AER330

Department Of
Materials
Science &
Engineering.

CANDIDATES ARE ADVISED TO READ THROUGH THE

INSTRUCTIONS GIVEN ON THIS PAGE CAREFULLY BEFORE
ATTEMPTING ANY QUESTIONS

AEROSPACE METALS

Autumn Semester (1) Exam 2017-2018

Duration of Exam: 2 hours

There are FIVE questions

Answer THREE questions ONLY

PLEASE WRITE YOUR ANSWERS IN THE ANSWER BOOK

PROVIDED NOT ON THE EXAM PAPER. ANYTHING WRITTEN ON
THIS PAPER WILL NOT BE CONSIDERED.
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There are FIVE questions

Answer THREE questions ONLY

1. (a) What is the process route to produce the Al-Li AA8090 T6 components for the
Merlin helicopter from melt? Which is the additional step in the processing route
compared to 2XXX and 7XXX series alloys? What two equilibrium precipitates are
formed in AA8090? (Hint: AA8090 contains Cu and Mg also). [5 marks]

(b) Compare and contrast the “minimum usable gauge” and density for both an Al-Li
alloy panel and a polymeric matrix composite panel. [3 marks]

(c) Sketch and label the phases that would form after direct chill (DC) casting of a
binary Al-4 wt.% Cu alloy. Sketch the concentration profile of copper in the alpha
grains. [3 marks]

(d) Which impurities are always found in aluminium alloys? Sketch the effect of
reduced amounts of such impurities on the strength vs. fracture toughness
relationship. [3 marks]

(e) The Boeing 787 Dreamliner has more than double the amount of titanium, in weight
percent, than that used on previous generations of Boeing aircraft. Give three
reasons why this is so.
[Hint: largely a carbon fibre reinforced composite fuselage and wing structure]
[3 marks]

(f) Rank the following light alloys in order of tensile strength, from high to low: (i)
Al7475 T73 condition; (ii) Al2024 T6 condition; (iii) Al2024 T4 condition; (iv) Ti-
10V-2Fe-3Al solution treated and aged; and (v) Ti-6Al-4V solution treated and
aged. State also how they would rank with respect to specific strength. [3 marks]

2. (a) Sketch and label a pseudo binary phase diagram for titanium alloys showing the
effect of alpha and beta stabilisers on phase boundaries. Indicate the divisions
between the five different classes of alloys and the martensitic start/finish line.
[4 marks]

(b) Describe the full processing route - from the Kroll Process through to machining of a
Rolls-Royce aero-engine compressor disk - for a near alpha titanium alloy such as
Ti-834. [10 marks]

(c) Describe, with the aid of sketches, the most desirable microstructure for optimum
properties for creep and fatigue resistance and how this would be generated during
the final forging/heat treatment stages with respect to the beta transus temperature.
[6 marks]

TURN OVER

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3. (a) What aluminium alloy class is normally used to make fire extinguishers? Hint: The
primary process of manufacture is cold extrusion. Post extrusion, what processing
steps would need to be taken to generate medium to high strength in the cylinder?
[2 marks]

(b) What aluminium alloy class is used to make drinks cans? How is such an alloy class
strengthened? [2 marks]

(c) Over the last couple of years, high performance cars such as the Jaguar XJ and Audi
A8 are employing aluminium in the chassis and superstructure:

i. In such high performance cars, what alloy class is predominantly used for the
sheet panels? What are the major alloy addition(s)? What is the major
strengthening mechanism? [3 marks]

ii. In such high performance cars, what alloy class is used for the predominantly
extruded components? What is the major alloy addition(s)? and what is the
major strengthening mechanism? [3 marks]

(d) i. Briefly compare the microstructure and pore morphology of plasma spray
deposited and EB-PVD (electron beam physical vapour deposition) deposited
YSZ (yttria stabilised zirconia) coatings.
(Hint: remember to comment on (a) how the microstructures are formed and (b)
the compliance and thermal conductivity of the coatings)
[5 marks]
ii. Explain with reasons any approach(es) that you would consider to improve the
creep resistance of Ni superalloys used in high pressure turbine blades.
[5 marks]

CONTINUED

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4. (a) The alloying (i.e. solute) additions in Ni based superalloys are often referred to as
belonging to the following five groups:

i. solid solution strengtheners (or elements that partition to gamma, γ);

ii. gamma prime, γ′ formers (or elements that partition to γ′);
iii. carbide formers;
iv. surface stabilisers; and
v. topologically close packed (TCP) phase formers.

The compositions of two single crystal alloys (TMS-138A and CMSX-11) and the
disc alloy (RR1000) are given below. Categorise the solute elements in each alloy
according to groups (i) to (v).

TMS-138A: Ni-5.8Co-3.2Cr-2.9Mo-5.6W-5.7Al-5.6Ta-5.8Re-3.6Ru-0.1Hf
CMSX-11: Ni-3Co-14.9Cr-0.4Mo-4.5W-3.4Al-4.2Ti-4.5Ta-0.04Hf
RR1000: Ni-18.5Co-15Cr-5Mo-3Al-3.8Ti-2Ta-0.5Hf-0.03C-0.02B-0.06Zr

(Hint: when categorising the solute elements notice that some elements are not
present in all three alloys) [5 marks]

Discuss why the Cr, Co and Mo contents of the two single crystal alloys are
different, and why the alloying elements B, C and Zr are added in RR1000 but not
in the two single crystal alloys. [3 marks]

(b) Bond coat alloys used in coating systems for Ni based superalloys can be of the
MCrAlY-X type where M = Co, Ni and X = Hf, Re, Si, Ta.
Why are Al, Cr and Y used and what are their typical concentrations in the bond
coat? [4 marks]

What is the role of each of the X elements in the bond coat? [4 marks]

(c) Draw the Ni rich part of the Ni-Al binary phase diagram to show:

i. the γ and γ+γ′ phase fields; and

ii. the γ′ solvus line [1 mark]
Use this diagram to describe a typical heat treatment for Ni based superalloys.
(Hint: remember to discuss the precipitation of γ′ and the importance of the γ/γ′
interface free energy on the nucleation of γ′) [3 marks]

TURN OVER

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5. (a) Give the crystal structures of the matrix γ (or gamma Niss = nickel solid solution)
and Ni3Al (gamma prime, γ′) in Ni based alloys and define the lattice misfit
parameter δ (delta).

What causes the lattice misfit parameter δ to change in Ni superalloys? [4 marks]

(b) The steady state creep rate for power law creep is given by the equation:

έSS = A σn exp(-Q/RT),

Explain the meaning of the terms, and discuss the implications for the selection of
alloying elements for improving steady state creep, paying particular attention to the
parameter Q. [4 marks]

(c) Consider a coating system on a Ni based superalloy consisting of bond coat,

thermally grown oxide and top coat. Discuss the microstructure and property
requirements for each component. [6 marks]

(d) Briefly discuss the heat treatment of Ni superalloy based disc alloys to produce dual
microstructure and then give the advantages and disadvantages of fine and coarse
microstructures for turbine discs. [6 marks]

END OF QUESTION PAPER

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