Assignment brief – QCF BTEC

Assignment Front Sheet

Qualification Unit number and title

 Pearson BTEC Level 3 Extended Diploma in Engineering
(180 cr.)
Unit 70: Aircraft Materials and
 Pearson BTEC Level 3 Diploma in Aeronautical Engineering Hardware
(120 cr.)
 Pearson BTEC Level 3 Diploma in Engineering (90 cr.)
Learner’s name Writer’s name

Yousif Ali Muhammed Asghar Ahmed

Hand out date Hand in deadline Submitted on

15th Sep. 2019 22nd Sep. 2019

Production, Identification, heat-treatment and application of ferrous and non-

Assignment title
ferrous metals and alloys

Criteria To achieve the criteria the evidence must show that the Evidence
Task no.
reference learner is able to: Page no.

Describe the production process of plain carbon steel and

a heat treatment after production that will add hardness Page 4
P1 1
to the surface of this steel

Use a given sample and a given identification method to

identify the type of an alloy steel and give two aircraft
P2 2 P5
structural applications for this material

Describe the production process for aluminium and a heat

treatment process that may be used to return the
P3 3 P6
aluminium to a malleable state after cold working

Identify the type of an alloy using a given sample and the

alloy group series method, and give two aircraft structural
P4 4 P7
applications for this material

Learner’s declaration
I certify that the work submitted for this assignment is my own. I have clearly referenced any sources used
in the work. I understand that false declaration is a form of malpractice.

Learner signature: Date:

Internal Verifier’s approval of this version

IV’s Name: Idriss Imzilen IV’s Signature: Date: 12th Sep. 2019
Assignment brief
Qualification Pearson BTEC Level 3 Diploma in Aeronautical Engineering (120 cr.)
Unit number- title Unit 70: Aircraft Materials and Hardware
Assessor’s name Obaid
Hand out date 15th Sep. 2019
Hand in deadline 22nd Sep. 2019

Production, Identification, heat-treatment and application of ferrous and

Assignment title non-ferrous metals and alloys
Purpose of this assignment
To understand the production, identification and heat-treatment processes.

Scenario
You have been recruited as a junior materials engineer by AIRBUS in their new fighter jet branch. AIRBUS
has a reputation of building state of the art commercial aircrafts. However, they decided to expand their
portfolio by entering high precision and competitive market of fighter jets.

You have been asked by your supervisor to answer the following tasks which will give your team some basic
knowledge of the materials used in aircrafts. These tasks will also equip you and your team with the processes
involved in producing certain alloys for aircraft applications.

Task 1
 1.1 Describe the production process of plain carbon steel.
Carbon steel is a steel type where the main alloying element is carbon, and properties depending on the
percentage of carbon present. Carbon steel consists of iron and carbon, and is the most common category of
steel.

CARBON STEEL MANUFACTURING

1. Carbon steel and mild steel were produced in three stages:

1-Primary steelmaking
2-secondary steelmaking
3-Casting

2. Secondary steel making

market demand for steel products of high quality and consistent nature has sparked the development of
secondary steel making process.

electric arc furnace

the steel composition in an electric furnace modified by adding or removing individual components or by
manipulating the temperature
steel deoxidizing
An important aspect of secondary steelmaking is the removal of oxygen. The presence of oxygen in molten steel
as it begins to solidify the reaction product with carbon to release carbon monoxide gas. Deoxidation control
can be used to change the characteristics of the finished product and for the suitability of the steel to be used
for different applications.

3. Casting

Traditional casting methods involve the lifting of a spoon with a crane so that the molten steel can be teemed
into individual molds mounted on rail cars. ingot molds are tapered slightly to facilitate the removal of the
ingot after solidification. Ingot transferred to the soaking pit where they are heated for hot rolling.
FINISHING CARBON STEEL

After the carbon steel-making process is finished, it is finished using a rolling, heat treatment, surface
treatment, or secondary processing downstream.

rolled products

solid cast ingot to be rolled into a more useful shape and size as that produced by the continuous casting.

Hot forming
The steel is heated above the recrystallization temperature to break as-cast microstructure.

cold forming
Cold forming done below the recrystallization temperature.

1.2 Describe how heat treatment is done after production that will add hardness to the surface of plain
carbon steel.
heat treating

The purpose of heat treating steel is to manipulate the mechanical properties by changing the distribution of
micro carbon in products and internal
Case-hardening or hardening of the surface is a surface hardening process while allowing metal metallic object
deeper underneath to keep it soft, thus forming a thin layer of hard metal (called "cases") on the surface. To
iron or steel with low carbon content, which have poor to no hardening themselves, case-hardening process
involves implanting additional carbon or nitrogen into the surface layer. Case-hardening is usually performed
after the part has been formed into its final form, but can also be done to improve the hardening element
content bar for use in welding pattern or a similar process.
Hardening desirable for the metal components are subjected to contact with harsh or abrasive material shear,
as a hardened metal more resistant to surface wear.

process
Flame or induction hardening
Flame or induction hardening is a process in which the surface of the steel is heated very quickly to a high
temperature (by the direct application of oxy-gas flame, or by induction heating) and then cooled rapidly,
generally using water; This creates a "case" of martensite on the surface. A carbon content of 0.3 to 0.6% by
weight of C is required for this type of hardening.

The results of the hardening process is controlled by four factors:

Design fire chief

The duration of heating
Temperature targets to be achieved
The composition of the metal being treated

carburizing
Carburizing is a process used for case-hardened steel with a carbon content between 0.1 and 0.3% by weight of
C. In this process steel is introduced into a carbon rich environment and high temperature for a certain time,
and then extinguished so that the carbon locked up in the structure ; one simple procedure repeatedly to heat
the part with a series of acetylene torch with fuel-rich flame and quench the carbon-rich liquids such as oil.
inland.

nitriding
Nitriding heat the steel to 482-621 ° C (900 to 1.150 ° F) in an atmosphere of ammonia gas and ammonia are
separated. Part time spent in this environment determine the depth of the case. hardness is achieved with the
formation of nitride.

cyaniding

Cyaniding is case-hardening process is fast and efficient; it is mainly used in low-carbon steel. Part heated to
871-954 ° C (1600-1750 ° F) in a bath of sodium cyanide and then goes off and rinsed in water or oil, to remove
residual cyanide.
carbonitriding

Carbonitriding similar to cyaniding except gas atmosphere of ammonia and hydrocarbons are used instead of
sodium cyanide. If this section is to be quenched, heated to 775-885 ° C (1.427 to 1.625 ° F); if not, then the part
is heated to 649-788 ° C (1.200 to 1.450 ° F).

ferritic nitrocarburizing
Main article: Ferritic nitrocarburizing
ferritic nitrocarburizing diffuses mostly nitrogen and carbon into the case several workpieces below a critical
temperature, about 650 ° C (1202 ° F). Below the critical temperature of the workpiece micro is not converting
into the austenite phase, but remain in the ferritic phase, which is why it is called nitrocarburization ferritic.

This provides evidence for [P1]

Task 2
2.1 Describe how spark test identification method can be used to identify Ferritic Stainless Steel.

Sparkle testing strategy is to decide the general classification of ferrous materials. This usually involves taking
a bit of metal, usually scrap, and apply it to the wheel so as to watch the sparkling granulation emitted. This
can be compared with a flashing or blinking graph of test realized to decide the order. Sparkle testing can also
be used for sorting ferrous materials, setting up the difference with each other by observing whether the flash
is similar or unique.
testing Flash is used on the grounds that it is quick, simple, and inexpensive. In addition, test test should not be
regulated in any capacity, along those lines, often, less scrap is used. The main inconvenience to start the test is
a failure to recognize the obvious material; if proof positive distinguish necessary, examination of the
substance must be used.The sparkle correlation technique is also detrimental to the material that is trying, in
any event somewhat.
2.2 List 2 aircraft applications for Ferritic Stainless Steel and explain how the properties of this material are
useful in such applications.

Ferritic steel is high chromium, magnetic stainless steel which has a low carbon content. Known for its good
tenacity, resistance to corrosion and crack corrosion, ferritic steel is commonly used in automotive, kitchen
and industrial applications.

And engines and the wings

This provides evidence for [P2]

Task 3

3.1 Describe the production process for aluminium.

1. First, bauxite ore is mechanically destroyed. Then, the crushed ore is mixed with caustic soda and processed
in the mill to produce a slurry (aqueous suspension) containing particles of very fine ore.

2. The slurry is pumped into the digester tank that serves as a pressure cooker. The slurry is heated to 230-520
° F (110-270 ° C) under a pressure of 50 lb / in 2 (340 kPa).
3. The hot porridge, which is now a sodium aluminate solution, passing through a series of flash tanks that
reduce stress and recover heat that can be reused in the purification process.
4. The slurry is pumped to a settling tank. Pasty lies in this tank, the dirt that will not dissolve in caustic soda
settle to the bottom of the ship. One manufacturer compares this process to the fine sand to settle to the bottom
of a glass of sugar water; sugar is not satisfied because it is dissolved in water, such as aluminum in settling
tanks remain dissolved in caustic soda.
5. After the dirt has settled out, the remaining liquid, which looks a bit like coffee, is pumped through a series
of filter cloth. Every fine particles of dirt remain in solution trapped by the filter. This material is washed to
recover alumina and caustic soda which can be reused.
6. The filtered fluid is pumped through a series of tanks rainfall of six storeys high. seed crystals of alumina
hydrate (alumina bonded with water molecules) was added through the top of each tank. Seed crystals grow as
they settle through the liquid and dissolved alumina sticking to them.
7. Crystal sediment (sediment in the bottom of the tank) and removed. After washing, they were transferred to
a kiln for calcination (heating to release the water molecules are chemically bound to the molecules of
alumina).

3.2 Describe the heat treatment process that may be used to return the aluminium to a malleable state after
cold working.

1) Full Anneal.
2) Rough machine within 1/8" or less of finish dimensions.
3) Stress relief anneal 650F.
4) Solution treat using holding fixture (die quench).
5) Cold stabilze as discussed below.
6) Maintain in W temper (cold storage) until finish machined.
7) Age harden to T6.

Annealing should be done at 775°F for at 2 to 3 hours at temperature, followed by controlled cooling at 50°F
per hour down to 500°F then air cooled. The aging precipitation heat treatment is done at 350°F for 8 hours
followed by air cooling. This produces the T6 temper.
 This provides evidence for [P3]

Task 4
4.1 Using the table, identify name of the alloy with code SAE 3530. Also identify the amount of each element
present in the alloy.

nickel-chromium steel .non-modified with 0.30%

carbon

c contains 1 to 1.5% nickel, 0.45 to 0.75% chromium,

and 0.38 to 0.80% of manganese is used.

4.2 Explain the reason why SAE 3530 is a good material for certain aircraft parts. List 2 aircraft structural
applications for this material.

SAE 3530- Nickle Chromium steel is high in hardness, strength and corrosion resistant properties, and very
adaptable to heat treated forgings requiring greater toughness and strength can be obtained in ordinary
carbon steel. Chrome-nickel or stainless steel is corrosion resistant metals

Aircraft parts are made at the SAE 3530 is:

1-aircraft turbine engines

2- Inertial structure as part of the landing gear, engine and aircraft pivot point.
 This provides evidence for [P4]

Evidence checklist

Assessment Criteria Is Evidence provided?

P1:
• Written task Y/ N

P2:
• Written task Y/ N

P3:
• Written task
Y/ N

P4:
• Written task Y/ N

Sources of information
• Class handouts and learning materials
• Individual research capacity
Assessment Record Sheet – First Submission
Pearson BTEC Level 3 Diploma in Aeronautical
Qualification Engineering (120 cr.) Assessor name
Unit number and title Unit 70: Aircraft Materials and Hardware Learner name

Criteria To achieve the criteria the evidence must show that the learner
Achieved?
reference
Describe the production process of plain carbon steel and a heat treatment after production that will Y/ N
P1
add hardness to the surface of this steel
Use a given sample and a given identification method to identify the type of an alloy steel and give Y/ N
P2 is able to: structural applications for this material
two aircraft
Describe the production process for aluminium and a heat treatment process that may be used to Y/ N
P3
return the aluminium to a malleable state after cold working
Identify the type of an alloy using a given sample and the alloy group series method, and give two Y/ N
P4
aircraft structural applications for this material

Assessor’s feedback
If the learner failed the assignment or just fallen short of a grade boundary – then he/she may Criteria
be given a re-submission opportunity if conditions are fulfilled.

P1

P2
 P3

P4

Learner’s feedback

Re-submission: Yes / No Re-submission date (as per the assessment plan): /

/

Is the Assessment Decision Internally Verified? Yes / No

Does the internal verifier agree with the grade awarded? Yes / No

Assessor’s signature Date

Internal Verifier’s (IV’s)

Date
Name and Signature

Learner’s signature Date

Internal Verification – Assessment Decisions Form

Programme title Pearson BTEC Level 3 Diploma in Aeronautical Engineering (120 cr.)

Unit(s) Unit 70: Aircraft Materials and Hardware

Assessor Internal Verifier

Production, Identification, heat-treatment and application of ferrous and non-ferrous metals and alloys
Assignment title

State why the assessment

decision is inaccurate.
Name of *If an inaccurate
Learner decision is recorded the
Internal Verifier must
List which assessment
recommend actions
and grading criteria List the assessment and
detailing the issues to be
Submission Type the Assessor has Assessment Decision grading criteria where
addressed before
(First, Resubmission, Retake) awarded. Please state Accurate (Y/N) inaccurate decisions have
assessment decisions are
specific criteria and not been made
issued to learners. The
an overall grade
Assessor and the
Internal Verifier must
then confirm that the
action has been
undertaken.
INTERNAL VERIFIER CHECKLIST Y/N

Has every learner and the Assessor confirmed the authenticity of the evidence?

Is there evidence of collusion or plagiarism?

Does the assessment feedback to each learner:

● Link to relevant assessment criteria

● Justify each assessment criterion awarded
● Provide appropriate guidance to the learner without giving specific actions for improvement
GENERAL COMMENTS (if appropriate)
Any actions required must be reviewed across the whole cohort.

Action Required Target Date for Completion

I confirm that the assessment decisions are accurate, there is no evidence of assessment malpractice and any action points have been
addressed and completed in respect of the whole cohort.

Internal Verifier’s signature Date

Assessor’s signature Date

Lead Internal Verifier’s signature

Date
(if appropriate)
Resubmission Authorization Form

Resubmission Deadline 6th Oct. 2019

Unit number and title Unit 70: Aircraft Materials and Hardware

Assignment title Production, Identification, heat-treatment and application of ferrous and non-ferrous metals and alloys

Resubmitted Targeted
Lead Internal Verifier’s feedback (Reason for resubmission)
criteria

P1

P2

P3

P4

Lead Internal Verifier’s Declaration

I authorise a resubmission for the learner because he/she met the following conditions:
 the learner has met initial deadlines set in the assignment, or has met an agreed deadline extension
 the Assessor judges that the learner will be able to provide improved evidence without further guidance
 the Assessor has authenticated the evidence submitted for assessment and the evidence is accompanied by a signed-and-dated learner
declaration of authenticity
Learner signature Date

Assessor signature Date

Lead Internal Verifier
Date
signature