Introduction

There are many stages in the manufacture of aircraft structures and engine components using metals, and it begins with the production and casting of the metal alloy. The mechanical properties, corrosion resistance and many other properties that influence the selection and performance of metals in aircraft are determined by their method of production and casting. The production process involves the melting of the base metal, addition of selected alloying elements in carefully controlled concentrations to the molten metal, and then casting of the molten metal into a solid product for subsequent forming and machining into the final aircraft component. The structure and properties of the metal alloys are highly sensitive to the processes used in their production and casting.

We study the processes used to produce and cast metal alloys for aircraft structural components. The making of metal alloys by the addition of alloying elements is described, including the selection and solubility of the elements into the base metal. The key aspects of metal casting are examined, including the process of solidification, the structure and properties of cast metal, the formation of defects and damage which can affect structural performance, and the process methods used to ensure high quality casting. The main methods used to cast metal alloys for aircraft structures and jet engine components are described, including permanent mould casting, pressure die casting, sand casting, investment casting, directional solidification casting, and single crystal casting.