AIRCRAFT MATERIAL AND HARDWARE

PRACTICAL DESCRIPTION

• 01. Identification of Ferrous metals

• 02.Heat treatment and surface hardening of ferrous metals
• 03.Testing of ferrous metals
• 04.Identification of non-ferrous metals
• 05.Heat treatment and surface hardening of non-ferrous metals
• 06.Testing of non-ferrous metals
• 07.Identification of composite
• 08.Composite structure and repairs.
• 09.Identification of plastic and Rubber parts.
• 10.Identification of wood, fabrics, Dopes used in aircraft.
• 11.Identification of corrosion on ferrous and non- ferrous metals.
• 12.Corrosion protection.
• 13.Thread cutting practices (external and Internal).
 Identification of Ferrous metals
• Tools/Equipment/Special tools Required
• 1.Bench Grinder
• 2.Steel Samples
• 3.Protectives goggles
• 4.Spark analysis/comparison Diagram
PROCEDURE
To identify the ferrous metals generally two
methods are used
1.The numerical index method
2. Spark testing method
• 1. The Numerical index Method
• 01.The SAE numerical code is the basic code for identifying ferrous
metals.
• 02. The SAE system is based on the use of four-or five digit
numbers.
• 03.The first number indicates the type of alloy used; for example, 1
indicates a carbon steel.
• 04. Two indicates % of alloying metals
• 05. The second and sometimes the third, number gives the amount
of the main alloy in whole percentage numbers.
• 06. The last two, and sometimes three, number gives the carbon
content in hundredths of 1 percent ( 0.01 percent).
 • SAE 2330
• 2 – Type of steel
• 3 – Percent of alloy (3-percent nickel).
• 30 –Carbon content (0.30-pecent carbon)
• SAE 71650
• 7- Types of steel (tungsten).
• 16- Percent of alloy (16- percent tungsten)
• 50-Carbon content (0.50-percent carbon)
• SAE 50100
• 5-Type of steel (chromium)
• Percent of alloy ( less than 1-percent chromium)
• 100-Carbon content
 SAE numerical code

• TYPE OF STEEL
• SAE NUMBERS
• 1.carbon steel • 1xxx
• 2.Plain carbon • 10xx
• 3.Free cutting Manganese • X13xx
• 4.Free cutting Screw Stock • 11xx
• 5.High manganese • 713xx
• 6.Nickel steels • 2xxx
• 7. 0.50% nickel • 20xx
• 8. 1.50% Nickel • 21xx
• 9. 3.50% nickel • 23xx
• 10. 00% nickel • 25xx
• Nickel chromium steels • 3xxx
• 1.25% Nickel:1.50% chromium • 32xx
• 3.50% nickel: 1.50% chromium • 33xx
• 3.00%nickel: .80 chromium • 34xx
• Corrosion and Heat resisting • 30xxx
• Molybdenum steels • 41xx
• Chromium-molybdenum • 43xx
• Chromium-Nickel-Molybdenum • 21xx
• Nickel- Molybdenum • 46xx & 48xx
• Chromium steels • 5xxx
• 0.60% to 1.10% chromium • 51xx
• 1.2% to 1.5% chromium • 52xxx
• Corrosion and Heat Resistant • 51xxx
• Chromium-vanadium Steels • 6xxx
• Tungsten Steels • 7xxxx & 7xxx
• Silicon Manganese steels • 9xxx
 • 2. Spark testing method.
• Safety precaution
• Keep cords and hoses away from heat, oil, and sharp
edges.
• Disconnect tools when not in use
• All observers should be kept at a safe distance away
from the work area.
• Secure work with clamps or a vise, freeing both hands to
operate the tool.
• Avoid accidental starting. The worker should not hold a
finger on the switch button while carrying a plugged-in
tool.
• PROCEDURE
• 1. Place all materials to be tested on a safe place
• 2. Switch on the bench grinder machine.
• 3. Firmly hold the piece of metal to be tested with a
proper gripping tool.
• 4. Bring the metal to be tested near the grinder and
gently make a contact of metal piece with grinder with a
required pressure.
• 5. The spark testing should be done carefully so that the
metal piece should not get loosened while carrying out
spark testing.
•
• Be sure to keep good footing and maintain
good balance.
• The proper apparel should be worn.
Loose clothing, ties, or jewelry can
become caught in moving parts.
• Glove and safety footwear are
recommended during use of electric tools.
• Use proper eye protection
 Heat treatment & surface
hardening of ferrous metals
• Heat treatment
• Heat treatment consists of a series of operations which
have as their aim to improvement of the physical
properties of a material. In case of the ferrous metal
these operations are hardening.
• Procedure
• Two important consideration of the heat treatment of a
ferrous metal are (1)Its chemical composition, which in
turns determine its critical point, (2)the rate of heating &
cooling to be used.
• At ordinary temperature the carbon in steel exists in the
form particles of iron carbide scattered thought out the
iron matric. At elevated temperature the carbon is
dissolved in the iron matric in the form of solid solution
called austenite & the carbide particles appears only
after the steel has been cooled. The temperature at
which this transformation takes place are called the
critical points and vary with the composition of the steel.
The percentage of carbon in the steel has the greatest
influence on the critical points of heat treatment.
• Types of steels
• Wrought iron -0.08%
• Lc 0.1-0.3% carbon
• Mc0.30% to 0.70%
• Hc-0.70%- 2.20% by weight
• For most steels, the hardening treatment consists of heating the
steel to a temperature just above the upper critical point, soaking or
holding for the required length of the time, and then cooling it rapidly
by plunging the hot steel into oil, water, or brine. Although most
steels must be cooled rapidly for hardening, a few may be cooled in
steel air. Hardening increases the hardness and strength of the steel
but makes it less ductile.
• Hardening precautions
• A variety of different shapes and sizes of tongs for hardening hot
steels is necessary. It should be remembered that cooling of the
area contacted by the tongs is retarded and that such may not
harden, particularly if the steel being treated is very shallow
hardening. Small parts may be wired together or quenched in
baskets made of wire mesh.
• When a selective hardening is desired, portions of the steel may be
protected by covering with alundum cement or some other insulating
material shallow hardening steels, such as plain carbon and certain
varieties of alloy steels, have a such a high critical cooling rate that
they must be quenched in brine or water to effect hardening.
• Tempering
• Tempering reduces the brittleness imparted by
hardening and produces definite physical properties
within the steel. Tempering always follows, never
precedes, the hardening operation. In addition to
reducing brittleness, tempering softens the steel.
Tempering is always conducted at temperatures below
the low critical point of the steel. Generally, the rate of
cooling from the tempering temperature has no effect on
the resulting structure; therefore, the steel is usually
cooled in still air after being removed from the furnace.
• Annealing
• Annealing of steel produces a fine grained, soft, ductile,
metal without internal stresses or strains. In the
annealed state, steel has its lowest strength. In general,
annealing is the opposite of hardening. Annealing is the
opposite of hardening. Annealing of steel is
accomplished by heating the metal to just above the
upper critical point, soaking at that temperature, and
cooling very slowly in the furnace.
• Normalizing
• The normalizing of steel remove the internal stresses set
up by the heat treating, welding, casting, forming, or
machining. Stress, if not controlled, will lead to failure.
Because of the better physical properties, aircraft steels
are often used in the normalized state, but seldom, if
ever, in the annealed state. Normalizing is accomplished
by heating the steel above the upper critical point and
cooling in still air. The more rapid quenching obtained by
air cooling, as compared to furnace cooling, results in
the a harder and stronger material than that obtained by
annealing