AIRCRAFT MATERIALS

AIRCRAFT MATERIALS

1. Basic requirements
• High strength and stiffness
• Low density
=> high specific properties e.g. strength/density, yield strength/density,
E/density
• High corrossion resistance
• Fatigue resistance and damage tolerance
• Good technology properties (formability, machinability, weldability)
• Special aerospace standards and specifications

2. Basic aircraft materials for airframe structures

• Aluminium alloys
• Magnesium alloys
• Titanium alloys
• Composite materials
Structural materials on small transport aeroplane
 Development of composite
aerospace applications over the last 40 years
Composite share in military aircraft structures in USA and
Europe

Structural materials on Eurofighter

Aluminium Alloys
Aluminium – Al
• plane centered cubic lattice
• melting point 660 °C
• density 2.7 g/cm³
• very good electrical and heat conductivity
• very good corrosion resistance
• low mechanical properties
• solid solutions with alloying elements
• maximum solubility is temperature dependent
– Cu: 6 % at 548 °C; 0.1 % at RT
– Mg: 17 % at 449 °C; 1.9 % at RT
– Zn: 37 % at 300 °C; 2 % at RT
– Si: 1.95 % at 577 °C; 0 % at RT

Substitution solid solution

a)alloying atom > aluminium atom
b)pure aluminium
c)alloying atom < aluminium atom
 Characteristics of aluminium alloys
Advantages
• Low density 2.47- 2.89 g/cm³
• Good specific properties – Rm/ρ, E/ ρ
• Generally very good corrosion
resistance (exception alloys with
Cu)
• Mostly good weldability – mainly
using pressure methods
• Good machinability
• Good formability
• Great range of semifinished
products
(sheet, rods, tubes etc.)
• Long-lasting experience
• Acceptable price
Shortcomings
• Low hardness, susceptibility to
surface damage
• High strength alloys (containing Cu)
need additional anti-corrosion
protection:
– Cladding – surface protection using
a thin layer of pure aluminium or
alloy with the good corrosion
resistance
– Anodizing – forming of surface oxide
layer (Al2O3)
• It is difficult to weld high strength
alloys by fusion welding
• Danger of electrochemical corrosion
due to contact with metals:
– Al-Cu, Al-Ni alloys, Al-Mg alloys, Al-
steel
 Designation of aluminium alloys according to EN

Wrought alloys Casting alloys

AL-PXXXX(A) AL-CXXXXX
designation basic alloying element designation basic alloying element

• 1XXX – pure aluminium • 1XXXX - > 99.0 % Al

• 2XXX - copper (Cu) • 2XXXX - Cu
• 3XXX - manganese (Mn) • 3XXXX - Si-Mg
• 4XXX - silicon (Si) - Si-Cu
• 5XXX - magnesium (Mg) - Si-Cu-Mg
• 6XXX - Mg + Si • 4XXXX - Si
• 7XXX - zinc (Zn) • 5XXXX - Mg
• 8XXX - other (eg. Li) • 7XXXX - Zn
• 8XXXX - Sn
 Important wrought aluminium alloys for aircraft structures
• 2XXX (Al-Cu, Al-Cu-Mg) - high strength, lower corrosion resistance
2014 (0.8Si, 4.4Cu, 0.8Mn, 0.5Mg)
2017 (0.5Si, 4Cu, 0.7Mn, 0.6Mg)
2024 (4.4Cu, 0.6Mn, 1.5Mg)
2024Alclad (with the surface layer of Al)
2027 (4.4Cu, 0.9Mn, 1.3Mg, 0.2Zn, 0.05Cr, 0.25Ti)
2124 (4.4Cu, 0.6Mn, 1.5Mg, 0.1V)
2219 (6.3Cu, 0.3Mn, 0.1V)
• 6XXX (Al-Mg-Si) -comparing to 2XXX - lower strength, better ductility
and corrosion resistance
6013 (0.8Si, 0.8Cu, 0.50Mn, 1.0Mg)
6061 (0.6Si, 0.28Mn, 1.0Mg, 0.2Cr)
6061Alclad
6056 (1.0Si, 0.9Mg, 0.8Cu, 0.7Mn, 0.25Cr, 0.2Ti+Zr)
• 7XXX (Al-Zn-Mg-Cu) – the highest strength, lower ductility, notch
sensitivity
7050 (2.3Cu, 2.2Mg, 0.12Zr, 6.2Zn)
7075 (1.6Cu, 2.5Mg, 0.13Cr, 5.6Zn), 7075Alclad
7175 (1.6Cu, 2.5Mg, 0.23Cr, 5.6Zn)
7475 (1.6Cu, 2.2Mg, 0.22Cr, 5.7Zn)
 Most important tempers aluminium alloys

• O - anealing
• W - solution treating + quenching (non stabil state)
• H - strain-hardening (strength is increased only due to cold working)
• T3 - solution treating + quenching + cold working + room
temperature aging
• T351 - solution treating + quenching + stress relief due to controlled
stretching + room temperature aging
• T4 - solution treating + quenching + room temperature aging
• T6 - solution treating + quenching + artificial aging
• T651- solution treating + quenching + stress relief due to controlled streching
+ artificial aging
• T7 - solution treating + quenching + artificial overaging
• T73 - solution treating + quenching + artificial overaging for the best stress
corrosion resistance
• T8 - solution treating + quenching + cold working + artificial aging
 Reference aluminium alloys in airframe structure

Structure Part Control parametr Reference alloys

Wing Upper panels compression 7150-T6/T77

Upper stringers compression 7050-T74
Lower panels damage tolerance (DT) 2024-T3, 2324-T39
Lower stringers tension + DT 2024-T3
Beams, ribs static properties 7050-T74, 7010-T76

Fuselage Upper panels compression, DT, formability 2024 clad-T3

Lower panels tension + DT 2024 clad-T3
Stiffeners tension/compression 7175-T73
Main frame complex 7010+7050-T74

Other All types 7010/7050/7075

parts
Use of aluminum-lithium alloys in commercial aircraft
 Casting aluminum alloys

• Designation (in addition to EN)

– Often used system (Aluminum Association - USA): three digit
designation - the first digit indicates a main alloying element
• 1XX  99,0 % Al
• 2XX Al - Cu
• 3XX Al - Si - Mg
Al - Si - Cu
Al - Si - Cu - Mg
• 4XX Al - Si
• 5XX Al – Mg
• 7XX Al - Zn
• 8XX Al – Sn

A letter ahead of designation marks alloys with the same content of main
alloying elements but with different content of impurities or micro alloying
elements.(e.g. 201 - A201, 356 - A356, 357 - A357)
Additional digit .0 means shape casting, digit .1 or .2 ingots
• Typical castings in aircraft structures

Al – front body of engine Al- steering part - 1,1 kg

32 kg - D=700 mm 390 x 180 x 100 mm

Al – casing - 1,3 kg Al – pedal - 0,4 kg

470 x 190 x 170 mm 180 x 150 x 100 mm
• General characteristics
– Micro and macro structures of metal are influenced by conditions of metal
solidification – quantity of nuclei, temperature interval of solidification,
cooling rate …
A fine, equiaxed grain structure is normally desired in aluminum
casting (Al-Ti or Al-Ti-B alloys are most widely used grain refiners)
– Mechanical properties are influenced by existence of casting defects –
porosity, inclusions (mainly oxides), shrinkage voids ….
– Alloys – heat treatable , non heat treatable
– Mechanical properties are mostly lower comparing wrought alloys of the
similar chemical composition
– High quality aircraft casting need careful metallurgical processing of liquid
metal
• Degassing – hydrogen elimination (hydrogen causes porosity)
• Grain refinement and modification for better mechanical properties
• Filtration for inclusions removing
 Solubility of hydrogen in
aluminum
Alloy Al-7Si – the effect During solidification - dissolved
of grain refinement hydrogen can precipitate and form
voids.
 Dendritic microstructure of hypoeutectic alloy
AlSi10Mg – sand casting

wall thickness 2 mm wall thickness 10 mm

There is direct relation between mechanical properties and dendrite

arm spacing (DAS) → different properties in different portions of
casting
• Alloys of Al–Cu system
- Composition 4 – 6 % Cu
- Copper substantially improves strength and hardness in the as-cast and
heat- treated conditions
- Copper generally reduces corrosion resistance and, in specific compositions
stress corrosion susceptibility
- Copper also reduces hot tear resistance and decreases castability
- Main advantage: high strength up to 300 °C
- Basic alloys
• ČSN 424351, 201, A 201, AL 7
• 242, A242
• B295
- Application:
Smaller , simple, high-strength castings for service at higher
temperatures (cylinder heads, pistons, pumps, aerospace housings, aircraft
fittings)
• Alloys of Al–Si + (Mg, Cu, Ni) system
– The most important alloys for aircraft castings
– Silicon improves casting characteristics (fluidity, hot tear resistance, feeding),
Si content depends on casting methods
• Sand and plaster molds, investment casting 5-7% Si
• Permanent molds 7-9% Si
• Die casting 8-12% Si
– Alloys containing Mg are heat treatable, hardening phase is Mg2Si
– Alloys Al-Si with alloying elements Mg and Cu have after heat treatment high
mechanical properties but lower plasticity and corrosion resistance
– Ni is alloying element in hypereutectic alloys for service at higher temperatures (e.g.
engine pistons)
– Strength and ductility can be improved using modification for refinement of eutectic
phases
• Principal – addition small quantities of Na or Sr into liquid metal before casting
• Results – increased tensile strength (40 %), impact strength (up to 400 %), ductility (2x)
– Mechanical properties can be improved also due to grain refinement buy rapid cooling
in permanent metal molds
 Representative aluminum alloys – sand casting

Mechanical properties
Alloy Temper

Rm Rp0,2 HB A
MPa MPa %

A 201.0 T7 496 448 - 6

AlCu4,5Ag0,7Mg0,25Mn0,3

A 356.0 F 159 83 - 6
AlSi7Mg0,35 T6 278 207 75 6
T61* 283 207 90 10

A 357.0 T6 317 248 85 3

AlSi7Mg0,55ZnBe0,05 T6* 359 290 100 5

* permanent mold casting

F as cast
.0 shape casting
Fiber metal laminates

• Consist of
alternating thin
metal layers and
uniaxial or biaxial
glass, aramid or
carbon fiber
prepregs
 Fibre metal laminates
• Developed types
- ARALL - Aramid Reinforced ALuminium Laminates (TU-DELFT)
- GLARE - GLAss REinforced (TU-DELFT)
- CARE - CArbon REinforced (TU-DELFT)
- Titanium CARE (TU-DELFT)
- HTCL - Hybrid Titanium Composite Laminates (NASA)
- CAREST – CArbon REinforced Steel (BUT - IAE)
- - T iGr – Titanium Graphite Hybrid Laminate (The Boeing Company)

• Advantages
Fibre metal laminates produce remarkable improvements in fatigue
resistance and damage tolerance characteristics due to bridging
influence of fibres. They also offer weight and cost reduction and
improved safety, e.g. flame resistance. They can be formed to limited
grade.
GLARE fire resistance comparing to 2024 alloy
Fiber metal laminates - application
AIRBUS A 380
Panels of fuselage upper part – 470 m² , GLARE 4
Maximum panel dimensions 10.5 x 3.5 m
Weight saving - 620 kg
Adhesive bonded stringers from 7349 alloy
 Sandwich materials

• Structure – consists of a lightweight core

material covered by face sheets on both
sides. Although these structures have a
low weight, they have high flexural
stiffness and high strength.
• Skin (face sheet)
– Metal (aluminium alloy)
– Composite material
• Core Sidewall panel for Airbus A320
– Honeycomb – metal or composite
(Nomex)
– Foam – polyurethan, phenolic,
cyanate resins, PVC
• Applications – aircraft flooring,
interiors, naccelles, winglets etc.
Effectivness of sandwich materials
List of problems (light alloys)
What are the main advantages of aluminium alloys for applications in aircraft structures?
What numerical designation system is used for identification of wrought aluminium alloy?
What is meaning of the first digit?
What groups of wrought aluminium alloys are usually used in aircraft structures?
Explain the designation of the following alloys:
- 2024 T4
- 7075 T6
- Alclad 2219
Why is sheet from 2xxx alloys often clad with pure aluminium?
What group of wrought aluminium alloys exhibits the best mechanical properties?
Compare alloys 6056 and 7050!
What are the main advantages and limitations of Al-Li alloys comparing to other Al alloys?
What is a common value of aluminium alloys elastic modulus in tension?
Recommend the alloys for aircraft skin!
Why are Mg alloys valuable for aerospace application?
What is damping capacity of magnesium alloys?
What are the main reasons for using of titanium alloys in airframe and engine structures?
What titanium alloy is the most widely used?
Compare the specific tensile strength and specific tensile modulus of 2090 and Ti-6Al-4V
alloys!
- (Specific value = value/density)
List of problems (composite and sandwich materials)

What is composite material?

What are advantages of composites comparing to metals?
What is prepreg?
What are common types of fibres?
What fibres have the highest specific tensile strength and specific tensile modulus?
( the specific property is the ratio value/density )
What is main role of matrix?
What are main advantages of epoxy, phenolic and bismaleimide (polyimide) matrices?
What are main advantages of using prepregs?
How the fibre orientation influences resulting mechanical properties of a composite?
What are typical tensile properties of epoxy prepregs UD laminates along and across fibres?
What is structure of sandwich material?
What are main advantages of sandwich panels compared to solid panels?
What materials are usually used for sandwich skins and core?
 Thank you

Made by sanskar kumar

XII A