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How do you evaluate aerospace materials for quality?

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Aerospace materials are the building blocks of aircraft, rockets, satellites, and other aerospace systems. They need to meet high standards of quality, performance, and reliability in extreme environments. How do you evaluate aerospace materials for quality? In this article, you will learn about some of the methods and tools that aerospace engineers use to test and inspect aerospace materials.

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1 Material properties

The first step in evaluating aerospace materials is to understand their properties and characteristics. These include physical, mechanical, thermal, electrical, optical, and chemical properties. Some of the common tests that measure these properties are tensile, compression, shear, fatigue, creep, fracture, hardness, corrosion, and conductivity tests. These tests can be done in a laboratory or in the field, using instruments such as load cells, strain gauges, extensometers, thermocouples, spectrometers, and microscopes.

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Brian Klett

The MacGyver of Engineering
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One must never forget the effect of geometrical change solely based on temperature change. Aerospace pushes the limits with an an extraordinary deltaT. Hardness is often misunderstood. Many steels can only achieve the hardness of ~60 HRC reasonably, this is dramatically effected by time at temperature. In an aerospace application this must be considered. You forgot to add piezoelectric sensing (typically accelerometers). When we delve in to polymer engineering the use of Thermal Gravimetric Analysis, Fourier Transform Infrared Spectroscopy, Differential Scanning Calorimetry. Among polymers, one must best select a polymer with a glass transition temperature appropriate to the application.

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Thanos Meletis

Aircraft Maintenance Engineer
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Depend what kind of system they support there are metal ,electrical or electronics, must perform Inspection,testing and confirmation for correct operation and function.

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2 Material defects

The second step in evaluating aerospace materials is to detect and analyze any defects or flaws that may affect their quality and performance. These defects can be caused by manufacturing errors, processing conditions, environmental factors, or service loads. Some of the common defects are cracks, porosity, voids, inclusions, delamination, and deformation. Some of the common methods to detect and analyze these defects are nondestructive testing (NDT) and destructive testing (DT). NDT methods use techniques such as ultrasonic, radiographic, magnetic, eddy current, acoustic emission, and thermographic inspection. DT methods use techniques such as metallographic, chemical, and mechanical analysis.

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Brian Klett

The MacGyver of Engineering
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Never underestimate the value of system resonance. The resonance of a system or component for that matter should remain constant but as wear and tear occur we see a shift. This shift in natural frequency of a particular mode on an airframe is indicative of changes to systems within.

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Paul A. Burke, PhD

Space Physicist at The Johns Hopkins University Applied Physics Laboratory || Faculty at The Johns Hopkins University Whiting School of Engineering
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When testing and evaluating materials using destructive testing, you must be able to characterize the distribution and statistical probability of such defects occurring. Since destructive testing inherently requires you to use a newly manufactured part in the design, you must have high confidence that the testing sample size was large enough to characterize all defects in parts which were not tested.

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3 Material standards

The third step in evaluating aerospace materials is to compare and verify their quality and performance against established standards and specifications. These standards and specifications are developed by organizations such as the American Society for Testing and Materials (ASTM), the International Organization for Standardization (ISO), the Society of Automotive Engineers (SAE), and the Aerospace Industries Association (AIA). They define the requirements, methods, and procedures for testing and inspecting aerospace materials. They also provide guidelines for quality control, quality assurance, and quality management.

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Paul A. Burke, PhD

Space Physicist at The Johns Hopkins University Applied Physics Laboratory || Faculty at The Johns Hopkins University Whiting School of Engineering
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When making the comparison between your results are established standards, you must ensure that the testing methodology used matches exactly. The same material tested in two different ways (3-point bend test vs. 4-point bend test) will yield differing results.

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4 Material selection

The fourth step in evaluating aerospace materials is to select the most suitable and optimal materials for a given aerospace system or application. This step involves considering various factors such as design objectives, functional requirements, operational conditions, cost, availability, and compatibility. Some of the common methods to select aerospace materials are material indices, material screening, material ranking, and material trade-off analysis. These methods use criteria such as strength, stiffness, density, toughness, durability, and thermal expansion.

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5 Material optimization

The fifth step in evaluating aerospace materials is to optimize their quality and performance by modifying their structure, composition, or processing. This step involves using various techniques such as alloying, heat treatment, surface treatment, coating, composite fabrication, additive manufacturing, and nanotechnology. These techniques can enhance or tailor the properties and characteristics of aerospace materials. They can also reduce or eliminate the defects and flaws of aerospace materials.

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Paul A. Burke, PhD

Space Physicist at The Johns Hopkins University Applied Physics Laboratory || Faculty at The Johns Hopkins University Whiting School of Engineering
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Most of material optimization occurs in the manufacturing and treatment phase. This could include heat treatment, cold-hardening, or surface finishing.

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6 Material validation

The sixth and final step in evaluating aerospace materials is to validate their quality and performance by testing and inspecting them in realistic or simulated conditions. This step involves using various facilities such as wind tunnels, test rigs, flight simulators, and launch pads. These facilities can expose the aerospace materials to various loads, stresses, strains, temperatures, pressures, vibrations, and shocks. They can also measure and monitor the response and behavior of the aerospace materials.

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Paul A. Burke, PhD

Space Physicist at The Johns Hopkins University Applied Physics Laboratory || Faculty at The Johns Hopkins University Whiting School of Engineering
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Documentation is of the upmost importance. The validation and verification methodology must be recorded and published. This allows the broader community to discuss and replicate your results.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you evaluate aerospace materials for quality?

1

2

3

4

5

6

7

1 Material properties

2 Material defects

3 Material standards

4 Material selection

5 Material optimization

6 Material validation

7 Here’s what else to consider

Aerospace Engineering

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How do you evaluate aerospace materials for quality?

1

2

3

4

5

6

7

1 Material properties

2 Material defects

3 Material standards

4 Material selection

5 Material optimization

6 Material validation

7 Here’s what else to consider

Aerospace Engineering

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