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- a self-explaining title
- method:
i) maximise interactions (with other courses and between students & professor)
ii) understand the basics ⇒ “think metallurgy” vs. “remember & use metallurgy”
(taking the fundamentals for granted)
Structure of the course
Unit 1 - Introduction to the course
Units 2, 3 – Elements of applied physical metallurgy
Unit 4 - Steels for aeronautics
Unit 5 - Elements of fracture mechanics
Unit 6 - Aluminium alloys for aeronautics
Unit 7 - Titanium alloys for aeronautics
Unit 8 - Superalloys for aeronautics
Unit 9 - Notions of mechano-electrochemical corrosion
UNIT 1
Mechanical
be strong, don’t break, stay strong Other functionalities
functional
(piping Chemical
structural
containers (energy storage)
(i.e. explicitly
load bearing) valves) Electrical
strength allied Insulation (Faraday cage)
to lightness trasmission (radio, signal)
i) strength (proof & ultimate σ) control (transduction, actuation)
ii) fatigue strength
iii) not lean to crack formation & propagation
iv) formability
Relevance of metals for aerospace applications
Mechanical
be strong, don’t break, stay strong Other functionalities
functional
(piping Chemical
structural
containers (energy storage)
(i.e. explicitly
load bearing) valves) Electrical
strength allied Insulation (Faraday cage)
to lightness trasmission (radio, signal)
i) strength (proof & ultimate σ) control (transduction, actuation)
ii) fatigue strength
iii) not lean to crack formation & propagation
iv) formability
assembly of grains
atomic
nanoparticle
batteries
Interacting with:
Airframe
Scarselli
Al
composition ⇒
structure/property relationships
properties:
mechanical: static
mechanical: dynamic
chemical
Airframe
Why?
Al
Ti
Why a Ti insert in an Al framework?
Airframe
Del Prete
Al
Why forged? Which Al alloys can be forged?
Airframe Same comments apply for components for the …
Del Prete
Airframe
De Giorgi / Ficarella
Propulsion
Jet Engine Materials
• Higher Operating Temperatures
• Higher Rotational Speeds
• Lower Weight Engine Components
• Longer Operating Lifetime
• Decreased Failure Occurrence
Propulsion
Materials Requirements
• thousands of operating hours at temperatures up to 1,100°C
• high thermal stresses caused by rapid temperature changes and
large temperature gradients
• high mechanical stresses due to high rotational speeds and large
aerodynamic forces
• low- and high-frequency vibrational loading
• oxidation
• corrosion
• time- , temperature- and stress-dependent effects such as creep,
stress rupture, and high- and low-cycle fatigue.
Propulsion
• Fan
disks/blade
• Compressor
disks/blades
Propulsion
Titanium Properties
• Specific gravity of 4.5 ( 58 % that of
steel, 160 % that of Al)
• Titanium alloys can be used up to
temperatures of ~ 590 °C
• Good oxidation/corrosion resistance
• High strength alloys hard to work:
many engine components are cast
Propulsion
• Corrosion/oxidation resistance
• Low Weight
Propulsion
Superalloys
• Nickel (or Cobalt) based materials
• Can be used in load bearing
applications up to 0.8Tm
• High strength /stiffness
• Specific gravity ~8.8 (relatively heavy)
• Over 50% weight of current engines
Propulsion
Typical Compositions of
Superalloys
CHEMICAL COMPOSITION, WEIGHT PERCENT
Ni Cr Co Mo W Ta Cb Al Ti C Zr Hf
ALLOY 713C BAL 12.5 4.2 2.0 6.1 0.8 0.12 0.10
MAR-M 247 BAL 8.2 10.0 0.6 10.0 3.0 5.5 1.0 0.20 0.09 1.5
CMSX - (SC) BAL 8.0 4.6 0.6 8.0 6.0 5.6 1.0 0.1
RENE’ 95 BAL 14.0 8.0 3.5 3.5 3.5 3.5 2.5 0.01 0.05
COMBUSTOR ALLOYS
Microstructure of a Superalloy
• Superalloys are dispersion hardened
• Ni3Al and Ni3Ti
in a Ni matrix
• Particles resist
dislocation motion and
resist growth at high
temperatures
Propulsion
Performance of superalloy
parts enhanced with
thermal barrier coatings
• Thin coating - plasma sprayed
• Ni/Co-Cr-Al-Y coating materials
• Increased corrosion/oxidation
resistance
Propulsion
INCONEL 625
HAST X
HASTELLOY X
INCONEL 625
HASTELLOY X
EQUIAXED MAR-M 247
MAR-M 247
WASPALOY WASPALOY
WASPALOY WASPALOY
WASPALOY
Propulsion: overview of key points of previous slides
Materials Requirements
for jet engines
• thousands of operating hours at temperatures up to 1,100°C
• high thermal stresses caused by rapid temperature changes and
large temperature gradients
• high mechanical stresses due to high rotational speeds and large
aerodynamic forces
• low- and high-frequency vibrational loading
• time- , temperature- and stress-dependent effects such as creep,
stress rupture, and high- and low-cycle fatigue.
• corrosion
Propulsion: overview
High Temperatures - ~1100 °C
• Creep becomes a critical factor when the operating
temperature reaches approximately 0.4 Tm
• Conventional engineering metals at 1100 °C:
» Steel ~0.9 Tm
» Aluminum ~1.4 Tm
» Titanium ~0.7 Tm
Superalloys
• Nickel-based
• Bear load up to 0.8Tm
• Specific gravity ~8.8 (>50% weight of engines)
Propulsion: overview
Terneplate sheets are formed into the shapes needed to construct the tank and
the seams are folded.
Solder is sweated into the seams. This provides a good leak-proof joint and the tanks
are relatively low cost.
The weight of a terneplate tank is more than that of an aluminium alloy tank.
The larger fuel tanks aluminium alloys 3003 (Al-Mn) or 5052 (Al-Mg).
Most wings have large empty spaces, and with the availability of appropriate sealants,
it has become standard practice to seal off a portion of wing to form a fuel tank.
In this case, the tank is made of Al alloys.
Fuel lines and fittings
The metal tubing usually is made of aluminium alloy,
and the flexible hose is made of synthetic rubber or Teflon.
Most of the rigid fuel lines used in an aircraft are made of 5052 (Al-Mg) aluminium alloy,
but in some aircraft the lines that pass through the wheel wells and some of the lines
in the engine compartments are made of stainless steel as insurance against damage
from either abrasion or heat.
CORROSION
COATINGS
COATINGS
Green-aircraft issues
Cr, Cd
ENERGY STORAGE: BATTERIES & SUPERCAPS
ENERGY STORAGE: BATTERIES & SUPERCAPS
Electrical-aircraft projects
NEXT GENERATION: FUEL CELLS
Programmi triennale (Leo / Cavaliere) Leo
CRISTALLOGRAFIA
strutture cristallografiche
sistemi cristallografici o di Bravais-geometrici
A.3) piani e direzioni cristallografiche
A.4) densità lineare, planare, volumetrica, strutture a massimo impacchettamento
sistemi di scorrimento
monocristalli e policristalli (cenni sulle strutture di solidificazione)
Cavaliere
SOLIDIFICAZIONE
CRISTALLOGRAFIA
B.1) Cinetica di cristallizzazione
A.1) Reticoli di Bravais e Celle elementari
B.2) Strutture di solidificazione
2) Sistemi Cristallografici e Reticoli
Difetti di solidificazione
A.2) Reticoli CFC, CCC, EC
(v. Tecnologie Meccaniche)
A.5) Indici di Miller e Miller-Bravais
A9.1) Sistemi di Scorrimento
A9.2) Piani di Scorrimento
Resistenza teorica dei cristalli ideali.
Leo
DIFETTI
A.6) difetti di punto (vacanze di tipo Schotty e Frenkel, atomi interstiziali,
atomi sostituzionali, impurezze e soluzioni solide),
A.8) difetti di superficie (bordi di grano, difetti di impilaggio, twinning e stacking fault).
Cavaliere
DIFETTI
Difetti di punto,
Difetti di linea,
Difetti di superficie,
Movimento ed energia delle dislocazioni,
Difetto di Impilaggio,
Geminati e Bordi di grano.
Leo
A.11) METODI DI RAFFORZAMENTO
per incrudimento
per affinamento del grano
per soluzione solida
per precipitazione
per dispersione
Cavaliere
DIFFUSIONE
A.12) I e II legge di Fick,
A.13) Percorsi diffusivi preferenziali
Meccanismi di ripristino.
Cavaliere
DIAGRAMMI DI STATO
C.1) Diagrammi di Stato binari
C1.1) Trasformazioni eutettica e peritettica
Es. Diagramma Cu-Sn
Es. Diagramma Al-Zn
Es. Diagramma Al-Cu
C.2) Diagrammi Ternari
Es. Diagramma Al-Mg-Cu
Leo
DIAGRAMMA Fe- C
C.5) punti critici
C.6) strutture di equilibrio e loro proprietà
Trasformazioni peritettica, eutettica ed eutettoidica (v. C1.1)
Cavaliere
DIAGRAMMA Fe-C
C.3) Modificazioni allotropiche
C.4) Soluzioni solide di C in Fe
Trasformazione perlitica
Trasformazione bainitica
Trasformazione Martensitica
Leo
Cavaliere
D.2) DIAGRAMMI TTT
Curve di Bain,
D.3) Digrammi TTT di acciai ipo-, iper- ed eutettoidici.
D.4) DIAGRAMMI CCT
D.5) Velocità critica di tempra,
D.6) Temprabilità,
Strutture di non equilibrio.
Leo
Cavaliere
TRATTAMETI TERMICI DEGLI ACCIAI
Ricottura, normalizzazione e tempra
Rivenimento
Trattamenti particolari
Trattamenti termochimici di diffusione
Cavaliere