Chapter 7
Aircraft Materials, Hardware, & Processes
Titanium is nonmagnetic and has an electrical resistance comparable to that of stainless steel. Some of the base alloys of titanium are quite hard. Heat-treating and alloying do not develop the hardness of titanium to the high levels of some of the heat-treated alloys of steel. It was only recently that a heat-treatable titanium alloy was developed. Prior to the development of this alloy, heating and rolling was the only method of forming that could be accomplished. However, it is possible to form the new alloy in the soft condition and heat-treat it for hardness.
Iron, molybdenum, and chromium are used to stabilize titanium and produce alloys that quench-harden and age-harden. The addition of these metals also adds ductility. The fatigue resistance of titanium is greater than that of aluminum or steel.
Titanium becomes softer as the degree of purity is increased. It is not practical to distinguish between the various grades of commercially pure or unalloyed titanium by chemical analysis; therefore, the grades are determined by mechanical properties.
Titanium Designations
The A-B-C classification of titanium alloys was established to provide a convenient and simple means of describing all titanium alloys. Titanium and titanium alloys possess three basic types of crystals: A (alpha), B (beta), and C (combined alpha and beta). Their characteristics are:
- A (alpha)—all-around performance; good weld ability; tough and strong both cold and hot; and resistant to oxidation.
- B (beta)—bendability; excellent bend ductility; strong both cold and hot, but vulnerable to contamination.
- C (combined alpha and beta for compromise performances)—strong when cold and warm, but weak when hot; good bendability; moderate contamination resistance; excellent forge ability.
Titanium is manufactured for commercial use in two basic compositions: commercially-pure titanium and alloyed titanium. A-55 is an example of commercially-pure titanium. It has yield strength of 55,000 to 80,000 psi and is a general-purpose grade for moderate to severe forming. It is sometimes used for nonstructural aircraft parts and for all types of corrosion-resistant applications, such as tubing. Type A-70 titanium is closely related to type A-55 but has yield strength of 70,000 to 95,000 psi. It is used where higher strength is required, and it is specified for many moderately stressed aircraft parts. For many corrosion applications, it is used interchangeably with type A-55. Both type A-55 and type A-70 is weldable.
One of the widely-used titanium base alloys is designated as C-110M. It is used for primary structural members and aircraft skin, has 110,000 psi minimum yield strength, and contains 8 percent manganese.
Type A-110AT is a titanium alloy that contains 5 percent aluminum and 2.5 percent tin. It also has high minimum yield strength at elevated temperatures with the excellent welding characteristics inherent in alpha-type titanium alloys.
Corrosion Characteristics
The corrosion resistance of titanium deserves special mention. The resistance of the metal to corrosion is caused by the formation of a protective surface film of stable oxide or chemi-absorbed oxygen. Film is often produced by the presence of oxygen and oxidizing agents.
Corrosion of titanium is uniform. There is little evidence of pitting or other serious forms of localized attack. Normally, it is not subject to stress corrosion, corrosion fatigue, intergranular corrosion, or galvanic corrosion. Its corrosion resistance is equal or superior to 18-8 stainless steel.
Laboratory tests with acid and saline solutions show titanium polarizes readily. The net effect, in general, is to decrease current flow in galvanic and corrosion cells. Corrosion currents on the surface of titanium and metallic couples are naturally restricted. This partly accounts for good resistance to many chemicals; also, the material may be used with some dissimilar metals with no harmful galvanic effect on either.
Copper and Copper Alloys
Copper is one of the most widely distributed metals. It is the only reddish-colored metal and is second only to silver in electrical conductivity. Its use as a structural material is limited because of its great weight. However, some of its outstanding characteristics, such as its high electrical and heat conductivity, in many cases overbalance the weight factor.
Because it is very malleable and ductile, copper is ideal for making wire. It is corroded by salt water but is not affected by fresh water. The ultimate tensile strength of copper varies greatly. For cast copper, the tensile strength is about 25,000 psi, and when cold rolled or cold drawn, its tensile strength increases to a range of 40,000 to 67,000 psi.
In aircraft, copper is used primarily in the electrical system for bus bars, bonding, and as lock wire.
Beryllium copper is one of the most successful of all the copper base alloys. It is a recently developed alloy containing about 97 percent copper, 2 percent beryllium, and sufficient nickel to increase the percentage of elongation. The most valuable feature of this metal is that the physical properties can be greatly stepped up by heat-treatment, the tensile strength rising from 70,000 psi in the annealed state to 200,000 psi in the heat-treated state. The resistance of beryllium copper to fatigue and wear makes it suitable for diaphragms, precision bearings and bushings, ball cages, and spring washers.
Brass is a copper alloy containing zinc and small amounts of aluminum, iron, lead, manganese, magnesium, nickel, phosphorous, and tin. Brass with a zinc content of 30 to 35 percent is very ductile, but that containing 45 percent has relatively high strength.
Muntz metal is a brass composed of 60 percent copper and 40 percent zinc. It has excellent corrosion-resistant qualities in salt water. Its strength can be increased by heat-treatment. As cast, this metal has an ultimate tensile strength of 50,000 psi, and it can be elongated 18 percent. It is used in making bolts and nuts, as well as parts that come in contact with salt water. Red brass, sometimes termed “bronze” because of its tin content, is used in fuel and oil line fittings. This metal has good casting and finishing properties and machines freely.