Aviation Maintenance Technician

B1 - Certification Series
SUMMARY MATERIALS
MATERIALS AND HARDWARE – Modul 6
MAKING STEEL (FERROUS METAL)
Produced from iron ore through the furnaces:
• PIG IRON (93% iron, 3% to 5% carbon).
• CAST IRON any iron containing >2% carbon alloy
• WROUGHT IRON (from pig iron mixed with some slag)
• INGOT IRON commercially pure iron (99.85% iron).
From pig iron will produce other type (addition or deletion of
carbon and alloys)
• OPEN HEARTH FURNACE
• BASIC OXYGEN/OXYGEN CONVERTER process.
• ELECTRICAL ARC
FERROUS METAL
The process addition or deletion of carbon and elements
alloying with steel to improve characteristics:
• Tensile strength.
• Hardenability, Toughness, Corrosion or Wear resistance.
• To fine grain size.
• Improve case hardening properties
STANDARIZATION (FERROUS METAL)

XX
X XX
Type of Steel

Major alloying element

Carbon range
STANDARIZATION (FERROUS METAL)

10
0 30
Carbon Steel

Plain Carbon Steel

.30% of carbon
STANDARIZATION (FERROUS METAL)
SAE NUMERICAL INDEX (Major Classification)
TYPE OF STEEL CLASSIFICATION
Carbon Steel 1xxx
Nickel Steel 2xxx
Nickel-chromium Steel 3xxx
Molybdenum Steel 4xxx
Chromium Steel 5xxx
Chromium-vanadium Steel 6xxx
Tungsten 7xxx
Nickel-chromium-vanadium 8xxx
Silicon-manganese 9xxx
CHARACTERISTICS
LOW CARBON STEEL (SAE 1010 to 1030 steel containing carbon
from 0.10 to 0.30%.) for making items as safety wire, certain
nuts
MEDIUM CARBON STEEL (SAE 1030 to 1050) is especially
adaptable for machining or forging.
HIGH CARBON STEEL (SAE 1050 to 1095) form is used for
making flat springs.
CHARACTERISTICS
NICKLE STEELS are produced by combining Nickel (3 to 3.75 %
nickel) with Carbon steel to increases the hardness, tensile
strength.
CHROMIUM STEEL obtained in Plain carbon steel, steel have
high in hardness, strength, and corrosion resistant properties.
CHROME-NICKLE or STAINLESS STEELS (18-8 steel) its content
of 18 % Chromium and 8 % Nickel increasing strengthens by
cold working.
CHROME-VANADIUM STEELS made by 18% Vanadium and
about 1% Chromium, when they heat treated have strength,
toughness and resist wear and fatigue.
CHARACTERISTICS
CHROME-MOLYBDENUM STEEL small percentages of
Molybdenum is used in combination with Chromium will get
tough and wear resistant.
INCONEL is a Nickel-Chromium-Iron alloy (Corrosion Resistant
Steel, CRES), has a nickel content greater than 50%.
NICKEL ALLOY
• Nimonics - group of nickel alloy contains 50-80% nickel
with chrome.
• Monel - 68% nickel and 29% copper
• K-monel - monel alloyed with alluminum 2–4 %
CHARACTERISTICS
MANGANESE 1.5% manganese, steel is strong and hard.
TUNGSTEN are used for contact-breaker, will melting in extremely
high temperature.
COBALT (HSS) addition to Chrome, Vanadium, Molybdenum and
Tungsten to improve ability to cut at high working temperatures.
VANADIUM improves the strength its toughness and resist to
fatigue.
WORKING PROCESS
Three methods of metal working :
• Hot working.
• Cold working.
• Extruding.
WORKING PROCESS
HOT WORKING
Mechanical working processes are done by Heated at above
critical temperature (recrystallization temperature), the size of
the grains will increase then placed in a Soaking to retards loss
of heat and crystalline of grain in interior gradually will
solidifies.
At the ingot condition mechanical process (example: rolling,
forging, extruding, etc) affecting the interior grain structure.
Most practical Steel is often harder and too brittle when put
under severe internal strain.
WORKING PROCESS
Hardening
Heating the steel to a set temperature (above critical temp),
soaking (retards loss of heat and gradually solidifies of grain)
and then cooling it rapidly it into oil, water, or brine it will be
hardness and brittle, cold by air it will increases the hardness
and less ductile more brittle.
To remove some of the brittleness should process the tempering
after hardening.
WORKING PROCESS
Tempering
Heating the steel to a specific temperature (below its hardening
temperature/low critical point), soaking/ holding it at that
temperature and then cooling it usually with air (room
temperature).
To remove some of the brittleness should process the tempering
after hardening.
WORKING PROCESS
Normalizing
Heated to the proper temperature (upper critical point),
holding it at that temperature until it is uniformly heated and
then cooling with the air (room temperature).
To relieve internal stress this process applies to iron base
metals only.
Annealing
heating the metal to a prescribed temperature (just above the
upper critical point), holding it for a specific length of time and
then cooling very slowly, back to the room temperature.
WORKING PROCESS
Case Hardening
Case hardening is a technique to reinforce the metal surface
(surface hardening) with the low carbon and low alloy steels
will changed chemically by introducing a high carbide or nitride
content. The core is unaffected chemically.
If high carbon steel is case hardened, the hardness penetrates
the core and causes brittleness.
The common forms of case hardening:
• Carburizing,
• Nitriding, and
• Cyaniding
WORKING PROCESS
Carburizing
Case hardening is a treatment process that produce by
carburized a surface has a high carbon surface and a low carbon
interior, the case is hardened while the core remains soft and
tough.
• Pack Carburizing - steel parts are packed in a container with
charcoal and soaked at that temperature for several hours.
• Gas Carburizing – by carburizing atmosphere use of various
gases a material rich in carbon.
• Liquid Carburizing - the steel is placed in a molten salt bath
that contains the chemicals (cyanide).
WORKING PROCESS
Nitriding
Most steels can be nitride by hardened and tempered before
being nitride. The best results special alloys are required
(nitralloy). With circulating introduce a gas ammonia into
nitrogen and hydrogen will penetrate the treatment process.
Cyaniding.
Type of case hardening that is fast and efficient dipped into a
heated cyanide bath produces a thin.
Not used in aircraft work; that cyanide salts are a deadly poison.
WORKING PROCESS
COLD WORKING
Mechanical working performed at temperatures below the
critical range will result the metal becomes so hard that it is
difficult to continue the forming process without softening the
metal by annealing.
Several cold working processes concerned are Cold Rolling and
Cold Drawing refers to the working of metal at room
temperature.
WORKING PROCESS
COLD WORKING

Drawn rod Drawing jaw

Hot rolled rod

25% - 45% reduction for each

Steel die draw
WORKING PROCESS
EXTRUDING
The extrusion process involves the forcing of metal through an
opening in a die with the cross section (Channel, angles, T-
sections, and Z-sections) or some other shape limited to the
more ductile materials.
At the ingot condition mechanical process (example: rolling,
forging, extruding, etc) affecting the interior grain structure.
Most practical Steel is often harder and too brittle when put
under severe internal strain.
WORKING PROCESS
EXTRUDING
HARDNESS TEST
Brinell Test
Measuring the hardness of a material by
pressing with standard ball 10 mm (0.4
inch) which is forced a load 3,000Kgs at
10 sec for ferrous metal or 500Kgs at 30
sec for non-ferrous.
The depth width of the impression left by
the indentation is measured to indicate
hardness use a calibrated microscope
then convert the measurement into the
Brinell hardness number on the
conversion table.
HARDNESS TEST
Vickers Test
Use Pyramid (diamond) indenter, like Brinell by applying a
load to an indenter.
The depth width of the impression left by the indentation is
measured average diagonals (d1 and d2).
HARDNESS TEST
Rockwell Test
By indenting the test material with a diamond cone or
hardened steel ball indenter forced preliminary minor load
(10 kgf), while the preliminary minor load is still applied an
additional major load is applied with resulting increase in
penetration.
HARDNESS TEST
Fatigue Strength Test
Fatigue is a weakness in materials,
especially metals, caused by
repeated variations of stress. The
specimen is alternately subjected
to tensile and compressive stress
(alternating stress).
HARDNESS TEST
Impact Test
To indicate the toughness of a
material.
• The IZOD – impact test and is used
to test materials at low temperature,
but where the test piece must be
tested at high or low temperatures
the CHARPY test is used
• The Charpy – the test is carried out
within the 6 sec of removal of the
test piece from the heating or
cooling bath.
NON-FERROUS METAL
Pure aluminium is extracted from rock bauxite by Bayer
process.
NON-FERROUS METAL
Aluminium
Types of aluminum may be divided into:
• CASTING ALLOYS
• Sand casting,
• Permanent mold casting (mold with metal), and Semi-
permanent with containing sand cores.
• Die castings, produced by forcing molten metal
• WROUGHT ALLOYS.
• Non heat-treatable aluminum alloys, mechanical
properties obtained by the cold work.
• Heat-treatable aluminum alloys, mechanical properties
are obtained by heating.
NON-FERROUS METAL
Casting Alloy
NON-FERROUS METAL
Casting Alloy
Two basic groups determined by:
• The alloying elements and cannot be changed after the
metal is cast.
• The alloying elements make it possible to heat treat to
produce the desired physical properties.
NON-FERROUS METAL
Casting Alloy Identification

A 214 T 6
(Zinc) Improve its qualities
Casting alloy
Process (Heat treated)
Composition alloying of casting
NON-FERROUS METAL
Metal Forming
Converting raw material into manufactured shape:
• Forging – process of forming a product by hammering or
pressing.
• Rolling – process of forming a product by passed through a
pair of rolls.
• Extruding – process of forming a product forced to flow
through a die
NON-FERROUS METAL
Metal Forming
NON-FERROUS METAL
Metal Forming
NON-FERROUS METAL
Aluminum Alloys Designations:
Wrought aluminum and wrought aluminum alloys
designated by a four-digits index system, divided into three
group:
• 1xxx group,
• 2xxx through 8xxx group,
• 9xxx group.
NON-FERROUS METAL
Aluminum Alloys Designations
Designations for Aluminum Alloy Groups

Aluminum 99.0% min and greater 1 xxx

Aluminum alloys, grouped by major alloying elements

Copper 2 XXX

Manganese 3 XXX

Silicon 4 XXX

Magnesium 5 XXX

Magnesium and Silicon 6 XXX

Zinc 7 XXX

Other elements 8 XXX

NON-FERROUS METAL
Aluminum Alloys Designations
1030 indicates
Aluminum of ≥ 99.00 %
Aluminum without special control. 1, 2, 3
with special control on one or more
impurities.
Indicates 99.30 % aluminum.
1075, 1175, 1275 indicate 99.75 %
aluminum.

1100 99.00% pure all, one control

1130 99.30% pure all, one control
1275 99.75% pure all, two control
NON-FERROUS METAL
Aluminum Alloys Designations

Group 2xxx – 8xxx

XX
X X XX
Alloy Type
Alloy Modification
0: original alloy
1-9: alloy modification

Different alloys in group.

NON-FERROUS METAL
Hardness Identification
• F indicates “as fabricated condition”
• O indicates dead soft, or annealed, condition
• H indicates strain hardened
• W indicates solution heat treated
• T indicates fully heat treated
NON-FERROUS METAL
Characteristic
Pure Copper
It is the only reddish colored metal, very malleable and
ductile electrical conductivity.
Pure Magnesium
A silvery white material weighing only two-thirds as much as
aluminum.
Magnesium Alloy – good casting characteristics consist of
magnesium alloyed with varying proportions of aluminum,
manganese, and zinc.
NON-FERROUS METAL
Characteristic
Pure Titanium
Used for making compressor disks, compressor blades and
vanes, approximately 60% heavier than aluminum and about
50% lighter than stainless steel
Titanium designations.
• A (Alpha), good weld ability; tough and strong, resists to
oxidation
• B (Beta), bend ability; excellent bend ductility but
sensitive to contamination.
• C (Alpha and Beta) strong when cold and warm, weak
when hot.
NON-FERROUS METAL
Characteristic
Pure Titanium
Titanium’s high melting temperature, approximately 3,300°F,
easily identified when touched with a grinding wheel, it
makes white spark traces that end in brilliant white bursts.
When rubbed with a piece of glass, moistened titanium will
leave a dark line similar in appearance to a pencil mark.
NON-FERROUS METAL
Characteristic
Basic Alloy Copper
Reddish colored metal in electrical conductivity, very
malleable and ductile ideal for making wire.
• Brass (Copper-Zinc) is a copper alloy contains zinc and
small of aluminum, iron, lead etc.
• Muntz metal is a brass composed of 60% copper and 40%
zinc
• Cupronickles (Copper-Nickel)
• Bronze (Copper-Tin contents)
NON-FERROUS METAL
Characteristic
Monel
High nickel alloy – strength and excellent corrosion
resistance consists 68% nickel, 29% copper, 0.2% iron, 1%
manganese, 1,8% other.
K-Monel – A nonferrous alloy containing mainly nickel,
copper, and aluminum adding a small amount of aluminum
to the Monel formula.
Inconel – Alloys of nickel produce a high strength, high
temperature alloy containing 80% nickel, 14%chromium,
small amounts of iron and other elements
NON-FERROUS METAL
Hardness Test
The Barcol tester is a portable unit designed
for testing aluminum alloys, copper, brass,
or other relatively soft materials.
NON-METAL
COMPOSITE
Consist of two or more materials have two constituent
materials: a binder or matrix, and a reinforcement.
NON-METAL
COMPOSITE
Consist of two or more materials have two constituent
materials: a binder or matrix, and a reinforcement. A matrix
supports them together in the composite material.
NON-METAL
COMPOSITE
Curing Stages of Resins
“A” stage: The components of the resin (base material and
hardener) have been mixed but the chemical reaction has not
started.
“B” stage: The components of the resin have been mixed and
the chemical reaction has started (Prepreg materials)
“C” stage: The resin is fully cured at room temperature others
need temperature cure cycle to fully cure
NON-METAL
COMPOSITE INSPECTION
Any delamination form on the interface between the layers.
Ring test (Coin Tapping/Tap hammer) a weight of 1oz used
to detect voids between the layers.
NON-METAL
COMPOSITE INSPECTION
NON-METAL
SEALANT
Sealing are to sealed withstand pressurization by air, to
prevent leakage, consists of
Two or more ingredients properly proportioned.
Ready for use as packaged
NON-METAL
SEALANT
Stresses adhesive joint
• Tensile.
• Shear
• Cleavage
• Peel
CORROSION
INTRODUCTION
Corrosion is a natural occurrence that attacks by
• Chemical attack
Resulting from exposure of caustic liquid or gaseous
agents.
• Electrochemical attack
Can occur that metal have (anodic change), and (cathodic
change)
CORROSION

Conductive liquid path (electrolyte)

Subject to corrosion Conductive material

has tendency to corrode

Electrochemical
CORROSION
INTRODUCTION
Corrosion can occur on surfaces of crystalline regions
(grains)
• High temperature environments concentration of water
vapor in the air
• Manufacturing processes can leave residual stress
• There are corrosive agents
• Micro organism (aerobic bacteria) - fungi are the micro-
organisms that feed on organic materials
CORROSION
TYPE OF CORROSION
Surface Corrosion
The most common form of corrosion and results from a
direct chemical attack, generally dulling of the surface, and
continue becomes rough.
CORROSION
TYPE OF CORROSION
Surface Corrosion
The most common form of corrosion and results from a
direct chemical attack, generally dulling of the surface, and
continue becomes rough.
CORROSION
TYPE OF CORROSION
Pitting Corrosion
The most common form of corrosion and results from a
direct chemical attack, generally dulling of the surface, and
continue becomes rough.
CORROSION
TYPE OF CORROSION
Fillform Corrosion
On metal surfaces having an organic coating system is
recognized by its characteristic worm-like trace of corrosion
products.
CORROSION
TYPE OF CORROSION
Intergrannular Corrosion
The corrosion attacks on the grain boundaries, improperly
during heat treated results from a lack of uniformity grain.
CORROSION
TYPE OF CORROSION
Exfoliation Corrosion
This corrosion advanced form of intergranular corrosion and
shows itself by lifting up the surface grains, the force of
expanding corrosion products occurring at the grain
boundaries.
CORROSION
TYPE OF CORROSION
Galvanic Corrosion
Occurs when two dissimilar metals make contact in the
presence of an electrolyte.
CORROSION
TYPE OF CORROSION
Stress Corrosion
Acting in conjunction with a damaging chemical environment
caused by internal or external loading. Internal stress may be
trapped in a part of structure during manufacturing
processes.
CORROSION
TYPE OF CORROSION
Fretting Corrosion
Also known as wear corrosion or friction oxidation can occur
at the interface of two highly loaded surfaces, vibration may
cause the surfaces to rub together resulting in an abrasive
wear known as fretting.
CORROSION
CORROSION PRONE AREA
Corrosion prone areas they are not kept clean, waste
products may accumulate causes corrosive attack should be
cleaned, inspected, and treated more frequently.
• At the bilge areas located under galleys and lavatories.
• Exhaust trail that areas should include the removal of
fairings-and access plates
CORROSION
TYPE OF CORROSION
Inergrannular Corrosion
The corrosion attacks on the grain boundaries, improperly
during heat treated results from a lack of uniformity grain.
CORROSION
SEALANT
Metal corrosion
• Tensile.
• Shear
• Cleavage
• Peel
CORROSION
SEALANT
Metal corrosion
• Tensile.
• Shear
• Cleavage
• Peel
CORROSION
SEALANT
Metal corrosion
• Tensile.
• Shear
• Cleavage
• Peel