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Unit 1: The Structure of Matter
Types of materials, natural properties, production methods. The Structure of the atom. Atom arrangement in materials. Atomic bonds. Crystalline and amourphous materials. Crystallization systems and typical examples of materials for each system. Material characteristics determined by their crystallic structure.
Unit 2: Chemical Kinetics and Thermochemistry
Metallographic structure. Disorder spread. Slide line theory. Slide line theory. Bond cleavage. How atom arrangement and bond types affect disorder spread. Defrοst curves. Diffusion.
Unit 3: Identification testing of material mechanical characteristics Ι
Tension: stress and strain, testing machines, elasticity measure, proportional limit, yield point, elastic and plastic deformation, shear tendency, correlation of mechanical and natural characteristics with the metallographic structure. Compression: test execution procedure, compression test case study.
Unit 4: Identification testing of material mechanical characteristics ΙI
Hardness measurement: methods, hardness measurement principles for each method, hardness correlation with yeild point and shear tendency. Fatigue: characteristic magnitudes of repeated loading, correlation of static and dynamic stress, effect of temperature, significance of fatigue test in the identification of aircraft material mechanical characteristics.
Unit 5: Alloys and phase diagrams
Alloy characterization in correlation with the phase diagram. Correlation of defrost curve and phase diagram. Solidification mechanism and creation of granules. Determination of temperature variables phase content with the lever rule. Microdiversity and macrodiversity. Typical phase diagrams of aircraft alloys.
Unit 6: Iron-carbon diagram (Fe-FeC3)
Steel properties, natural, mechanical and metallographic characteristics. Crucial temperatures and Fe-FeC3 content in equilibrium diagram. Ferrite, austenite, pearlite, cementite. Differentiation of mechanical and metallographic characteristics for each phase. Μetallographic structure formation mechanism. Metal hardening techniques. Granule size control. Work hardening. Aging. Phase Phase conversion.
Unit 7: Aircraft Materials – Ferrous 7η
Characteristics, properties and identification of common steel alloys used in aircraft. Hot treatment and application of steel alloys. Ferrous material testing for hardness, strength, tension resistance, fatigue resistance and impact resistance. Steel thermal treatments. Martensite. Quick defrost diagrams - steel staining. Annealing, recrystallization. Steel classification and nomenclature according to their behavior in quick defrost. Stainless steels.
Unit 8: Corrosion
Basic knowledge of chemistry. Galvanic corrosion treatment. Types of corrosion and their identification. Corrosion causes. Material types and their sensitivity to corrosion. Chemical and electrochemical corrosion, oxidation. Protection from corrosion. Non constructive control methods (characteristics of each method , areas of application in aircraft technology).
Unit 9: Aircraft materials – non ferrous
Characteristics, properties and identification of common non ferrous materials used in aircraft. Hot treatment and application of non ferrous materials. Non ferrous material testing for hardness, strength, tension resistance, fatigue resistance and impact resistance. Characteristic properties of aluminum and titanium alloys: commercial names, mechanical and metallographic characteristics, phase diagrams, resistance to corrosion, applications in aircraft technology.
Unit 10: Aircraft Materials – Composite and non metallic
Characteristics, properties and identification of common composite and non metallic materials, excluding wood, used in aircraft. Seam seal. Fault detection in composite materials. Composite material repair. Types of composite materials (matrix material and reinforcement form and material). Mechanical characteristics and matrix ejector. Composite material natural characteristics and corrosion reaction. Composite material stress and their application in aircraft technology. Polymers and ceramic materials. Atom arrangement. Natural and mechanical characteristics. Polyers and ceramic material methods of preparation. Applications in aircraft technology. Resistance to corrosion and mechanical characteristics.
Unit 11: Mechanical materials and equipment
Joints. Screw thread. Screw nomenclature. Types of threads, dimensions and tolerances of standardized threads used in aircraft. Screw thread measurement. Bolts, types of bolts: specification, identification and aircraft bolt marking, international standards. Nuts: self-locking, anchor nuts, standardized. Machine screws: aircraft specifications. Quick set screws: types and uses, insertion and removal. Metal sheet joint screws, guide pins. Safety systems. Βelt washers and spring lock washers, locking plates, rivets. Pal-nuts, safety wire, quick release joints, wrenches, spring locks, safety pins. Aircraft rivets. Types of solid and blind rivets: specifications and identification, hot treatment. Pipes and Connectors. Identification and types of rigid and flexible tubes and their connectors used in aircraft. Springs. Bearings. Classic connectors for hydraulic pipes, fuel pipes, oil pipes, air system pipes and aircraft air system pipes. Spring types, materials, characteristics and applications. The function of bearings, loads, material, structure. Types of bearings and their application. Motion transmission systems. Types of motion transmission systems and their application. Transfer ratio, reduction and multiplication, through motion transmission gear systems, gear boxes, idler gears. Belts, pulleys, chains and gear wheels.
Unit 11: Electrical materials and equipment
Control cables. Cable types. Extreme applications, clamps and compensation devices. Pulleys and cable system components. Curved cables. Flexible aircraft control systems. Εlectric cables and connectors. Types of cables, structure and characteristics. High voltage and coaxial cables. Crimping.
1st Lab Activity: Lathe basic parts
Students should recognize the basic parts of a conventional lathe and describe the protective measures that must be taken while working in the workshop.
2nd Lab Activity: Diameter and thread machining
Students should analyze step by step the procedure that should be followed on a conventional lathe for machining cylindrical surfaces and threads in a steel test specimen.
3rd Lab Activity: Special machining on a lathe
Students should identify the components of a conventional lathe used for machining conical surfaces, asymmetric pieces, spherical surfaces and threads.
4th Lab Activity: Calculation of time required for lathe machining
Students should calculate the machining time required for the formulation of a complex test specimen on a conventional lathe, using the cutting parameters found in commercial catalogues of cutting tools.
5th Lab Activity: Basic parts of a CNC lathe
Students should distinguish the basic parts of CNC lathe and name its technical characteristics against those of a conventional lathe.
6th Lab Activity: Construction design of a simple component on a CNC lathe
Students should name the programming instructions of a CNC lathe and apply them for the creation of a cutting tool drive program in order to construct a simple component.
7th Lab Activity: Construction design of a complex component on a CNC lathe
Students should apply the programming instructions for the creation of a cutting tool drive program in order to construct a complex component on a CNC lathe.
8th Lab Activity : Βasic parts of a milling machine
Students should recognize the basic parts of a conventional milling machine and distinguish its technical characteristics against those of a NCN milling machine. They should also recognize the cutting tools of the milling machine and determine the cutting parameters using relevant commercial catalogues.
9th Lab Activity: Construction design of a simple component on a CNC milling machine
Students should name the programming instructions of a CNC milling machine and apply them for the creation of a cutting tool drive program in order to construct a simple component.
10th Lab Activity: Component design for machining on CNC milling machine, using CAD/CAM software
After a demonstration of component design for machining on a CNC milling machine with the use of CAD/CAM, students should apply the programming instructions for the creation of the cutting tool drive program in order to construct the same component.
11th Lab Activity: Drilling and Grinding machines
Students should recognize the basic parts of a conventional drill and calculate the machining time required for drilling, taking into consideration the cutting parameters. Students should also recognize the basic parts of grinding machines, describe their function and calculate the machining time required for grinding, taking into consideration the cutting parameters.
12th Lab Activity : Writen Examination
Students must answer in writing questions related to topics covered in all lab activities during the semester.
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