AIRCRAFT MATERIALS AND PROCESSES(21AE32)

COURSE LEARNING OBJECTIVES: This course will enable students to

1. Acquire knowledge of different aerospace materials & their properties.

2. Understand the Heat Treatment processes of aircraft metals and alloys

3. Characteristics and Applications of Aluminium alloys, Ceramics, Composites and Material

Testing..
Course Outcomes: At the end of this course, students are able to:
CO1 Apply the knowledge about the mechanical behaviour of different aircraft & aerospace
Materials.(L-3)
CO2 Understand use of ferrous and non-ferrous materials in aircraft construction
Materials(L-2)
CO3 Explain the applications of Aluminium alloys, Ceramics and Composites Materials. (L-2)

CO4 Evaluate the importance of high temperature materials and their characterization. (L-3)
Syllabus: AIRCRAFT MATERIALS AND PROCESSES(21AE32)
Syllabus Of Finite Element (17ME61)
Module-4: Ceramics and Composites:
Introduction, modern ceramic materials,
 Cermets,
Glass ceramic,
Production of semi-fabricated forms,
 Carbon/Carbon composites,
Fabrication processes and its aerospace applications
involved in metal matrix composites,
Polymer composites.
 MODERN CERAMIC MATERIALS
• Ceramics are generally made by taking
mixtures of clay, earthen elements, powders,
and water and shaping them into desired
forms.
• Once the ceramic has been shaped, it is fired
in a high temperature oven known as a kiln.
• Often, ceramics are covered in decorative,
waterproof, paint-like substances known as
glazes.
 CHARACTERISTICS OF CERAMICS

High temperature stability

High hardness
Brittleness
High mechanical strength
Low elongation under application of stress
Low thermal and electrical conductivities
 CLASSIFICATION OF CERAMICS :
• Ceramics are classified in many ways:
 Based on their composition
 Based on their specific applications
 Based on their engineering applications
 BASED ON THEIR COMPOSITION

 Oxides
 Carbides
 Nitrides
 Sulphides
 Fluorides
 BASED ON THEIR SPECIFIC APPLICATIONS

• -Glasses
• -Clay products
• -Refractories
• -Abrasives
• -Cements
• -Advanced ceramics for special applications
 BASED ON THEIR ENGINEERING APPLICATIONS

Traditional and engineering ceramics

Traditional ceramics–most made-up of clay, silica
and feldspar
Engineering ceramics–these consist of highly
purified aluminium oxide(Al2O3), silicon
carbide(SiC) and silicon nitiride (Si3N4)
 GLASSES:
• Glasses are a familiar group of ceramics – containers,
windows, mirrors, lenses, etc.
• They are non-crystalline silicates containing other
oxides, usually CaO, Na2O, K2O and Al2O3 which
influence the glass properties and its colour.
• There is no definite temperature at which the liquid
transforms to a solid as with crystalline materials.
• A specific temperature, known as glass transition
temperature is defined based on viscosity above which
material is named as super cooled liquid or liquid, and
below it is termed as glass.
 CLAY PRODUCTS
• clay is the one of most widely used ceramic raw
material.
• It is found in great abundance and popular because
of ease with which products are made.
• Clay products are mainly two kinds – structural
products (bricks, tiles, sewer pipes) and white-wares
(porcelain, chinaware, pottery, etc.).
 REFRACTORIES:

• These are described by their capacity to

withstand high temperatures without melting or
decomposing; and their inertness in severe
environments.
• Thermal insulation is also an important
functionality of Refractories.
 Abrasives:

• These are used to grind, wear, or cut away other

material.
• Thus the prime requisite for this group of materials
is hardness or wear resistance in addition to high
toughness.
• Diamond, silicon carbide, tungsten carbide, silica
sand, aluminium oxide / corundum are some typical
examples of abrasive ceramic materials.
 CEMENTS:
 Cement, plaster of Paris and lime come under this
group of ceramics.
 The characteristic property of these materials is that
when they are mixed with water, they form slurry
which sets subsequently and hardens finally.
 Thus it is possible to form virtually any shape.
 They are also used as bonding phase, for example
between construction bricks.
 Advanced ceramics:

• These are newly developed and manufactured

in limited range for specific applications.
• Usually their electrical, magnetic and optical
properties and combination of properties are
exploited.
• Typical applications: heat engines, ceramic
armours, electronic packaging, etc.
 Oxides:

1.Aluminium oxide / Alumina (Al2O3):

• It is one of most commonly used ceramic material.
• It is used in many applications such as where
material is operated at very high temperatures
under heavy loads, as insulators in spark plugs, and
in some unique applications such as dental and
medical use.
• Chromium doped alumina is used for making lasers.
2. Titanium oxide (TiO2):
It is mostly found as pigment in paints. It also
forms part of certain glass ceramics. It is used to
making other ceramics like BaTiO3.
3. Uranium oxide (UO2):
• It is mainly used as nuclear reactor fuel.
• It has exceptional dimensional stability because
its crystal structure can accommodate the
products of fission process.
 Carbides:

1. Silicon carbide (SiC):

• It is known as one of best ceramic material for
very high temperature applications.
• It is used as coatings on other material for
protection from extreme temperatures. It is also
used as abrasive material.
• It is used as reinforcement in many metallic and
ceramic based composites. It is a semiconductor
and often used in high temperature electronics.
 Nitrides:

• Aluminium nitride:
• Because of its typical properties such as good
electrical insulation but high thermal
conductivity, it is used in many electronic
applications such as in electrical circuits
operating at a high frequency.
• It is also suitable for integrated circuits. Other
electronic ceramics include – barium titanate
(BaTiO3) and Cordierite (2MgO-2Al2O3-5SiO2).
Fabrication and processing of ceramics

 Powder Metallurgy
 Injection Molding
 Extrusion
 Manufacturing Process of Ceramics
• Extrusion:
Injection Molding:
Powder Metallurgy
 CERMET:

• The word "cermet" conies from the

combination of ceramics and metals
• These cermet materials are, therefore,
combinations of high melting substances
ceramic and a metal.
• The ceramic in general has high temperature
resistance and hardness, and the metal has
the ability to undergo plastic deformation.
 Properties of Cermet:

High temperature resistance

High Hardness
Ability to undergo plastic deformation
Superior wear and corrosion properties
More resistance to high velocity impacts
Light weight
Better thermal shock resistance
High strength
Moderate thermal conductivity
 Applications of ceramics/cermets:

 Parts of Aircraft Engines

 Brakes in Aircraft (stops aircraft safely after
landing)
 Insulating Tiles in Space vehicles
 Nose cones and high-temperature coatings in
Space vehicles
 Glass Ceramics:

• Glass-ceramics are polycrystalline materials of

fine microstructure that are produced by the
controlled crystallisation (devitrification) of a
glass.
 Properties Of Glass Ceramics:

₣ High strength
₣ High impact resistance
₣ Low co-efficient of thermal expansion,
sometimes even negative co-efficient of
thermal expansion
₣ Good resistance to thermal shock
₣ A range of optical properties, from translucent
to opaque
 Applications Of Glass Ceramics:

• Canopies
• Windows
• lenses, and panels