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The materials used in aircraft should posses properties, which permit them to perform the intended functions successfully, while in use. The objective is to achieve complete structural integrity at minimum structural weight and minimum cost. Modern high-speed aircrafts demand:
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Highest safety Reliability of performance Complete structural control Minimum structural weight and Minimum cost
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In aircraft manufacturing unique application of

Metallic materials
Non-metallic materials and Composites are employed.

Hence, aircraft materials should posses Quality Highest importance. Materials free from internal defects and gases. Measured by cleanliness and soundness. Structural efficiency Ratio of strength weight/density, UTS, YS, %E, %RA. to

Fatigue strength Resistance to cyclic loads. Materials should posses high endurance limit to take full advantage of ultimate strength.
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 Fracture toughness Resistance to formation and crack propagation. materials are required.

crack Tough

Corrosion resistance High resistance to general corrosion and stress corrosion. Materials which can with stand service conditions Materials should withstand rapid and gradual changes in climatic, static and dynamic loads without affecting physical and mechanical properties. Cost of material and fabrication Lower initial cost, easy availability, economical to fabricate, durable and minimum overall cost.

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Metallic materials find the highest application in construction of airframes.

MiG-27 Aluminium alloys% Ferrous alloys % Magnesium alloys % Titanium alloys % Others % 52.0 43.5 2.8 1.0 0.7 MiG-29 53.5 31.5 1.0 9.0 5.0 SU-30 61.5 15.0 2.2 18.1 3.2

Metallic materials are classified into WROUGHT ALLOYS CAST ALLOYS AND POWDER 2-Feb-14 METALS.
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WROUGHT ALLOYS can be processed to any desired shapes by cold or hot working methods. Sheets, rods, extrusions, profiles, forgings are example. They posses good workability in hot and cold condition. Desired mechanical properties can be achieved by suitable heat treatment. Highly stressed components are fabricated by using wrought alloys.
CAST ALLOYS have good cast ability. Hence, intricate shapes can be made. In case of investment castings minimum or no machining is required. Castings can also be heat treated to achieve desired mechanical properties. Considerable numbers of castings are used in airframes.

POWDER METAL products like brake pads, carbon brush, and sintered parts are produced when the alloys are difficult to melt by conventional process and when conventional methods are not possible.
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AEROSPACE MATERIAL STANDARDS RUSSIA INDIA UK GOST GOsudarstvennyj STandartov IS DTD Indian Standards Directorate of Materials research and Development

BS
US

British Standards Institute

(Aerospace Series)

AMS Aerospace Material Specification ASM American Society for Metals AISI American Iron and Steel Institute

GERMAN FRANCE

DIN

Deutsches Institut Fur Normung

AFNOR Aerospatiale Technical Management standard AIR French Air ministry Standard
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MIL

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Army, Navy & Air force Military standards

METALLIC materials, based on chemistry are classified as FERROUS ALLOYS and NON- FERROUS ALLOYS. NOTATION FOR FERROUS ALLOYS

Russian
Y C X H M

English
U G S KH N M

Element
Carbon Manganese Silicon Chromium Nickel

Russian English Element

T K T D K YU F V Titanium Copper Cobalt Aluminium Vanadium Tungsten

Molybdenum B

Beginning with: S-steel, SH- bearing

2-Feb-14 Ending with: A-high quality, SSH- ESR Quality, GK- hot rolled 9

FERROUS ALLOYS have high load bearing capacity. Alloy of iron and carbon is called steel and is a ferrous alloy. Addition of elements like chromium, manganese, silicon, nickel, titanium, molybdenum, etc. makes alloy steels.
Ferrous alloys are further classifies as CARBON STEELS Low Carbon Steel %C 0.10-0.30 S10, S20, A12, A20, A30 Medium Carbon Steel % C 0.30-0.70 S45, S50, S70 High Carbon Steel % C 0.70-2.0 U7, U8, U9A These are used as machined components, fasteners, clamps, brackets, pins, rivets, sheet springs, Lever.
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 ALLOY STEELS
MEDIUM ALLOY. Alloying elements <10 percentage * Excellent static and dynamic strength. Good weld ability. Chromansil steel 30KHGSA for welded and machined parts, air bottles, structural parts, standard parts, eye bolts, cylinders, stay rods. Chromansil with nickel 30KHGSN2A-VD Landing gear, high strength parts and bolts. 40KHN2SVA (AE643) u/c brace bolt, wing shaft pin. Spring steels 50KHFA, 65S2VA flat and helical springs, AFU & after burner springs. Steel fasteners 16KHSN, 20G2A rivets, screws, anchor nuts, nuts, 40 KH for crank shaft, 12KHN4A for gears, shafts, pins, axles Bearing steel SH KH15 for bearings,
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HIGH ALLOY Alloying elements > 10percentage * these are corrosion resistant and heat resistant steels and are called stainless steels. Classified further as AUSTENITIC,

FERRITIC and
MARTENSITIC STAINLESS STEELS. AUSTENITIC (high % Cr & Ni) are non-magnetic, ductile, can be cold formed. High corrosion resistance. Hardened by cold working only. Ex: 12KH18N10T Engine shrouds, ss pipes, ss standard parts, ss locking wires, ss balls, clamps, straps. KHN38VT (AE703) tail cone,

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FERRITIC (12 to 14% Cr) are of low nickel and extremely low carbon content. Magnetic, ductile, cold formable, heat resistant and non-heat treatable. 08KH13, 13KH13 axle, bush 10KH12SYU, 10KH17NT bearing MARTENSITIC steels are resistant and heat treatable. magnetic, corrosion

20KH13, 14KH17N2 are used for bolts, nuts and valves. VNS2 (08KH15N5D2T) used for welded tanks, gun chute, frames, profiles EP310(VNS5)(13KH15N4AM3) 06KH14N6D2MBT are used in SU30 FERROUS CAST ALLOYS: 45L, 35KHGSL for bushes NLG link, door bracket and VNL-3 (08KH14N5M2D) for tie pieces and coupling of air intake channel.
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fuel

NON-FERROUS ALLOYS
NOTATION FOR NON FERROUS ALLOYS
RUSSIAN ENGLISH ELEMENT RUSSIAN ENGLISH ELEMENT

A M C M

A M S MTS

Aluminium Copper Lead Manganese

H M

B ZH N MG

Beryllium Iron Nickel Magnesium

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O
TSH

Tin
Zinc

K
X

K
KH

Silicon
Chromium
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ALUMINIUM BASE ALLOYS

Aluminium base alloys are major airframe material. High strength to weight ratio, easy to fabricate, available in various desired shapes, reasonably good corrosion resistance and weld ability, high electrical conductivity and high thermal conductivity are advantages of these alloys.

HEAT TREATABLE ALUMINIUM ALLOYS

DURALUMIN (Al-Cu-Mg) D1, D16, D19, D20, used for skin, body, rivets, tank 1 profile, stabilizer panels. D16 & D19 are not weld able, D20 is weld able, and D19P is for heat resistant rivets. Sheets of D16 and D19 are protected from corrosion by cladding with pure Aluminium. Other products are protected by anodizing and painting.
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HIGH STRENGTH ALLOY (Al-Zn-Cu-Mg) V93, V95 used for aircraft structural parts like wing spar, under carriage beam, ejection seat rails, wing panels, engine mounting bkt, flap bkt, bell cranks. ALUMINIUM FORGING ALLOY (Al-Cu-Mg-Fe-Ni) AK4, AK4-1, (Al-Si-Mg) AK6, AK8 use as bell cranks, piston forgings, crankcases, wheel hub, NLG bkt. ALUMINUM-LITHIUM ALLOYS 01420 for fairing, profiles and skin sheets (Li 1.5-2.6, Mg 4.0-7.0, Mn 0.24-0.4, Ti 0.1-0.2%)

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NON-HEAT TREATABLE ALLOYS

These are of low strength. Mechanical properties cannot be improved by heat treatment. Excellent for weld able structures. Magnalium (Al-Mg) AMG2, AMG3, AMG5, AMG5P, AMG6 Finds application in drop tanks, oil pipe lines, hydraulic tanks, AMG2N is used as honeycomb foils inside control surface parts. Cast alloys AL19 (Al-Cu-Mn-Ti) for parts working at 1753000C, impeller pump housing. (HT) AL9 (Al-Si-Mg) complicated shaped castings, control stick handle body (NHT) VAL10 2-Feb-14 (HT). cranks. (Al-Cu-Mg-Be) ejection seat parts, bell
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MAGNESIUM BASE ALLOYS

Lightest engineering alloy used in airframe with strength of 20 to 35 kg/mm2. Poor corrosion resistance, poor toughness, high notch sensitivity in fatigue. Magnesium alloys are potential weight saver in airframes. Principal alloying elements are Aluminium, zinc and manganese. Corrosion resistance can be improved by surface oxidation treatment.

MA8 (Mn2-Ce0.2) for frames, floor beams and trim tabs, profiles, cover skins.
BM65-1 (Zn5-Zr0.5) for flap bracket ML5 (Al8MnBeZn) for leading edges, LG hubs, Control column body, wheel flange, leading edge.

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TITANIUM ALLOYS
High mechanical properties (50 to 90 kg/mm2 UTS) , low specific weight (4.5 gm/cm3), outstanding corrosion resistance and oxidation resistance up to 5000C have made titanium alloys increased use in air frames. Corrosion resistance of the alloys are reasonably good, especially in seawater and against crevice attack. OT4-1 (Ti-2.5Al-1.5Mn) tail cone, drag chute door VT22 (Ti-5Al-1Cu-5Mo-5V) hydraulic tanks special

VT5-1 (4-5.5Al-2-3Sn) Skin frames, guide units of compressor body

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COPPER AND COPPER ALLOYS

Copper alloys have high thermal and electrical conductivity, high corrosion resistance and high ductility. M1 (Cu99.9percentage), M2(Cu99.7percentage), M3 (Cu99.5percentage) are pure copper used in packing, sealing rings, washers, rivets, fuel connecting pipes. Brass, an alloy of copper with zinc is used for screws, pins, nozzles, bushes, elbows and slide blocks. Notable are L63 (Cu60.5-63.5 Zn rest) and LS59-1(Cu57-60, Pb0.8-1.9, Zn rest)
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 Bronzes are alloys of copper with Aluminium (Al bronze), Nickel (Ni bronze), Manganese (Mn bronze), Beryllium (Be bronze), Titanium (Ti bronze) Aluminium bronze grade BrAZHN 10-4-4 and BrAZHMTS 10-3-1.5 are used as antifriction bearing bushes in under carriage, flywheels, and nipples. The alloy is corrosion, shock and fatigue resistant. Beryllium bronze BrB2 is used as leaf springs, spring contacts, bellows, and radiator tubes.

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COMPOSITE MATERIALS
Bonded sandwich construction, honey comb construction, provide light weight, thick sections and are used in control surfaces of aircraft like wing flaps, stabilizers, ailerons and rudder. Honeycomb structure consists of a thick low-density core of Aluminium alloy foil, AMG2N 0.030mm thickness and made up of countless number of cells with close resemblance to a bee honeycomb. The core is bonded to the skin of duralumin D16/D19 called facing sheets by structural adhesives like redux or epoxy. Sandwich structures provide extremely lightweight and strong panels. They have properties like vibration damping, thermal and acoustic insulation.
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