MODULE 1

Aircraft Materials
(Level 2)
PPT1.1 ET-GC05:Aircraft Materials and Hardware Rev No.0
Module Objectives
 Identify properties and types of aircraft
Ferrous materials.
 Identify steel alloys.
 Identify heat treatment of Ferrous
Materials.
 Identify properties and types of aircraft
Non-Ferrous materials.
 Identify Non-ferrous alloys.
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Module Objectives
 Identify heat treatment of Non-Ferrous Materials.
 Identify properties and types of aircraft
Composite and Non-Metallic materials.
 Identify basics of Composite and Non-metallic
material repair.
 Identify Properties, Types and repair of Fabric
coverings.
 Identify corrosion and its protection.

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Module Structure

Lesson 1 Lesson 2 Lesson 3

Aircraft Aircraft Aircraft
Materials- Materia Materials-
Ferrous ls Composite &
Non-Ferrous Non-Metallic
Lesson 4

Corrosion

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 Lesson 1:
Aircraft Materials-Ferrous

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 Properties of Metals-1
• “Ferrous”
• Ferrous comes from the Latin "ferrum"
meaning iron
• Knowledge of the Properties of Metals:
• Help in material selection
• Prevent deviation from design specification

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 Properties of Metals-2
• Properties of metals:
• Hardness
• Ability to resist abrasion,
penetration, cutting, or
permanent distortion
• may be increased by:
• cold working
• heat treatment

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 Properties of Metals-3
• Properties of metals:
• Strength - ability to resist deformation.

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 Properties of Metals-4
• Properties of metals:
• Density
• weight of a unit volume of a material
• affects aircraft weight and balance
• affects the strength to weight ratio
• E.g aluminum has a lower density than a piece
steel with the same weight and volume.

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 Properties of Metals-5
• Properties of metals:
• Malleability
• Property to be hammered,
rolled, or pressed into various
shapes
• Good property for sheet
metal work
• Eg. cowlings, fairings, or wingtips

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 Properties of Metals-6
• Properties of metals:
• Ductility
• property to be permanently
drawn, bent, or twisted
into various shapes
• similar to malleability
• Eg. wires and tubing

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 Properties of Metals-7
• Properties of metals:
• Elasticity
• Ability to return to original size and shape when
and shape when applied
force is removed
• Fails beyond elastic limit
• Eg. spring steel.

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 Properties of Metals-8
• Properties of metals:
• Toughness
• Ability to withstand
tearing or shearing

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 Properties of Metals-9
• Properties of metals:
• Brittleness
• allows little bending or deformation without
shattering
• break or crack without change of shape
• not a very desirable property
• Eg. Cast iron, cast aluminum, and very hard
steel

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 Properties of Metals-10
• Properties of metals:
• Fusibility
• ability to become liquid by heat
• Useful for welding
• E.g Steels fuse around 2,600 °F and
aluminum alloys at approximately 1,100 °F.

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 Properties of Metals-11
• Properties of metals:
• Fusibility
• ability to become liquid by heat
• Useful for welding
• E.g Steels fuse around 2,600 °F and
aluminum alloys at approximately 1,100 °F.

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 Properties of Metals-12
• Properties of metals:
• Conductivity
• ability to carry heat or electricity
• important in welding or type of jig used
• bonding electrical conductivity eliminate radio
interference

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 Properties of Metals-14
• Properties of metals:
• Thermal Expansion
• contraction and expansion due to heat change
• Important in jigs, castings, and tolerances
necessary for hot rolled material

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 Common Steels used In Aircraft-1
• Properties & Identification :
•The SAE and AISI four digit numerical index:
• 1st digit - principal alloying element in the steel.
• 2nd digit- percentage of alloying element
• last two digits- percentage in 100th of a percent
of the carbon in the steel
• 5th digit required for carbon more than 0.99%,

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 Common Steels used In Aircraft-2
Properties & Identification :

•Eg of SAE and AISI four

digit numerical index:

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Common Steels used In Aircraf-
• Common steels are:
i. Plain carbon steel= Iron + Carbon
ii. Alloy steel = Iron + Carbon +
Others
 Common Steels used In Aircraft-3
• Incidental elements:
• Small unspecified quantities of certain
elements present in alloy steels
• Maximum amount of each element varies
from metal to metal.

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 Common Steels used In Aircraft-4

Steel alloy classification

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 Common Steels used In Aircraft-5
• Metal stock:
• Sheets
• bars
• rods
• tubing
• extrusions
• forgings, and
• castings

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 Common Steels used In Aircraft-6
• Spark test: used to identify various ferrous metals

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 Common Steels used In Aircraft-7
• Metal Identification by Spark Test

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 Common Steels used In Aircraft-8
• Iron
• Ferrous comes from the Latin "ferrum" meaning
iron.
• Pure iron is too soft and reactive

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 Common Alloy Steels used In Aircraft-9
• Iron
• Pure iron is too soft and reactive
• Iron Ore:
• iron ore + coke + limestoneFurnac pig iron
Mol e
• pig iron cast iron
d

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 Common Steels used In Aircraft-10
• Cast Iron:
• Molded and cooled pig iron from furnace
• is basically alloy of iron, silicon, and high
carbon
• Wrought Iron:
• contains pure iron and iron silicate
• low in carbon

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 Common Steels used In Aircraft-11
• Steels:
• alloy of iron and carbon
• Carbon in cast iron is more than carbon in
wrought steel.
• Wrought steel never contains free carbon
(graphite).

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 Common Alloy Steels used In Aircraft-12
• Plain Carbon Steel:
• Carbon content of:
• Low carbon or 'mild' steel up to 0.3%
• Medium carbon steel 0.3% to 0.8%
• High Carbon Steel 0.8% to 1.7%
• Above 1.7% , the carbon is free (uncombined)

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 Common Alloy Steels used In Aircraft-13

carbon steel alloy

steel

Alloying elements

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 Common Alloy Steels used In Aircraft-14
• purpose of alloying
• improve desirable metallic properties
• Naming of alloys
• named after the principal alloying elements

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 Common Alloy Steels used In Aircraft-15
• 2xxx Nickel
• 3% - 3.75% nickel
• increase hardness, tensile strength, and elastic
limit
e.g. SAE 2330 steel used for aircraft bolts,
cable terminals, keys, clevises, and pins

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 Common Alloy Steels used In Aircraft-16
• 3xxx Nickel-chromium steel
• Nickel gives toughness to steel, and chromium
hardens it.
• used in corrosion suspected areas
• widely known as stainless steel (cres)

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 Common Alloy Steels used In Aircraft-17
• Inconel
• Nickel-Chromium-Iron alloy with Nickel content
greater than 50 percent
• resembles stainless steel ( CRES) in
appearance.
• electrochemical test can be used to distinguish
Inconel and CRES

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 Common Alloy Steels used In Aircraft-18
• 4xxx molybdenum steel
• used on aircraft structural part
• Tough, strong, weldable and easy to machine
• Eg. SAE 4130- used on fuselage frames and
engine mounts.

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 Common Alloy Steels used In Aircraft-19
• 6xxx Chrome-vanadium steel
• strong and tough
• used extensively for ball and roller bearings,
wrenches and other hand tools

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 Common Alloy Steels used In Aircraft-20
• Heat Treatment of Alloy Steels
• controlled heating and cooling to develop certain
desirable characteristics:
• Hardness
• softness
• Ductility
• tensile strength
• refined grain structure

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 Common Alloy Steels used In Aircraft-21
• Heat Treatment of Alloy Steels
• Heating forms alloy- base metal solid solution
and changes the structure of the metal
• Consideration in heat treatment
• Chemical composition
• rate of heating, soaking and cooling

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 Common Alloy Steels used In Aircraft-22
• Critical points

carbon steel-Heating critical points

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 Common Alloy Steels used In Aircraft-23
• heat treatment processes:
• hardening
• annealing
• tempering
• normalizing

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 Common Alloy Steels used In Aircraft-24
• Hardening:
• Three conditions must be satisfied
• carbon content ( > .30% carbon)
• temperature range( above the UCP)
• cooling media (brine, oil, water)

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 Common Alloy Steels used In Aircraft-25
• Annealing:
• the process of softening a hardened steel
• heating to the UCP
• soaking for 1 to 2 hours
• cooling slowly in furnace, heated sand or ash

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 Common Alloy Steels used In Aircraft-26
• Tempering
• removing some hardness to make it tougher
• heated in oil or brine bath of 300°F to 1200°F
• Steel toughness is proportional to temp.
• Normalizing
• removes internal stresses due to heat treating,
welding, casting, forming,

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 Progress Test-PT1.1
1. Give five examples of the properties of a metal
2. Which property of metal is useful in sheet metal
that is worked in to curved shapes?
3. ____ is the property to withstands little
deformation
4. In the SAE/AISI four digit numerical index system,

which digit indicates the principal alloying

element?
5. What are incidental
PPT1.45 elements?
ET-GC05:Aircraft Materials and Hardware Rev No.0
 Progress Test-PT1.1
6. Which one represent nickel alloy among the
1000,
2000, 3000 and 4000 series
7. In 4130 alloy steel, the major alloying element is
________ % of major alloying element is ____ and %
of carbon is_____
8. Which one has free carbon (graphite)?
A. low carbon steel
B. high carbon steel
PPT1.46 C. cast ironET-GC05:Aircraft Materials and Hardware Rev No.0
 Progress Test-PT1.1
9. Apart from its composition, what two other
conditions negatively affect the properties of
steel?
10. Chrome-nickel is also known by the name
______
or ____‘Stainless Steel’ or 'Corrosion Resistant
Steel’
11. What are the most common forms of heat
treatment for ferrous metal?
12. What will happen
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 Lesson Summary-1
• metals and their alloys have different desirable
and undesirable physical and mechanical
properties
• a four digit numbering index sponsored by SAE
and AISI is used to identify the chemical
compositions of structural steels
• Spark testing is a common means of identifying
various ferrous metals
• Plain carbon steels are alloys of iron and carbon
up to 1.7% carbon
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 Lesson Summary-2
• Low , medium and high carbon steels are grouped
under plain carbon steels
• Alloy steels contain iron, carbon, sulphur,
phosphorus, nickel, chromium, molybdenum and
vanadium etc. in varying proportions
• Heat treatment is a process of heating and cooling
of metals in the solid state to change its
mechanical properties

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 Lesson 2:
Aircraft Materials-Non-Ferrous

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 Properties & Identification-1
• Nonferrous:
• have elements other than iron as their base or
principal constituent
• Eg. aluminum, titanium, copper, magnesium,
as well as such alloyed metals as Monel and
babbit.

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 Properties & Identification-2
• Aluminum Alloy
• Has high strength to weight ratio
• Alloying improves structural properties
• Pure aluminum has good corrosion resistance.
• Alloying with Copper improves strength but
decrease corrosion resistance

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 Properties & Identification-3
• Classification:
• Casting alloys
• sand, permanent mold or die casting
• Wrought alloys
• shaped by rolling, drawing or forging.
• used for the construction of stringers,
bulkheads, skin, rivets ---

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 Properties & Identification-4
• Designation:
• Four digit index system
• The system has three distinct groups
• 1xxx
• 2xxx to 8xxx
• 9xxx (unused series)

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 Properties & Identification-5
• 1xxx group:
• 1st digit- major alloying element (99% pure Al)
• 2nd digit- alloy modification
• last two digits- hundredths of 1% above
original 99% of Al.

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 Properties & Identification-6
• 2xxx-8xxx Group:
• 1st digit- (major alloying element)
• 2xxx - Cu 3xxx - Mn 4xxx - Si 5xxx - Mg
6xxx - Mg and Si 7xxx-Zn 8xxx- other
elements
• 2nd digit- alloy modification
• last two digits- identify the different alloys in
the group

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 Properties & Identification-7
• Magnesium Alloys
• lightest structural metal
• highly susceptible to corrosion
• tendency to crack under excessive vibration
• can ignite and burn (use dry-powder fire
extinguisher in case of fire)

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 Properties & Identification-8
• Identification:
• series of letters and numbers
• 1st letter or letters- main alloying elements
• middle digits- percentage each elements
• last letter and number – alloy heat
treatment

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 Properties & Identification-9
• Magnesium Alloys
• Example: AZ31A - T4
• AZ- The main alloying elements are Al and
Zn
• 31- 3% aluminum and 1% zinc.
• A - Indicates that the alloy is original.
• T4 - The alloy has been solution heat treated

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 Properties & Identification-10
• Nickel and Nickel Alloys
• nickel alloys used in aircraft:
• Monel
• Inconel
• can be welded or easily machined
• Aluminum containing nickel Monels are heat-
treatable

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 Properties & Identification-11
• nickel Inconel alloys:
• Maintain their strength and corrosion
resistance under high heat
• Inconel and stainless steel appears similar
• cupric chloride and hydrochloric acid solution is
used to identify the two.
• nickel Inconel= shiny spot and
• stainless steel=copper colored spot

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 Properties & Identification-12
• Copper and Copper Alloys
• Limitation:
• not good as structural material due to its
heavy weight
• merit:
• high electrical and heat conductivity
• ideal for making wire because it isvery
malleable and ductile

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 Properties & Identification-13
• Beryllium copper:
• has high Positive response to heat treatment
• Increase in tensile strength
• resistance to fatigue and wear

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 Properties & Identification-14
• Muntz Brass
• excellent corrosion resistant in salt water
• Positively responds to heat treatment
• used in making bolts and nuts
• Red brass(bronze)
• used in fuel and oil line fittings

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 Properties & Identification-15
• Titanium
• Strong, light weight and corrosion resistant
• hardened by cold working
• inert-gas arc welded to prevent oxidation
• Titanium classification:
• A (alpha
• B (beta)
• C (Combined A and B)

PPT1.65 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Heat Treatment of Non-Ferrous Materials-1
• Heat treatment of aluminum:
• Solution heat treatment
• Precipitation heat treatment

• Heating
• Soaking Solution heat treatment
• Quenching

PPT1.66 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Progress Test-PT1.2
1. Why is aluminum preferred for aircraft
construction?
2. Which class of aluminum is most used in aircraft ?

3. What do 2117 and 2024 have in common? Why?

4. Why does magnesium machining require extra
care? What prevents part from burning?
5. Which nickel alloy is used in gears and parts that

require high strength

PPT1.67 andandtoughness?
ET-GC05:Aircraft Materials Hardware Rev No.0
 Progress Test-PT1.2
6. What is the main use of copper in aircraft?
7. What elements constitute bronze?
8. What are the classes of titanium and its alloys?
9. Which of the two aluminum heat treatment
processes come first?
10. Which aging process requires moderate
temperature?

PPT1.68 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Lesson summary-1
• Aircraft non ferrous materials include metals such
as Al, Mg , Ni, Cu, Ti and their alloys
• Pure aluminum is soft and corrosion resistant
• Aluminum is alloyed to improve its strength
• A four digit number is used to classify aluminum
and its alloys
• Magnesium powders can easily catch fire.
Sanding, grinding and filling must be done with
care.
PPT1.69 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Lesson summary-2
• Monel and Inconel are the most known nickel
alloys
• Inconel and stainless steel have similar
appearance and can be identified using acid spot
test
• Copper has high electrical and heat conductivity
and used in aircraft electrical systems
• Brass and bronze are the two most known copper
alloys.
• Titanium is light weight, strong , corrosion
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 Lesson summary-3
• Aluminum alloys have two types of heat
treatments
• Solution heat treatment includes heating, soaking
and quenching. Temperature varies with alloy
types
• natural aging at room temperature or artificial
aging (precipitation heat treatment) at some
elevated temperature is used to harden solution
heat treated metals

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 Lesson 3:
Aircraft Materials – Composite &
Non-Metallic

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 Composite & Non-Metallic-1
• definition of Composite:
• a combination of two or more macro
constituents which are different in composition
or form
• constituents retain their properties and
identities
• Develops new structural properties not present
in the individual constituents

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 Composite & Non-Metallic-2
• constituents:
• Fibers- carries load
• Matrix- transfers load to
the fibers

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 Composite & Non-Metallic-3
• Composites carry more load in the fiber direction
• Transverse property- matrix ability to transfer
loads from one fiber to another
• Some reinforcing fibers:
• Fiberglass
• Kevlar
• Carbon (graphite)
• Boron
• Quartz etc.
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 Composite & Non-Metallic-4
• Characteristics and Properties
• high strength-to-weight ratio
• corrosion and fatigue resistance
• good vibration resistance compared to sheet-
metal structures
• lower assembly costs and fewer parts
• smooth surface reduces aerodynamic and
parasitic drag

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 Composite & Non-Metallic-5
• Types and Identification of Composite

• Consists of only
solid plies
Solid laminate composite structure
• Each ply is a fabric
impregnated with resin
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 Composite & Non-Metallic-5
• Core types:
• rigid foam

• wood
• Honeycomb:
• Paper
• Nomex
• carbon, fiberglass or metal

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 Composite & Non-Metallic-6
• Plastics:
• Thermoplastic
• soften when heated and harden when cooled
• Thermosetting
• reheating has no softening effect
• Forms of plastics:
• monolithic (solid)
• laminated

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 Composite & Non-Metallic-7
• Rubber:
• Natural Rubber
• better properties than synthetic rubber
• But easily deteriorates
• Synthetic Rubber
• most widely used such as butyls, Bunas, and
neoprene.

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 Composite & Non-Metallic-8
• sealant:
• prevents:
• pressurization leak
• fuel leak
• fume passage
• weather corrosion

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 Composite & Non-Metallic-9
• Sealant supply:
• one part (semkit)
• two parts (pot sealant)

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 Composite & Non-Metallic-10
• Mixed sealant has:
• Application Time
• Tack Free Time
• Curing Time
• Assembly Time

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 Composite & Non-Metallic-11
• Bonding agents:
• Are Adhesives

Re-entrant

Defused
adhesive
molecules

Mechanical Chemical Combined

bond bond bond

Types of bond
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 Composite & Non-Metallic-12

Stresses on a bonded joint

Tension Shear

Cleavage
Peel

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 Composite & Non-Metallic-13
• Types of adhesive:
• Flexible adhesives
• where part is flexing or part in relative
motion
• Structural adhesives
• where there is high load
• Part relatively rigid

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 Composite & Non-Metallic-14
• Adhesive Forms:
• liquid
• paste
• film
• foaming types

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 Composite & Non-Metallic-15
• Adhesive Forms:
• liquid
• paste
• film
• foaming types

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 Wooden Structures-1
• Characteristics and Properties:
• Lightweight
• Strong
• has long life when it is properly preserved
• Classifications:
• hardwood – from deciduous trees
• Softwood- from evergreen trees

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 Wooden Structures-2
Properties of aircraft structural wood

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 Wooden Structures-3
Types of Wood

Ply wood Laminated Wood

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 Wooden Structures-4
• Ply wood
• contains uneven number of veneers
• grain of adjacent layers run at 450 or 900
• outer layers = face
• inner layer = core

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 Wooden Structures-5
• Aircraft glue
• Determines strength
• Follow specifications in AC 43.13-1B.
• Plastic resin and resorcinol are FAA -approved for
use on certificated airplanes

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 Wooden Structures-6
• Preservation of Wooden Structure
• Fungal Decay and dry rot are major problems
• Provide adequate rain holes at low points of the
aircraft
• Keep air and moisture from the wood
• Apply wood preservative and varnish

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 Wooden Structures-7
• Requirements for wood selection:
• Moisture content -12%
• Minimum annual rings per inch-6
• Maximum slope of the grain -1 inch in 15 inches

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 Wooden Structures-8
• Factors affecting wood quality:
• strength to weight ratio
• water content
• grain arrangement
• annual rings/inch
• type of cut

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 Wooden Structures-9
• Unacceptable defects:
• check
• decay
• compression failure
• pike knots

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 Fabric Covering-1
• Fabric Terms

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 Fabric Covering-2
• Types of Fabrics used In Aeroplanes
• the earliest skin covering
• replaced by metal and
advanced composite

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 Fabric Covering-3
• Natural/organic fabrics
• cotton - is still used
• linen
• Inorganic fabrics
• polyester fibers- widely used
• glass filaments

PPT1.100 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Fabric Covering-4
• Approved Fabric Materials
• fabric, tapes, threads, cords, glues, dopes,
sealants, coatings, thinners, additives,
fungicides, rejuvenators, and paints

PPT1.101 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Fabric Covering-5
• Approved Fabric Materials

PPT1.102 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Fabric Covering-6
• General Fabric Covering Process
• Involves three steps:
• select an approved fabric
• follow the applicable STC steps to attach the
fabric to the airframe and to protect it from the
elements
• apply the approved topcoat to give the aircraft
its color scheme and final appearance.

PPT1.103 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Progress Test-PT1.3
1. Define composite material.
2. What are the two constituting elements of a
composite?
3. Which materials are referred to as advanced
composite materials?
4. List some advantages of composite
5. What is the difference between solid laminate and
sandwich composite structure?
PPT1.104 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Progress Test-PT1.3
6. The two types of plastics are ______ and _______
7. What are the most widely used synthetic rubbers?
8. Which of the PR1440 sealant type is applied with
brush?
9. Write the stresses experienced by adhesive
joints?
10. Which wood species is considered as a reference
wood?

PPT1.105 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Progress Test-PT1.3
11. What are the requirements for wood selection?
12. What do Checks, shakes, and splits have in
common?
13. Define warp of a fabric.
14. write the two types of fabrics used on aircraft.
15. List the three steps of fabric covering process.

PPT1.106 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Lesson Summary-1
• Composite structures are manufactured using
fibrous materials and matrix.
• reinforcement fibers carry the loads while the
matrix transfer loads from one fiber to another.
• The two types of composite structures are solid
laminate and sandwich construction.
• Materials such as plastics, rubbers, bonding
adhesives and sealants are also widely used in
aircraft
PPT1.107 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Lesson Summary-2
• Wood was used extensively in the early days of
aircraft construction.
• Aircraft wood comes in solid, laminate and ply
types.
• Wooden aircraft parts are joined with glues.
• Plastic resin and resorcinol are FAA -approved for
use on certificated airplanes.
• Before use, check Wood for acceptable or
unacceptable defects.
PPT1.108 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Lesson Summary-3
• Use approved fabrics made of polyester and glass
fibers to cover FAA-certificated aircraft
• AC 43.13-1 is an approved source of information
concerning the inspection and repair of aircraft
wood and fabric

PPT1.109 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Lesson 4:
Corrosion
(Level 1)

PPT1.110 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Chemical Fundamentals-1
• Definitions:
• Corrosion: chemical or electrochemical
deterioration of a material
• complex, natural and continuous process
• affect equipment life cycles, downtime, and
overall system reliability

PPT1.111 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Chemical Fundamentals-2
• Conditions for Corrosion
• All metals corrode in a natural environment.

• Simplified Corrosion Cell

PPT1.112 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Chemical Fundamentals-3
• Slowing or stopping corrosion
• Eliminate any one of the four conditions

PPT1.113 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Galvanic Action, Microbiological, Stress-1
• Galvanic Corrosion
• different metals + electrolyte
• corrosion deposit builds up
at the joint between the
metals

PPT1.114 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Galvanic Action, Microbiological, Stress-2
• Microorganisms
• Bacteria:
• Make an area Damp
• Change oxygen concentration
• produce acidic wastes

PPT1.115 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Galvanic Action, Microbiological, Stress-3
• Stress Corrosion
• Also called stress corrosion
cracking (SCC)
• caused by residual stress
and corrosion

PPT1.116 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-1
• Uniform Surface Corrosion
• Caused by direct chemical attack
• proceeds uniformly over
the entire exposed surface
• Can be prevented by
Coating/sealing

PPT1.117 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-2
• Galvanic Corrosion + Corroded End (anodic, or least noble)

Magnesium
Magnesium alloy
Zinc
Aluminum (1100)
Cadmium
Steel or Iron

Lead
Tin

galvanic series of metals Nickel (active)

Copper

and alloys (sample). Silver

Titanium
Graphite
Gold
Platinum

– Protected End (cathodic, or most noble)

PPT1.118 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-3
• Pitting Corrosion
• Causes localized holes
• white or gray powdery deposit

PPT1.119 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-4
• Intergranular Corrosion
• attacks grain boundaries of metals

ross-Section of 7075-T6 Aluminum Alloy

PPT1.120 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-5
• Exfoliation Corrosion
• advanced form of intergranular corrosion
• separation occurring at the grain boundaries

At edge Adjacent to Fasteners

PPT1.121 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Types of Corrosion & Their Identification-6
• Crevice Corrosion
• stagnant solution in a
crevice

PPT1.122 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-7
• Filiform Corrosion
• wormlike

PPT1.123 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Types of Corrosion & Their Identification-8
• Erosion Corrosion
• Caused by an attack of a corrosive fluid against
the metal surface
• Corrosion Fatigue
• caused by the combined effects of cyclic stress
and corrosion

PPT1.124 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Causes Of Corrosion-1
• Type of Material
• Proper material selection reduce corrosion
• Heat Treatment
• cause local difference in chemical composition
• Dissimilar Metals
• Rate of corrosion depends on the difference in
their activities

PPT1.125 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Causes Of Corrosion-2
• Anode and Cathode Surface Area

PPT1.126 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Causes Of Corrosion-3
• Presence and concentration of Electrolytes
• Temperature
• Biological Organisms
• Mechanical Stress

PPT1.127 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Material Types, Susceptibility To Corrosion-1
• Order of Corrodibility in Common Metals
1. Magnesium 8. Tin
2. Aluminum 9. Silver
3. Zinc 10. Tungsten
4. Iron 11. Vanadium
5. Cadmium 12. Chromium
6. Nickel
7. Lead
PPT1.128 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Progress Test-PT1.4
1. Define corrosion
2. State the four conditions for corrosion to occur
3. How does galvanic corrosion occur?
4. List five types of corrosion
5. What causes intergranular corrosion?

PPT1.129 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Progress Test-PT1.4
6. What is the cause of crevice corrosion?
7. How do you identify filiform corrosion?
8. What type of corrosion occurs between two
surfaces which are in relative motion?
9. Mention three causes of corrosion?
10. Compare the corrodibility of aluminum and
magnesium

PPT1.130 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Lesson Summary-1
• Corrosion is a natural phenomena that
deteriorates metals
• Corrosion requires favorable conditions to occur
• Corrosion can be slowed or stopped by eliminating
any of the favorable conditions
• There are different forms of corrosion which can be
identified by their effects and corrosion products
• Metals have different degree of corrodibility

PPT1.131 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Module Review-1

PPT1.132 ET-GC05:Aircraft Materials and Hardware Rev No.0

 Module Review-2
• metals and their alloys have different desirable
and undesirable physical and mechanical
properties
• Metals and their alloys have identification
numbers
• Ferrous metals have iron as their principal element
• Properties of metals can be changed by alloying
with other elements , by heat treatment or cold
working
PPT1.133 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Module Review-3
• Composite is replacing wood and metals as aircraft
materials
• composite structures are made from solid laminate
or sandwich construction.
• plastics, rubbers, bonding adhesives and sealants
are also widely used in aircraft
• Wood & fabric aircrafts are still in service and
knowledge of their repair is important
• Aircraft metals are susceptible to corrosion
PPT1.134 ET-GC05:Aircraft Materials and Hardware Rev No.0
 Any Questions?

Thank You!

PPT1.135 ET-GC05:Aircraft Materials and Hardware Rev No.0