Aerospace Materials and Material Technologies Volume 1 Aerospace Materials 1st Edition by Eswara Prasad, R J H Wanhill 9811021341 9789811021336

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ISBN 10: 9811021341
ISBN 13: 9789811021336
Author: N. Eswara Prasad, R. J. H. Wanhill

This book is a comprehensive compilation of chapters on materials (both established and evolving) and material technologies that are important for aerospace systems. It considers aerospace materials in three Parts. Part I covers  Metallic Materials (Mg, Al, Al-Li, Ti, aero steels, Ni, intermetallics, bronzes and Nb alloys); Part II deals with Composites (GLARE, PMCs, CMCs and Carbon based CMCs); and Part III considers Special Materials. This compilation has ensured that no important aerospace material system is ignored. Emphasis is laid in each chapter on the underlying scientific principles as well as basic and fundamental mechanisms leading to processing, characterization, property evaluation and applications. This book will be useful to students, researchers and professionals working in the domain of aerospace materials.

Aerospace Materials and Material Technologies Volume 1 Aerospace Materials 1st Table of contents:

1 Magnesium Alloys
Abstract
1.1 Introduction
1.2 Classification and Designation
1.3 Physical Metallurgy of Mg Alloys
1.3.1 Role of Different Alloying Elements
1.3.1.1 Zinc (Zn)
1.3.1.2 Zirconium (Zr)
1.3.1.3 Aluminium (Al)
1.3.1.4 Rare Earth (RE) Elements (Nd, Ce, La, Gd, Pr)
1.3.1.5 Manganese (Mn)
1.3.1.6 Silver (Ag)
1.3.1.7 Silicon (Si)
1.3.1.8 Thorium (Th)
1.3.1.9 Transition Elements (Copper (Cu), Iron (Fe), Nickel (Ni), Cobalt (Co))
1.3.1.10 Lithium (Li)
1.3.1.11 Yttrium (Y)
1.3.1.12 Beryllium (Be)
1.3.1.13 Calcium (Ca)
1.3.2 Precipitation Reactions in Mg Alloys
1.3.3 Strengthening in Mg Alloys
1.4 Aerospace Mg Alloys
1.4.1 Casting Alloys
1.4.2 Wrought Alloys
1.4.3 Welding and Machining
1.4.4 Recent Advancements in Mg Alloys
1.5 Mechanical Properties
1.5.1 Tensile Properties
1.5.2 Fatigue and Fracture Resistance
1.5.3 Creep and Oxidation Properties
1.5.4 Corrosion Behaviour
1.5.4.1 General Corrosion
1.5.4.2 Galvanic Corrosion
1.5.4.3 Stress Corrosion Cracking (SCC)
1.5.4.4 Corrosion Fatigue
1.5.4.5 Advances in Corrosion Protection Techniques
1.6 Global Scenario and Indian Programmes
1.7 Summary
Acknowledgments
References
2 Aluminium Alloys for Aerospace Applications
Abstract
2.1 Introduction
2.2 Classification and Designation
2.2.1 Wrought Alloys
2.2.2 Cast Alloys
2.2.3 Temper Designations
2.3 Age-Hardenable Aluminium Alloys
2.4 Effects of Alloying Elements
2.5 Mechanical Properties
2.5.1 Strength and Fracture Toughness
2.5.2 Fatigue
2.5.3 Fatigue Crack Growth
2.5.4 Corrosion Resistance
2.6 Typical Aerospace Applications of Aluminium Alloys
2.7 Indian Scenario
2.7.1 Gaps in Indian Aerospace Aluminium Technologies
2.7.2 Type Certification of Aluminium Alloys in India
2.8 Summary and Conclusions
Acknowledgments
References
Some Useful Data Handbooks
3 Aluminium–Lithium Alloys
Abstract
3.1 History of Alloy Development
3.2 Aircraft Structural Property Requirements
3.3 Physical Metallurgy of Al–Li Alloys
3.4 Processing Technologies
3.5 Mechanical Properties
3.5.1 Tensile Properties
3.5.2 Fatigue Properties
3.5.3 Fracture Toughness and R-curves
3.6 Corrosion and Stress Corrosion Cracking
3.7 Current Indian Scenario
3.8 Conclusions
Acknowledgments
References
4 Titanium Sponge Production and Processing for Aerospace Applications
Abstract
4.1 Introduction
4.2 Established Methods of Titanium Extraction
4.3 World Production of Titanium Sponge—Recent Developments
4.4 Indian Scenario on Titanium Sponge Production
4.4.1 Development of Kroll Technology at DMRL, Hyderabad
4.4.2 Development of Combined Process Technology at DMRL, Hyderabad
4.4.3 Quality Evaluation and Processing of Aerospace Grade Sponge
4.4.4 Commercial Production of Titanium Sponge at KMML, Chavara, India
4.4.5 Quality Assurance Program at KMML Sponge Plant
4.4.6 Type Certification of Titanium Sponge—The Approach
4.5 Properties of Ti Sponge
4.6 Concluding Remarks
Acknowledgments
References
5 Titanium Alloys: Part 1—Physical Metallurgy and Processing
Abstract
5.1 Introduction
5.2 Physical Metallurgy of Titanium Alloys
5.2.1 Crystal Structure
5.2.2 Elastic Properties
5.2.3 Deformation Modes
5.2.4 Slip Modes
5.2.5 Alloying Additions
5.2.6 Phase Transformations
5.3 Primary Processing: Melting and Consolidation
5.3.1 Vacuum Arc Remelting (VAR)
5.3.2 Cold Hearth Melting (CHM)
5.3.3 Melt-Related Defects
5.3.4 Conditioning and Homogenization
5.4 Secondary Processing
5.4.1 Forging
5.4.2 Rolling
5.5 Titanium Alloy Castings
5.6 Indian Scenario on Titanium Alloy Processing
5.7 Summary
Acknowledgments
References
Bibliography
6 Titanium Alloys: Part 2—Alloy Development, Properties and Applications
Abstract
6.1 Introduction
6.2 Titanium Alloy Developments and Applications
6.2.1 Commercially Pure Titanium and α-Titanium Alloys
6.2.2 High Temperature Near-α Titanium Alloys
6.2.3 α + β Titanium Alloys
6.2.3.1 Processing and Microstructures of α + β Titanium Alloys
6.2.3.2 Mechanical Properties of α + β Titanium Alloys
6.2.3.3 Applications of α + β Titanium Alloys
6.2.4 β Titanium Alloys
6.2.4.1 Introduction: General Characteristics
6.2.4.2 Processing and Microstructures
6.2.4.3 Mechanical Properties of β Titanium Alloys
6.2.4.4 Applications of β Titanium Alloys
6.3 Summary
Acknowledgments
References
Bibliography
7 Aero Steels: Part 1—Low Alloy Steels
Abstract
7.1 Introduction
7.2 Classification and Designation
7.3 Compositions of Low Alloy Steels
7.3.1 Ultrahigh-Strength Steels (UHSS)
7.3.2 Bearing Steels
7.4 Effects of Alloying Elements
7.4.1 Critical Transformation Temperatures
7.4.2 Formation and Stability of Carbides
7.4.3 Grain Size
7.4.4 Eutectoid Point
7.4.5 Hardenability
7.4.6 Volume Change
7.4.7 Resistance to Softening While Tempering
7.5 Strengthening Mechanisms
7.6 Melting of Low Alloy Steels
7.7 Fabrication of Low Alloy Steels
7.8 Heat Treatment
7.9 Surface Hardening of Steels
7.10 Engineering Properties
7.11 Indian Scenario
7.12 Summary and Conclusions
Acknowledgments
References
8 Aero Steels: Part 2—High Alloy Steels
Abstract
8.1 Introduction
8.2 Secondary Hardening Steels
8.2.1 Effects of Alloying Elements in Secondary Hardening Steels
8.2.2 Processing and Thermal Treatments
8.2.3 HP 9-4-X Steels
8.2.4 AF1410 Steel
8.2.5 AerMet Steels
8.2.6 Ferrium Steels
8.3 Maraging Steels
8.3.1 Effects of Alloying Elements in Maraging Steels
8.3.2 Processing and Heat Treatments of Maraging Steels
8.4 Precipitation Hardening (PH) Steels
8.4.1 Mechanical Properties of Typical PH Stainless Steels
8.4.2 Processing and Heat Treatments of PH Stainless Steels
8.4.3 Weldability of PH Stainless Steels
8.5 Illustration of Martensitic PH Steels Diversity: Custom 455, 465 and 475
8.5.1 Processing and Heat Treatments of Custom 455, 465 and 475 Stainless Steels
8.5.2 Weldability of Custom 455, 465 and 475 Stainless Steels
8.6 Indian Scenario
8.7 Summary
References
Bibliography
9 Nickel-Based Superalloys
Abstract
9.1 Introduction
9.2 Classification of Nickel-Based Superalloys
9.3 Physical Metallurgy
9.3.1 Chemical Composition
9.3.2 Microstructural Constituents
9.3.3 Heat Treatment
9.3.4 Strengthening Mechanisms
9.4 Manufacturing Processes
9.4.1 Wrought Alloys
9.4.2 Cast Superalloys
9.5 Properties of Superalloys
9.5.1 Tensile Properties
9.5.2 Creep Resistance
9.5.3 Fatigue
9.5.4 Fatigue Crack Growth
9.6 Evolution of Advanced Nickel-Based Superalloys
9.6.1 First Generation Superalloys
9.6.2 Second Generation Superalloys
9.6.3 Third Generation Superalloys
9.6.4 Fourth Generation Superalloys
9.6.5 Fifth Generation Superalloys
9.6.6 Sixth Generation Superalloys
9.7 Concluding Remarks
Acknowledgments
References
10 Structural Intermetallics
Abstract
10.1 Introduction
10.2 Crystal Structures and Compositions of Selected Intermetallics
10.2.1 Nickel Aluminides
10.2.2 Titanium Aluminides
10.2.3 Iron Aluminides
10.2.4 Molybdenum Silicides
10.2.5 Niobium Silicides
10.3 Processing
10.4 Properties of Ni-, Fe-, and Ti-Based Aluminides
10.4.1 Property Surveys
10.5 Aerospace Applications
10.5.1 Silicides
10.5.2 Aluminides
10.5.3 Indian Scenario
10.6 Summary
References
11 Bronzes for Aerospace Applications
Abstract
11.1 Introduction
11.2 Bronzes
11.2.1 Effects of Alloying Elements
11.2.2 Aluminium Bronzes
11.2.3 Aluminium-Silicon Bronzes
11.2.4 Silicon Bronzes
11.2.5 Phosphor Bronzes
11.2.6 Beryllium Bronzes
11.2.7 Manganese Bronzes
11.2.8 High Leaded Tin Bronzes
11.2.9 Sintered Bronzes (Oil Impregnated Bronzes)
11.2.10 Aircraft Bronze (French Bronze)
11.2.11 Nickel-Silicon Bronzes
11.3 Processing of Bronzes
11.3.1 Melting Practices
11.3.2 Casting Practices
11.3.3 Hot-Working
11.3.4 Cold-Working and Annealing
11.4 Indigenous Development of Aluminium and Silicon Bronzes for Aerospace
11.5 Summary and Conclusions
Acknowledgments
References
12 Niobium and Other High Temperature Refractory Metals for Aerospace Applications
Abstract
12.1 Introduction
12.2 Niobium Alloys
12.2.1 Nb Alloys and Their Properties
12.2.2 Production Methods for Niobium
12.2.3 Melting and Refining of Niobium and Preparation of Nb-Based Alloys
12.2.4 Processing of Niobium
12.2.5 Applications of Niobium and its Alloys
12.3 Niobium-Silicide Based Composites
12.4 Other Refractory Metals
12.4.1 Tantalum and its Alloys
12.4.2 Molybdenum and Its Alloys
12.4.3 Tungsten and Its Alloys
12.4.4 Rhenium and Its Alloys
12.5 Indian Scenario
12.6 Summary
References
Composites
13 GLARE®: A Versatile Fibre Metal Laminate (FML) Concept
Abstract
13.1 Introduction
13.2 GLARE: A Family of Materials
13.3 GLARE Applications
13.4 GLARE Properties
13.4.1 Damage Tolerance (DT): GLARE Basics
13.4.2 Fatigue Evaluation: The MLB Test
13.4.3 Residual Strength
13.4.4 DT Certification of GLARE
13.4.5 Impact Resistance
13.4.6 Flame Resistance
13.4.7 Corrosion Resistance
13.4.8 Inspections and Repairs
13.5 GLARE and Other Candidates for Primary Aircraft Structures
13.6 Summary
Acknowledgments
References
14 Carbon Fibre Polymer Matrix Structural Composites
Abstract
14.1 Introduction
14.2 Types of Composites
14.3 CFRP Composites
14.3.1 CFRP Composite Matrices
14.3.2 CFRP Composite Fibres
14.3.3 CFRP Aerospace Components Production
14.3.4 Reference Guidelines for CFRP Materials and Processing
14.4 CFRP Properties
14.4.1 Specific Mechanical Properties and Practical Weight Savings and Costs
14.4.2 Impact Damage and Inspections
14.4.3 Repairs of CFRP Structures
14.5 Safety and Damage Tolerance of CFRP Components and Structures
14.5.1 Strength and Safety Definitions
14.5.2 Reduction Factors on Allowables
14.5.3 Testing to Determine Allowables
14.5.4 Damage Tolerance (DT) Allowables
14.5.5 Repair Issues: Validation
14.6 Developments Old and New
14.6.1 3D CFRP Components and Structures
14.6.2 Self-healing CFRPs
14.7 Current Indian Scenario (Contribution Partly by K. Vijaya Raju)
14.7.1 Light Combat Aircraft TEJAS
14.7.2 Light Transport Aircraft SARAS
14.8 Summary
References
Bibliography
15 C/C and C/SiC Composites for Aerospace Applications
Abstract
15.1 Introduction
15.2 Carbon Reinforcements
15.2.1 Carbon Fibre Reinforcements
15.2.2 Other Carbon Reinforcing Materials
15.3 Carbon Fibre Preforms
15.4 C/C Composites Processing
15.4.1 Chemical Vapour Impregnation (CVD/CVI)
15.4.2 Liquid-Phase Impregnation Process
15.5 Properties of C/C Composites
15.5.1 Mechanical Properties of C/C Composites
15.5.2 Thermal Properties of C/C Composites
15.6 Example Applications of Aerospace C/C Composites
15.6.1 C/C Composite Brake Pads
15.6.2 C/C Nozzle and Throat
15.6.3 C/C Combustion Chamber
15.7 C/SiC Composites
15.7.1 C/SiC Fibre/Matrix Interface/Interphase
15.7.2 Oxidation
15.8 C/SiC Composite Processing
15.8.1 Chemical Vapour Impregnation (CVD/CVI)
15.8.2 Polymer Infiltration and Pyrolysis (PIP)
15.8.3 Liquid Silicon Infiltration (LSI)
15.9 Properties of C/SiC Composites
15.10 Applications of Aerospace C/SiC Composites
15.10.1 Thermal Protection Systems (TPS) and Hot Structures for Space Vehicles
15.10.2 Jet-Vanes for Rocket Motors
15.10.3 C/SiC Nozzles and Components for Rocket and Jet Engines
15.10.4 C/SiC Composite Nozzle Throats
15.11 Indian Scenario for C/C and C/SiC Development
15.12 Summary
Acknowledgments
References
16 Ceramic Matrix Composites (CMCs) for Aerospace Applications
Abstract
16.1 Introduction
16.2 CMC Constituents
16.2.1 Ceramic Matrices
16.2.2 Ceramic Reinforcements
16.2.3 Interfaces
16.3 Toughening by Fibre Reinforcement/Crack Bridging
16.4 Processing of CMCs
16.5 CMCs Properties
16.6 Aerospace Applications
16.7 Summary
Acknowledgments
References
17 Nanocomposites Potential for Aero Applications
Abstract
17.1 Introduction
17.2 Metal Matrix Nanocomposites (MMNCs)
17.2.1 Strengthening Mechanisms
17.2.2 Synthesis and Processing
17.2.3 Current Developments in Lightweight MMNCs
17.3 Polymer Matrix Nanocomposites (PMNCs)
17.3.1 Reinforced Strengthening
17.3.2 Fabrication of PMNCs
17.3.3 Current Challenges in PMNCs
17.4 Ceramic Matrix Nanocomposites (CMNCs)
17.4.1 Types of Reinforcement/Strengthening Mechanisms
17.4.2 Fabrication of CMNCs
17.5 Characterization of Nanocomposites
17.6 Future Aerospace Applications
17.7 Conclusions
Acknowledgments
References
Special Materials
18 Monolithic Ceramics for Aerospace Applications
Abstract
18.1 Introduction
18.2 Mechanical Properties
18.2.1 Strength Properties
18.2.2 Fracture Toughness
18.2.3 Thermal Shock Resistance
18.2.4 Creep and Creep Crack Growth
18.2.5 Mechanical Property Improvements via Toughening Micro Mechanisms
18.3 Ultrahigh-Temperature Ceramics for Aerospace Applications
18.3.1 Alumina Ceramics
18.3.2 Zirconia Ceramics
18.3.3 Silicon Nitride Ceramics
18.3.4 Silicon Carbide Ceramics
18.3.5 Molybdenum Disilicide (MoSi2) Ceramics
18.3.6 Carbon Ceramics
18.4 Emerging Monolithic Ceramics for Aerospace Applications
18.4.1 Titanium Boride Ceramics
18.4.2 Zirconium Boride Ceramics
18.5 Indian Scenario
18.6 Summary
Acknowledgments
References
19 Nano-enabled Multifunctional Materials for Aerospace Applications
Abstract
19.1 New Challenges for High Performance Aerospace Materials
19.2 Definitions
19.3 Examples of Functional Materials
19.4 Studies of Functional Materials and Potential Aerospace Applications
19.5 Nanomaterials and Structures for Aerospace: An Overview
19.6 Specific Assessments of Some Nanostructural Materials
19.6.1 Carbon Compounds
19.6.2 Ablative Applications
19.6.3 Sensor Films (Spacecraft)
19.6.4 Superhydrophobic coatings
19.7 Update of Nanofunctional Materials Research
19.8 Summary
Acknowledgments
References
20 MAX Phases: New Class of Carbides and Nitrides for Aerospace Structural Applications
Abstract
20.1 Introduction
20.2 Physical Metallurgy of MAX Phases
20.2.1 Polymorphism of MAX Phases
20.3 Synthesis Procedures
20.3.1 Synthesis of Thin MAX Phases
20.3.2 Synthesis of Bulk MAX Phases
20.3.3 Synthesis of MAX Phases in Commercially Viable Bulk Forms
20.4 Properties of MAX Phases
20.4.1 Physical Properties
20.4.2 Chemical Properties
20.4.3 Mechanical Properties
20.5 Applications
20.6 Summary and Conclusions
Acknowledgments
References
21 Shape Memory Alloys (SMAs) for Aerospace Applications
Abstract
21.1 Introduction
21.2 SME Mechanisms
21.2.1 SMA Behaviour
21.3 SME Alloys
21.3.1 Properties of Commercial SMAs
21.3.2 Ni–Ti Alloy Variants
21.4 Aerospace Applications of SMAs
21.4.1 Overview
21.4.2 Actual and Potential Applications in Aircraft
21.4.3 Applications in Spacecraft
21.5 Concluding Remarks
References
Bibliography
22 Detonation Sprayed Coatings for Aerospace Applications
Abstract
22.1 Introduction
22.2 Detonation Spraying
22.2.1 The Spraying Process
22.2.2 Equipment Characteristics
22.3 DSC Technology Compared with Other Thermal Spray Techniques
22.4 DSC Coating Applications in Aerospace
22.4.1 Tungsten Carbide/Cobalt (WC–Co) Coatings
22.4.2 Modified Tungsten Carbide/Cobalt (WC–Co–Cr) Coatings
22.4.3 Cr3C2–NiCr Coatings
22.4.4 Abradable Coatings
22.4.5 Thermal Barrier Coatings (TBCs)
22.4.6 Coating Refurbishments
22.5 Other Coating Processes
22.6 Summary and Concluding Remarks
Acknowledgments
References
23 Piezoceramic Materials and Devices for Aerospace Applications
Abstract
23.1 Introduction
23.1.1 Origin of Piezoelectricity
23.1.2 Piezoelectric Charge Coefficient (D)
23.1.3 Notation of Axes
23.1.4 Structure of PZT
23.1.5 Piezoelectric Effect—Importance of Poling
23.2 Preparation of Piezoelectric Powders
23.2.1 PZT Materials
23.2.2 PMN Materials
23.2.3 PZT–PMN Materials
23.2.4 PMN–PT Materials
23.3 Fabrication of PZT Devices
23.3.1 Fabrication of Multilayered Stacks
23.3.2 Amplified PZT Actuators
23.3.3 Ring Actuators
23.4 Aerospace Applications of PZT ML Stacks
23.4.1 Shape and Vibration Control
23.4.2 Structural Health Monitoring (SHM)
23.5 Other Applications
23.5.1 Piezo Energy Harvesting
23.5.2 Piezo Fuel Injection Systems
23.6 Conclusions
Acknowledgments
References
24 Stealth Materials and Technology for Airborne Systems
Abstract
24.1 Introduction
24.2 History of Stealth Technology
24.3 Threat Perception and Analysis
24.4 Multispectral Stealth
24.4.1 Visual Stealth
24.4.2 Infrared Stealth
24.4.3 Radar Stealth
24.4.3.1 Radar Cross-Section (RCS)
24.4.3.2 RCS Reduction
24.5 Radar-Absorbing Materials and Structures (RAMS and RAS)
24.5.1 Radar-Absorbing Materials (RAMs)
24.5.2 Classification of RAMS
24.5.2.1 Magnetic Absorbers
24.5.2.2 Dielectric Absorbers
24.5.2.3 Conducting Polymers
24.5.2.4 Nanomaterials
24.5.3 Radar-Absorbing Structures (RAS)
24.6 Plasma Stealth
24.7 Acoustic Stealth
24.8 Counter Stealth
24.9 Currently Available Stealth Aircraft
24.10 Summary
References
25 Paints for Aerospace Applications
Abstract
25.1 Importance of Paints for Aerospace Applications
25.2 Selection of Paint Formulations for Aerospace Applications
25.3 Paint Application Areas in Military Aircraft
25.3.1 Airframes
25.3.2 Radomes
25.3.3 Gear Boxes
25.3.4 Fuel Tanks
25.3.5 Stored Aircraft Weapons
25.4 Special Functional Paints
25.4.1 Camouflage Paint Schemes
25.4.2 Radar Signal Absorbing Paints (RAPs)
25.4.3 Fluorescent Paints
25.4.4 Anti-Skid Paints
25.4.5 Hydrophobic Paints
25.4.6 Infrared (IR) Paints
25.4.7 Intumescent Paints
25.4.8 Miscellaneous Paints
25.5 Properties, Testing and Analysis of Paints
25.5.1 Chemical Analysis
25.6 Ageing of Paints
25.6.1 Outdoor Weathering
25.6.2 Accelerated Weathering
25.7 Airworthiness Certification of Paints
25.8 Volatile Organic Compound (VOC) Regulations
25.9 Paint Monitoring
25.10 Some Important New Developments
25.11 Indian Scenario
25.12 Conclusions
Acknowledgments
References
26 Elastomers and Adhesives for Aerospace Applications
Abstract
26.1 Elastomers
26.1.1 Introduction
26.1.2 Varieties of Elastomers
26.1.3 Elastomer Compounding
26.1.4 Vulcanising
26.1.5 Elastomer Types and Properties [8–10]26.1.6 Elastomer Aerospace Requirements
26.1.7 Aerospace Applications of Elastomers
26.2 Adhesives
26.2.1 Introduction
26.2.2 Advantages of Adhesive Bonding
26.2.3 Mechanisms of Adhesive Bonding
26.2.3.1 Adhesion
26.2.3.2 Adherend surface
26.2.4 Surface Treatment of Substrates
26.2.5 Adhesive Type and Properties
26.2.6 Adhesive Joint Design [47, 48]26.2.7 Aerospace Applications of Adhesives
26.3 Indian Scenario
26.4 Conclusions

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