Aerospace Materials II

Aerospace Materials II (251 - 15338)
Study: Bachelor in Aerospace Engineering
Semester 2/Spring Semester
2ND Year Course/Lower Division

*Considered lower division; however, please note the prerequisite.

PREREQUISITES:
Students are expected to have completed:
Aerospace Materials I

Competences and skills that will be acquired and learning results:

To understand the structure, composition, processing, properties and performance of different families of metallic materials used in aerospace and relationship among them.
To be able to select metallic materials for applications in different aerospace engineering fields.
To know the more adequate standardized tests to evaluate properties and performance of metallic materials, and to analyze the results.
Regarding general capabilities or skills, during the year, students will acquire the following abilities:
- Ability to solve complex problems.
- Ability to look for, to understand and to differentiate the relevant information to be able to take a decision.
- Ability to use multi-disciplinary knowledge to solve a problem.
- Ability to work in groups and distribute work to face up to complex problems.

Description of contents:

- Solidification of Metals. Generation of the Microstructure. Metal Casting Processes. Cast Structures
Defects in Castings.
- Metal forming processes. Work hardening. Recovery, Recrystallization and Grain Growth. Effect of metal forming processes on properties and microstructure. Formability.
-Phase Diagrams. Invariant Reactions. Influence of alloying elements. Equilibrium phase transformation.
- Non-equilibrium phase transformations. TTT diagrams: ITT and CCT. Heat Treatments: Quenching, Tempering, Annealing, Normalizing. Hardenability
-Introduction to Fracture. Types of Fracture. Fracture modes. Fracture mechanics. Stress concentration. Griffiths theory. Stress intensity factor. Fracture toughness and Impact test. Brittle Ductile transition.
- Introduction to Fatigue. High cycle fatigue. Low cycle fatigue. Effect of variable cycles. Fatigue crack growth.Structural features of fatigue. Designing against fatigue failure
-Creep. Creep curve. Effect of stress and temperature on creep. Creep stages. Creep design and life prediction. Developing creep-resistant materials.
- Corrosion. Basic electrochemical corrosion. Types of corrosion. Corrosion control and prevention. High temperature corrosion.
- Friction. Wear. Friction and wear tests. Lubricants. Wear and friction in metal-working processes. Materials selection for tribological system.
- Designation of Aluminium Alloys. Heat treatable aluminium alloys. Non heat treatable aluminium alloy. Applications of Al alloys in aerospace. Mg alloys.
- Designation of Titanium alloys. Properties of Ti alloys. Heat Treatments for Ti alloys. Applications.
- Ultra high strength steels. PH stainless steels. Maraging Steels.
- Ni-based alloys and superalloys. Properties and applications.
- Intermetallics in aerospace. Properties and applications.
- Main surface treatments: Galvanizing; Electrodepostion; Organic Coatings; CVD; PVD: Thermal Spraying. Thermochemical Treatments. Thermal Barrier Coatings.
- Introduction to joining processes. Welding. Welding processes for aerospace applications.
- Common NDT method. Visual Inspection. Liquid Penetrants. Magnetic Particle. Eddy Current. Radiographic. Ultrasonic Acoustic Emissions. Method comparison.

Learning activities and methodology:

-The course will consist of Master Classes where the theory of the topics will be presented and Tutorial Classes where applications and examples will be emphasized and problems exercises will be solved
- There will be tutorial sessions for the students
- There will be 6 hours of practical laboratory work of compulsory assistance. The laboratory sessions will result in the acquisition of practical abilities related to the content of the course
- All the teaching material (lecture notes, handouts, exercises and problems, laboratory manual and additional material) will be distributed to the students through aula global

Assessment System:

Continuous evaluation will consist of two parts:
(i)exercises and tests to be solved in groups or individually, during classes, or other activities (at least 3 activities) that will count 30% of the total mark.
(ii)laboratory practices, that will be assessed with a questionnaire that will be handed in at the end of each laboratory session, and that will count 10% of the total mark.
Percentage of continuous evaluation assessment (exercises, tests, laboratory): 40
-The final examination is will count for 60% of the total mark of the lecture course. Help sessions and tutorial classes will be held prior to the final exam.
Percentage of end-of-term-examination: 60
Minimum mark for end-of-term-examination: 5
In order to pass, the final mark must be at least 5.

Basic Bibliography:

Adrian P. Mouritz. Introduction to aerospace materials . Woodhead publishing. 2012
CALLISTER WD. Materials science and engineering: an introduction. John Wiley & Sons. 2003
Campbell, F.C.. Manufacturing technology for aerospace structural materials . Elsevier. 2006
Donachie, Matthew J. Superalloys : a technical guide. American Society Metals. 2002
Kalpakjian, S.Addison. Manufacturing Engineering and Technology. Wesley Publishing. 1992
Polmear, I.J. Light alloys : from traditional alloys to nanocrystals . Elsevier/Butterworth-Heinemann. 2006