AIRCRAFT MATERIALS AND PROCESSES

Course Code: BTA 603 Credit Units: 03

Course Objective:
This course builds up a strong knowledge base of aerospace students in respect of various important materials used in
the manufacture of aircraft including certain salient manufacturing processes that are specific to the aircraft
manufacturing. The course also covers the design principles of jigs and fixtures that are used for manufacturing
various components and assemblies of aircraft so as to ensure symmetry of the geometric shapes and to obtain
accuracy/repeatability in dimensions.

Course Contents:
Module I: Introduction
Properties of flight vehicle materials, Importance of strength/weight ratio of materials for Aerospace Vehicles:
Structures, Importance of temperature variations, factors affecting choice of material for different parts of airplane.

Module II: Light Metal Alloys

Aluminum alloys, Heat treatment, High strength and high corrosion resistant alloys, Magnesium alloys and their
properties, Heat treatment. Application to Aerospace Vehicle of these alloys.

Module III: Aircraft Steels

Classification of alloy steels, Effect of alloying elements, Carbon steels v/s Alloys steels, corrosion resistant steels,
Heat treatment, Corrosion prevention methods, Selection and application of steel alloys to aircraft manufacture.

Module IV: High Strength and Heat Resistant Alloys

Classification of heat resistant materials and iron, Nickel and cobalt base alloys, Refractory materials: Ceramics,
Titanium and its alloys, properties of Inconel, Monal and K-Monal, Nimonic and super alloys: Application to
Aerospace vehicles.

Module V: Metal Joining Processes

Weld ability, Standard welding practices e.g. gas welding, resistance welding. Welding of light alloys, Riveting.

Module VI: Jigs and Fixtures for Aircraft

General design, Method of location of cylindrical and flat surfaces. Design principles of Wing Jig, Fuselage jig and
other components.

Module VII: Aircraft Manufacturing Processes

Profiling, Hydro forming, mar forming bending rolls, Spar milling, Spark erosion and Powered metal parts, integral
machining, Contour etching, High energy rate forming, Manufacturing of honeycomb structures, General methods of
construction of aircraft and aero engine parts.

Examination Scheme:

Components A CT S/V/Q HA EE
Weightage (%) 5 10 8 7 70
CT: Class Test, HA: Home Assignment, S/V/Q: Seminar/Viva/Quiz, EE: End Semester Examination; Att:
Attendance

Text & References:

• Chapman WAJ, “Workshop Technology”, Vol. I, II, III.

• G.F. Titterton, “Aircraft Materials and Processes”, Himalayan Books, New Delhi
• G.B.Ashmead, “Aircraft Production Methods”. :
• Lalit Gupta, “Advanced Composite Matertials”, Himalayan Books, New Delhi,1998