Alloys. Cast Aluminium
alloys. Applications in aerospace. Aluminium Processing
and Joining
Main surface treatments: Galvanizing; Electrodeposition;
Organic Coatings; CVD; PVD: Thermal Spraying.
Thermochemical Treatments. Thermal Barrier Coatings
Common NDT method. Visual Inspection. Liquid
Penetrants Magnetic Particle. Eddy Current.
Radiographic. Ultrasonic Acoustic Emissions. Nondestructive testing. Method comparison.
12
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
IMPORTANT
INFORMATION
ABOUT THE
LABORATORY
SESSIONS
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
AEROSPACE MATERIALS II
LABORATORY SESSIONS
• 4 Laboratory sessions.
✓
✓
✓
✓
Cold working of metals
Heat treatments
Metal casting
Non-destructive techniques
¡¡¡COMPULSORY ATTENDANCE!!!
Absence at laboratory practices without any justification
implies that the student cannot attend the ordinary
exam.
Communication with the laboratory coordination by email: ALWAYS indicate in SUBJECT: SUBJECT_NAMEGROUP- REASON
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
LABORATORY COORDINATION:
Manuel Torres
(matorres@ing.uc3m.es)
Office: 1.1J08
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
AEROSPACE MATERIALS II
LABORATORY SESSIONS
•
In the Master Group section of Aula Global you will find the
lists of students and schedules corresponding to each
laboratory group :
- 8-10 students aprox. per group
- There are groups A, B and C. VERIFY your group and
whether
you have any schedule compatibility issues.
•
The laboratory guide can be found in Aula Global
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
AEROSPACE MATERIALS II
LABORATORY SESSIONS
SAFETY IN LABORATORIES
•
Safety videos uploaded in the Small Group section of
Aula Global should be watched.
- GENERAL SECURITY VIDEO
- CHEMISTRY LAB SECURITY VIDEO
•
You must correctly answer all the questions of the
SECURITY TESTS (One test for each video). The
deadline closes the 17th of MARCH. You can
perform the tests as many times as necessary to
answer all the questions correctly.
ANSWERING ALL THE QUESTIONS OF THE TESTS
CORRECTLY ENABLES YOU TO ENTER THE LABORATORY!!!
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
ENTRANCE TO THE
LABORATORY WILL NOT
BE ALLOWED TO THOSE
WHO DO NOT CARRY OUT
THE TESTS CORRECTLY
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
AEROSPACE MATERIALS II
SAFETY IN LABORATORIES - COVID-19
TO BE ALLOWED INTO THE LABORATORY IT
IS MANDATORY:
• Bringing: mask, safety glasses and lab
coat
• Washing your hands before and after the
lab session
• Cleaning the workplace at the end of the
practice
• You will be provided with gloves
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
AEROSPACE MATERIALS II
LABORATORY SESSIONS
VIDEOS
In Aula Global, you can find the videos corresponding to
each laboratory session. It is mandatory to watch these
videos before to go to the laboratory.
Session 1: Cold working of metal
Session 2: Heat treatments
Session 3: Metal Casting
Session 4: Non-destructive techniques
•
During the practice you must make a report in pairs that you must deliver
one week after the day of the practice, as your teacher will indicate that
day.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Outline
Course Outline and Objectives
Classification: Engineering Metals
General Properties of Metals
Metallic Materials Today
Milestones in Metallic Materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
19
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
CLASSIFICATION OF METALS
METALLIC MATERIALS
Ferrous Alloys
Dpt. Materials Sci. and Eng. and Chem. Eng.
(90%)
UC3M
NON-Ferrous Alloys
(10 %)
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
CLASSIFICATION OF METALS
METALLIC MATERIALS
Ferrous Alloys
(90%)
Steels
Cast Irons
< 2 %C
Low alloy
<5% alloying elements
Low C (< 0,25 %)
• plain
• HSLA
Medium C (0,25 – 0,6 %)
• plain
• Heat Treatable
High C (0,6 – 1,4 %)
• plain
• Tool
Dpt. Materials Sci. and Eng. and Chem. Eng.
> 2 %C
High alloy
>5% alloying
elements
Tool steels
Grey Iron
Stainless steels
Ductile or
Nodular Iron
White Iron
Malleable Iron
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
CLASSIFICATION OF METALS
METALLIC MATERIALS
NON-Ferrous Alloys (10 %)
Light alloys
Cu alloys
Super alloys
and
Intermetallics
Refractory
metals
Precious
metals
Au, Ag, Pl
Al alloys
Bronzes
Co based
W, Mo, Ta, Nb
Ti alloys
Brasses
Ni based
Mg alloys
Alpaca
Fe based
W: 19,3 g/cm3
Mo: 10,3 g/cm3
Ta: 16,7 g/cm3
Nb: 8,57 g/cm3
Al: 2,7 g/cm3
Ti: 4,5 g/cm3
Mg: 1,7 g/cm3
Cu: 8,96 g/cm3
Dpt. Materials Sci. and Eng. and Chem. Eng.
Co: 8,86 g/cm3
Ni: 8,9 g/cm3
Fe: 7,87 g/cm3
UC3M
Au: 19,3 g/cm3
Ag: 10,5 g/cm3
Pl: 21,5 g/cm3
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Application examples
Metal
Iron alloys
Light alloys
Copper alloys
Application examples
Carbon steel
Stainless steel
Castings
Al alloys
Tools, construction, automotive
Naval construction, chemical material transport,
food industry, medical instruments
Cylinders, pistons, motor bodies, wear-resistant
materials.
Aerospace industry, construction, transport,
electrical conductors
Mg alloys
Automotive, sports equipment, aerospace
industry
Ti alloys
Aerospace industry, chemical industry, medical
industry, sports equipment
Electrical conductor
Heat exchange, chemical industry, naval industry
Copper
Bronze
Brass
Pressure container
Aerospace industry (turbines), coins
Nickel alloys
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
23
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Application examples
Metal
Iron alloys
Light alloys
Copper alloys
Application examples
Carbon steel
Stainless steel
Castings
Al alloys
Tools, construction, automotive
Naval construction, chemical material transport,
food industry, medical instruments
Cylinders, pistons, motor bodies, wearresistant materials.
Aerospace industry, construction, transport,
electrical conductors
Mg alloys
Automotive, sports equipment, aerospace
industry
Ti alloys
Aerospace industry, chemical industry, medical
industry, sports equipment
Electrical conductor
Heat exchange, chemical industry, naval industry
Copper
Bronze
Brass
Pressure container
Aerospace industry (turbines), coins
Nickel alloys
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
24
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Outline
Course Outline and Objectives
Classification: Engineering Metals
General Properties of Metals
Metallic Materials Today
Milestones in Metallic Materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
25
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties of materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
26
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties of metallic materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
27
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties of metallic materials
Relatively high Young Modulus (rigid)
Can achieve high strength
Normally ductile
High workability
Relatively high toughness
Electrically conductive
Magnetic properties (Iron)
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
28
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
30
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
32
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
34
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
• Metallic
– The
– The
– The
materials’ properties have their origin in:
nature of the metallic bond
crystal structure
presence of defects
Edge dislocation
Screw dislocation
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
35
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
• Metallic materials are normally POLYCRYSTALLINE
Unit cell
Crystal structure
Aggregate of single crystal grains
Microstructure revealed on material
surface
http://www.ebsd.com/12-ebsd-for-beginners
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
36
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
• Microstructure determines many of the physical properties of
materials
Scanning
electron
microscopy
Electron
Backscatter
Diffraction
SEM
EBSD
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
37
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties of metallic materials
• They can be composed of one or various phases, according to
their composition (alloys)
• Phases can have different sizes and shapes and can be distributed
in a different way, forming a MICROSTRUCTURE.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
38
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties
• Some properties of metals depend on their microstructure
and therefore can change when the microstructure is
altered.
Microstructure dependent
properties
Microstructure
independent properties
• Thermal expansion
• Thermal and electric conductivity
• Yield point
• Young modulus
• Resistance to fatigue
• Toughness
• Resistance to corrosion and wear
• Heat capacity
• Melting point
Dpt. Materials Sci. and Eng. and Chem. Eng.
• Hardness
• Ductility
• Tensile strength
UC3M
• Creep
• Density
39
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties
Microstructure
independent
properties
Microstructure
dependent properties
•
•
•
•
•
•
•
•
Yield point
Tensile strength
Ductility
Toughness
Creep
Resistance to fatigue
Hardness
Resistance to corrosion and
wear
• Thermal and electric
conductivity
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
•
•
•
•
•
Density
Young modulus
Thermal expansion
Heat capacity
Melting point
40
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
41
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General Properties
Other properties
• Diffusion: ability to form alloys –
solid solutions
• Phase diagrams
• Ability to modify its properties
• Thermal treatments
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
42
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
Nature of the bond<> properties <> types of materials <>
Processing and applications
• Metallic bond (>20-120 kcal/mol): Atomic nucleus surrounded by
a sea of e- (non-directional).
– Compact packing (density)
– Possibility to substitute atoms
(solid solutions) →alloys
– Conductivity
– Workability
Applied force
– High stiffness
• Band theory (conductivity)
conduction band
Antibonding orbitals
Bonding orbitals
Dpt. Materials Sci. and Eng. and Chem. Eng.
empty states
filled states
UC3M
valence band
43
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
CRYSTALLINE STRUCTURES
BCC
FCC
HCP
Fe (Tª<912 ºC)
Fe (912<Tª<1400 ºC)
Ti (Tª< 882ºC)
Ti (Tª>882ºC)
Al, Cu, Ni
Co, Mg, Zn
W, Mo
Nº Slip systems:
Dislocation motion
12
12
3
Closed packed planes and directions → easier slip/plastic deformation →
Ductility (FCC>BCC>HCP)
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
44
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
CRYSTALLINE STRUCTURES
SLIP SYSTEMS
FCC
BCC
HCP
Planes
{111}
{110}
{0001}
<110>
<111>
<2110>
4 x 3 = 12
6 x 2 = 12
1x3=3
Directions
Plastic deformation (slip) and
dislocation movement is more
difficult along a non-closed
packed (a) compared to a closedpacked plane (b)
Closed packed planes and directions → easier slip/plastic deformation →
Ductility (FCC>BCC>HCP)
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
45
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
CRYSTALLINE STRUCTURES : Interstitial sites
• TETRAHEDRAL (Coord. Nº 4)
• OCTAHEDRAL (Coord. Nº 6)
In compact structures:
• Nº of tetrahedral sites =2n
• Nº of octahedral sites =n
• n = Nº atoms in the cell
Importance of Interstices (example): SOLUBILITY OF C IN IRON
▪ Different packing factors: fbcc=0.68 and ffcc=0.74
Vinterstices(fcc)<Vinterstices(bcc),
but No.interstices(fcc)>No.interstice(bcc)
▪ Explains the solubility of C in Fe:
Troom. Feα(bcc) 0.02-0.05%C  ferrite
High T (>910 ºC)  Feγ(fcc) 2%C austenite
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Fe-
(fcc)
Fe-
(bcc)
Aerospace Materials46
II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
Defects in Crystalline Structures
Understanding crystalline defects is KEY in the
understanding of mechanical response to applied stress!!
Metals are NOT single crystals,
they have crystalline defects.
The presence of defects
determines the deformation of the
material under certain stress
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
The most common defect is the
presence of grain boundaries
47
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
Defects in Crystalline Structures
- Point defects: vacancies, interstitials, impurities
allow DIFFUSION → alloy formation
- Line defects: dislocations (insert an extra plain)
allow slip→ PLASTIC DEFORMATION
- Plane defects: grain boundaries,
interfaces, surfaces
control mechanical properties
high reactivity
- Volume defects: inclusions, pores, cracks
“Extra row of kernels between other rows”
they affect negatively conductivity
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
chem.libretexts.org
48
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
General properties and their origin
DEFORMATION
Dislocation movement (edge and screw) when a shear stress is applied
Vector de Burger’s = b
A.R. West. “Solid State Chemistry and its applications”. Wiley. Chichester,1992
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
https://youtu.be/kk2oOxSDQ7U
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Outline
Course Outline and Objectives
Classification: Engineering Metals
General Properties of Metals
Metallic Materials Today
Milestones in Metallic Materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
50
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
51
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
The ASHBY prediction
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
52
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Breakdown of materials in automotive industry
units: kg
Steel, iron
Light alloys
Lubricants, fuel
Other materials
Other metals
Electric/electronic Materials
Thermoplastics
Paint and Adhesives
Thermostable
Elastomers
Thermoplastic Elastomers
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Textiles and other composites
Ceramics and glasses
13-53
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Breackdown of materials used in aircrafts
BOEING 787
Mass breakdown of structural materials in the new Boeing 787
(http://seattlepi.nwsource.com/boeing/787/787primer.asp)
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Breackdown of materials used in aircrafts
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
55
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Breackdown of materials used in aircrafts
Figure 1. (a-left) Material usage and (bright) typical system cost distribution
trends for fighter aircraft
http://www.tms.org/pubs/journals/jom/0003/martin-0003.html
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
56
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Materials used in aircrafts
Cost-reduction opportunities by implementing metal-process technologies:
Low Cost Ti Plate
has Strong Cost
Impact
(a) Machined titanium frames
Al-Be Can Reduce
Cost and Survive
Higher Temps @
Equivalent Weight
(b) Composite pylon skins
http://www.tms.org/pubs/journals/jom/0003/martin-0003.html
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
57
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Materials used in aircrafts
Cost-reduction opportunities by implementing metal-process technologies:
Vacuum die casting of
Titanium is Lower Cost
than Complex
Machined Forging
(c) titanium hinge forgings
Laserforming of Flanges
Eliminates Material Waste
from Machining Ti Plate
(d) machined titanium support ribs.
http://www.tms.org/pubs/journals/jom/0003/martin-0003.html
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
58
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
The Gas Turbine
LPC: Low Pressure
Compressor
HPC: High Pressure
Compressor
HPT: High Pressure
Turbine
LPT: Low Pressure
Turbine
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
59
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
The Gas Turbine
The different materials used in a RollsRoyce jet engine.
Titanium
Nickel-based superalloys
Steel.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
60
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
The Gas Turbine
Evolution of materials used in aero gas turbines
• Civil aero-engine performance development has depended heavily
on advances in materials, not only by virtue of their properties but
also in their manufacturing and processing
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
61
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Historical evolution of the turbine blade surface temperature in
aeroengines
• New materials, such as molybdenum based superalloys are
necessary in order to achieve further technological gains
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
13-62
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Metallic materials today
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Outline
Course Outline and Objectives
Classification: Engineering Metals
General Properties of Metals
Metallic Materials Today
Milestones in Metallic Materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
64
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
STONE AGE - (200.000 BC - 2500 BC)
Mesolithic age (8000 BC – 4000 BC)
Starts of domestication of animals and cultivation of wild
varieties of crops. Small settlements. Fire
Needs:
o Tools for agriculture (hoe, sickle, quern) –
Stone+Wood
o Tools for cooking (pots, containers) – fired ceramics
Neolithic age (4000 BC – 2500 BC)
Development of agriculture, domestication of animals.
Large scale settled communities.
Needs:
o New textiles to replace animal skins – vegetable fibers
o Machines for weaving the threads into cloth
o Construction of buildings
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
65
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
BRONZE AGE - (3000 BC - 1200 BC)
•
10000 years ago: Gold, silver and copper mostly
used for jewellery, decorative items and pots and
pans for cooking, rather than tools.
•
3000 BC: Beginning of metallurgy. Discovery of
smelting led to alloying copper with tin → Bronze
BRONZE:
• Better malleability than stone
• Improve castability and hardness
→ Sophisticated tools, the first swords
Stronger and more durable tools.
Bronze age civilizations
→ TECHNOLOGICAL ADVANCE
Growth of commerce/Need for records
→ Development of the first writing
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Needs and challenges
o Organized system of production and division
of labor
o Higher degree of specialization and diversity
of skills
o Communication, coordination, trade and
transportation
66
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
IRON AGE - (1200 BC - 550 BC)**
**The transition happened at different times in different places
Metallic iron:
Occasional lumpy-by product from lead and
copper smelting. It was collected as a spongy
mass or bloom.
Intentional smelting of iron: Hittites (1500
BC).
• Hittite monopoly of ferrous knowledge
dispersed with the empire about (1200 BC).
• Small additions of carbon to iron + heat
treatments → massive increases in strength
Ferrous metallurgy:
• Tools or weapons that are equal or superior
to bronze.
• Mass production of tools and weapons made
from steel
• Damascus sword: Forged iron from sponge
iron.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
67
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
IRON AGE - (1200 BC - 550 BC)**
IRON AS THE DEMOCRATIC METAL:
• Rise in the living standards among larger
masses of population
• Applications of iron: Tools and
agricultural implements, precious
objects, weaponry (swords, shields,
armour).
• Increment in agriculture productivity →
surplus
Needs and challenges:
o New methods of working materials
o Organization arrangements
o Specialized craftsmen
o Decentralization of power → Democracy
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
**The transition happened at different times in
different places
68
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
STEEL
DATE
FACT
CONSEQUENCES
1709
Abrahan Darby I discovered that
carbon coke can replace
charcoal in the cast iron
manufacturing
1807
Sir Humphry Davy develops the
process known as electrolysis to
separate elemental metal salts
1827
Friedrich Wöhler isolated
elemental aluminum
1856
Henry Bessemer patents a low
cost process to manufacture
steel
1863
Emile and Pierre Martin develop
the Siemens-Martin furnace for
large production of steel
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
69
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
STEEL
DATE
FACT
CONSECUENCE
1709
Abrahan Darby I discovered that
carbon coke can replace
charcoal in the cast iron
manufacturing
Dramatically decreases the cost of casting (allowing
mass production) and saving huge tracts of
deforestation.
1807
Sir Humphry Davy develops the
process known as electrolysis to
separate elemental metal salts
New metals were discovered.
Electrometallurgy and electrochemistry were founded
1827
Friedrich Wöhler isolated
elemental aluminum
It opens the possibility of exploiting the most abundant
metallic element in Earth´s crust
1856
Henry Bessemer patents a low
cost process to manufacture
steel
It opens an era of massive use of cheap steel in
transportation, construction, and generally in the
industry.
1863
Emile and Pierre Martin develop
the Siemens-Martin furnace for
steel large production
Allowed the production of large amounts of steel, scrap
steel combining with iron ore, gas burners, making steel
the material most recycled metal.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
70
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Materials Science
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2000
1900
1800
1700
1000
0
-4000
-8600
-35000
-100000
-500000
-185000000
Leads to the
appearance of the
Metallography and
Physical
Metallurgy as a
result (and
Materials
Science).
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Materials Science
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2000
1900
1800
1700
1000
0
-4000
-8600
-35000
-100000
-500000
-185000000
Start using a
microscope to
identify and
correlate
esructuras crystal
observations with
the properties of
the material.
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Materials Science
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2000
1900
1800
1700
1000
0
-4000
-8600
-35000
-100000
-500000
-185000000
Initial work of the
phase diagram
more important in
metallurgy, laying
the foundation for
an indispensable
tool in many other
material systems.
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Materials Science
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2000
1900
1800
1700
1000
0
-4000
-8600
-35000
-100000
-500000
-185000000
Enacts the paradigm
"processingstructure-properties"
that guides the area
of ​Materials Science
and Engineering.
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Materials Science
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2000
1900
1800
1700
1000
0
-4000
-8600
-35000
-100000
-500000
-185000000
Lets understand
the mechanisms
of hardening
alloys capable
of being
hardened by
precipitation.
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Materials Science
DATE
FACT
CONSECUENCE
1863
Henry Clifton Sorby uses light
microscopy to reveal the
microstructure of steel
Leads to the appearance of the Metallography
and Physical Metallurgy as a result (and
Materials Science).
1890
Adolf Martens examines the
microstructure of a hard steel and
finds many varieties of patterns.
Start using a microscope to identify and
correlate crystal structure observations with
the properties of the material
1898
William Roberts-Austen develops
the phase diagram Fe-C
Initial work of the phase diagram more
important in metallurgy, laying the foundation
for an indispensable tool in many other
material systems.
1912
Albert Sauveur publishes
“Metallography and Heat
Treatment of iron and steel”
Enacts the paradigm "processing-structureproperties" that guides the area of ​Materials
Science and Engineering.
1937
André Guinier and G. D. Preston
independently report the strength
mechanism of Al-Cu alloys by
precipitation of intermetallic
Lets understand the mechanisms of
hardening alloys capable of being hardened
by precipitation
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
76
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials – Technology and new metals
DATE
FACT
CONSECUENCE
1878
William Siemens patents the electric
arc furnace
Ancestor of modern electric arc furnace, which
is the foundation of the modern steel and many
other alloys.
1886
Charles Martin Hall and Paul Heroult
discovered the reduction of alumina
into aluminum
It facilitates the beginning of the use of
aluminum for commercial purposes.
1904
Leon Guillet develops the first
stainless steel
Extend the versatility of the use of steel in
corrosive applications.
1906
Alfred Wilm discovers the
precipitation of aluminum
Appears first duralumin alloy, structural
aluminum.
1926
Paul Merica patents the addition of
small additions of Al to Ni-Cr alloy and
invents the first “super alloy”
Leads to commercialization of the propulsion
engine and improves the efficiency of power
turbines.
1940
Wilhelm Kroll develops an economic
process to extract titanium
Establishes the possibility of a necessary
material in the reactors, biomaterials, ...
1958
Frank VerSnyder develops a
directionally solidified turbine blade
Improves performance of aircraft engines,
saving airlines millions of dollars per year.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
77
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Milestones in metallic materials
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
2000
1900
1800
1700
1000
0
-4000
-8600
ALCOA
-35000
-100000
-500000
-185000000
It facilitates
the beginning
of the use of
aluminum for
commercial
purposes.
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Materials are the fundamental building blocks of culture
The material world is not just a
display of our technology and
culture, it is part of us, we
invented it, we made it and it
makes us who we are.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
79
Aerospace Materials II
Universidad
Carlos III de Madrid
www.uc3m.es
CLUSTER AEROSPACIAL DEL PAIS VASCO
Dpt. Materials Sci. and Eng. and Chemical Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
CLUSTER AEROSPACIAL ANDALUCÍA
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Universidad
Carlos III de Madrid
www.uc3m.es
CLUSTER AEROSPACIAL MADRID
Dpt. Materials Sci. and Eng. and Chemical Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
Aerospace Materials II
Topic 1: Introduction to aerospace materials II.
Next class
METALLIC MATERIALS
TOPIC 2. SOLIDIFICATION OF METALS
1.
2.
3.
4.
Solidification. Nucleation
Solidification. Growth
Cast structures
Defects in Castings
THANK YOU FOR YOUR ATTENTION!
Dpt. Materials Sci. and Eng. and Chem. Eng.
UC3M
85
Aerospace Materials II