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Year 12 Engineering 2025 > Module 7 Task 3 > Flashcards

Module 7 Task 3 Flashcards

(54 cards)

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1
Q

What some elements you can alloy with Aluminium?

A

Copper, Silicon, Magnesium, Zinc, Iron, Nickel

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2
Q

How is Fibre metal laminate made?

A

It is created by bonding layers of metal and fibre reinforced polymers to combine the strengths of both materials.

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3
Q

Why is copper alloyed with Aluminium?

A

Copper improves the aluminiums strength and hardness whilst also improving characteristics like machinability, fatigue resistance and creep resistance

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4
Q

Key benefits and properties of Fibre metal laminate?

A
  • String and durable
  • Lightweight
  • Fire resistant
  • Impact resistant
  • Fatigue resistant
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5
Q

In which industries is Fibre metal laminate used?

A
  • Aerospace industry
  • Automotive industry
  • Medical applications
  • industrial sectors
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6
Q

Where is Aluminium copper used in Aircrafts?

A

It is primary used in components such as fuselage skin, flaps, wings, or the landing gear.

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7
Q

What are some specific applications of fibre Metal Laminate?

A
  • Aircraft Fuselage
  • Automotive body panels
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8
Q

Why is Fibre Metal laminate suitable for high-performance environments?

A

Because it has a high fatigue resistance and can withstand high temperatures.

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9
Q

What are some physical properties of the 2000 series Aluminium?

A

High tensile strength, resistance to crack formation, poorer corrosion resistance due to addition of copper, alluminium alloys are good conductors of electricity, a high strength to weight ratio which is important due to the pressure differences an aircraft faces.

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10
Q

What are the changes in the macrostructure in Fibre Metal Laminate?

A

The macrostructure of Fibre Metal Laminate changes by forming layered metal and fibre-reinforced polymer sheets, creating strong interfaces, directional strength, and improved damage resistance.

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11
Q

How does alloying copper with Aluminium change the macrostructure of the material?

A

The grain is changed in size and shape, as copper influences the solidification of behaviours. Heat treatments to combine the materials also change the micro and macrostructure of the material.

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12
Q

What are the changes in the microstructure in Fibre Metal Laminate?

A

It Changes in the number and diameter of formed dimples in the aluminum skins.

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13
Q

What heat treatment does 2000 Series aluminium (aluminium copper) undergo?

A

It goes through:
- a solution: heating of an material to allow alloying material to dissolve into the aluminium matrix (copper)
- Quenching: the rapid cooling of the alloy by plunging it into water, preventing precipitating deformation
- annealing: softens the alloy, reducing hardness, increasing ductility
- Homogenizing: reduce segregation of alloying elements

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14
Q

Why is strength enhanced in Fibre Metal Laminate?

A

The incorporation of carbon fibre, which has a high tensile strength.

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15
Q

How do Fibre Metal Laminate’s compare to other metal alloys?

A
  • Better fatigue resistance
  • Improved impact performance
  • Higher specific strength
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16
Q

What are the positive effects of heat treatment on Fibre metal laminates?

A
  • Enhanced mechanical properties
  • Improved formality
  • Increased plasticity
  • Greater fracture toughness
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17
Q

What are the negative effects of heat treatment for Fibre metal laminates?

A
  • Risk of layers separating
  • Reduced stiffness
  • Decreased mechanical properties
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18
Q

What factors can cause changes in the macrostructures of fiberglass?

A

Aging, environmental expose, and material processing

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19
Q

What are potential consequences of macrostructural changes in compositites?

A
  • Failure of bonding
  • dimensional changes
  • interfacial zone changes
  • increased porosity
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20
Q

What is Carbon fibre made of? And how thin are the fibres? and what are they embedded in?

A

Carbon Fibre is an extremely thin carbon atoms formed into strands that are 5-10 microns in diameter. These strands are embedded into a polymer resin matrix such as epoxy.

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21
Q

What roles do the fibres and the matrix play in carbon fibre composites?

A

The carbon fibres provide strength and stiffness, while the matrix binds the fibres together, transfers loads, and protects them from environmental damage.

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22
Q

What defines a well-manufactured composite at the microstructural level?

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A

Even fibre distribution and consistent fibre orientation

23
Q

List some key applications of carbon fibre.

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A

Aerospace industry, automotive (Formula 1, supercars, hypercars), sports equipment, construction, and medical fields.

24
Q

what are two common types of fibre orientation in composite microstructures?

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A

unidirectional and woven

25
What forming processes are used to form Reinforced Fibre Glass
- the melting and extrusion of the glass fibers and resin
26
Where are Reinforced glass Fibres used in aircrafts?
they are used in load-bearing components; - wing - tail - vertical stabilizers aswell as interior components - flooring - airducts - other cabin components
27
Why is carbon fibre considered to have a great weight-strength ratio?
Because it is stronger than steel but significantly lighter.
28
What does it mean that carbon fibre is anisotropic?
It means the fibres are aligned in specific directions, making it very strong along the fibre direction but weaker across the fibre.
29
What does the macrostructure of carbon fibre depend on?
Fibre orientation, such as unidirectional or woven fabric layouts.
30
What is kevlar?
a light weight and strong synthetic polymer. It is a weaved material that is 5 times stronger than steel, with high tensile strength. It is made of a chemical compound made of carbon, oxygen, nitrogen and chlorine atoms. This mixture is spun into fibres or strands
31
What does the Microstructure change in Carbon Fibre?
Changes in fibre content, matrix compositions, voids, or delamination. Defects or resin – rich areas can cause localised weakness.
32
What happens to mechanical properties when matrix degradation and voids occur?
There is a loss of load transfer efficiency and a reduction in mechanical strength.
33
How does damage affect carbon fibre materials?
It causes a significant reduction in toughness and residual strength.
34
What is one primary effects of heat treatment on carbon fibre?
It can increase the carbon fibers strength and stiffness by improving the carbon crystallinity.
35
How is Kevlar formed? And what are the benefits of this process?
Intermolecular hydrogen bonding, creates a strong structure, with the fibres aligning parallel to eachother such that the tensile strength is so high. Alternatively Kevlar lacks certina properties a hybrid composite can be made, in which it is bonded to another material e.g. Carbon fiber
36
How does heat treatment affect the microstructure of carbon fibers?
It helps reduce defects and impurities, leading to improved fiber quality
37
How does heat treatment influence the fiber-matrix interface?
It can improve bonding between the fiber and matrix, enhancing composite mechanical properties.
38
What is Aluminium silicone?
It is a group of lightweight, high-strength materials forms by combing aluminium and silicon.
39
What is the structure of Aluminium Silicone?
The structure mainly depends on the silicon content and cooling rate during solidification.
40
Describe the microstructure of hypoeutectic Al-Si alloys (Si < 12.6%).
Coarse or fine aluminum grains depending on cooling rate and grain refiners.
41
What are the general properties of Al-Si alloys?
Light-weight, moderate strength, corrosion resistant, good machinability, and increased fluidity of aluminum.
42
What is the microstructure and macrostructure of Kevlar?
Microstructure - crystalline polymer chains (rigid and rod-like because of parallel arrangement) Macrostructure - Consists of long continuous rigid threads that can be turned into more workable forms e.g. (woven into fabrics, layered into composites nd stacked into laminated plates)
43
What are common applications of Al-Si alloys?
Used in plane components such as fuselage, gearbox, engine parts, and landing gear.
44
What mainly influences the structure of aluminium silicon, are the changes in the aluminium silicone Macrostructure?
The silicon content and cooling rate during solidification. Controlled by cooling rate during casting. Slow cooling → coarse grains and larger silicon particles. Fast cooling → fine grains, more uniform structure.
45
What are the changes in the properties of Kevlar? and why do they happen?
The changes in properties are due to the composition and crystalline structure and it can be heated up to 500 degrees Celsius unlike steel.
46
What are the changes in the aluminium silicone Microstructure?
Contains primary aluminum dendrites and silicon particles. Heat treatment makes silicon particles finer and rounded. Grain refiners produce finer aluminum grains, enhancing toughnessDiagram of a diagram of a liquid Diagram of a diagram of a liquid
47
How does silicon affect the fluidity of aluminium-silicon alloys?
Silicon increases fluidity, making the alloy easier to cast into complex shapes.
48
What is Aluminium Silicon magnesium
a hardenable alloy, also known as 6000 series alluminium. through the process of heat treatmeants it can become harder.
49
What are the benefits of aluminium-silicon alloys regarding weight and density?
They have lower weight and density, making them ideal for lightweight applications.
50
What are physical properties of Aluminium Silicon Magnesium
- medium to high strength - high fracture resistance - good welding suitability - corrosion resistance - good formability
51
How and Where is 6000 series aluminium and Kevlar used in aircrafts?
6000 series is used in wrought form and as a casting alloy applications: - Airframe brackets - engine housings - landing gear doors - interior structural panels - Avionics casings
52
Describe the microstructure and macrostructure of Aluminium Silicon Magnesium
6000 series is Eutectic at 13.9% and 594 degrees celsius. The matrix has an extremely high strength to weight riatio as the silicon allows for the machinability of the material to be improved and the magnesium allows for a higher strength.
53
What heat treatment is used in the alloying of Aluminium Silicon and Magnesium?
Precipitation hardening which involves the formation and growh of finegrained particles within the matrix of th original alloy. Precipitation hardening, involves the heating of an alloy to a set of prescribed temperatures over intervals of time. This time temperature profile is unique to specific alloys.
54
What are the effects of precipitation hardening for 6000 series aluminium?
increases the maximum stress a material can undergo without deforming plastically (yield strength), and improves corrosion resistance or the original alloy.

Year 12 Engineering 2025 (10 decks)

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