New approach to flying high

Aerospace plastics production have recorded rapid growth in the past few years as a result of increasing use of such key products in this market that include carbon fbre reinforced plastic (CFRP), glass reinforced plastic (GRP) and aramid reinforced plastic (ARP).

Carbon fibres, in particular, are preferred material for various industrial applications. According to the report by ResearchandMarkets, the global market for carbon fibres and carbon fbre composites is mainly driven by the wind energy, aerospace and defense, as well as sports and leisure sectors. Global demand alone for CFRP is projected to rise annually by as much as 15% to reach 210,000 MT by 2020. In terms of value, demand for CFRP, estimated at $10.25 billion in 2012 is expected to record annual growth of 11.9% over 2012-2020 to hit $25.2 billion by 2020.

In the aerospace industry, Airbus has pioneered the use of composites and other advanced materials in aircraft design and manufacturing, resulting in an industry-leading product line of economical and environmentally-friendly jetliners – from the single-aisle A320 Family to the 21st century A380 flagship. As composite materials can result in weight reduction since they typically are 20% lighter than aluminium and are known to be more reliable than other traditional metallic materials, reduced aircraft maintenance costs and lower number of inspections during service have been achieved. Additional benefts of composite technologies include added strength and superior durability for a longer lifespan. Composites are corrosion-free, which lessens the quantity of chemicals necessary to protect structural components. The weight reductions from composites also result in lower fuel consumption during an aircraft’s operational lifetime.

Composites versus metallics

To fully leverage on the benefits of using composites, Airbus is continuously developing technologies to improve the speed of composite manufacturing, as it is more complicated than with traditional metallics. In addition, the company regularly seeks new-generation applications for composite materials during the development processes and beyond.

More than 50% of Airbus’ A350 XWB is made of composites, marking a signifcant milestone for aircraft production. This jetliner also represents the first Airbus aircraft that utilises a higher percentage of composite technologies than metallic applications. Its fuselage panels, frames, window frames, clips, and door are made from CFRP, with a hybrid door frame structure consisting of this material and titanium being used for the frst time.

By applying composites on the A350 XWB, Airbus has increased the service intervals for the aircraft from six years to 12, which signifcantly reduces maintenance costs for customers. The high percentage of composites also reduces the need for fatigue-related inspections required on more traditional aluminium jetliners, and lessens the requirement for corrosion-related maintenance checks.

Beyond the in-service inspection requirements, composite materials are evaluated during the manufacturing process through non-destructive testing (NDT) to guarantee “defect-free” qualities. Airbus also recognises the individual operational advantages of both composites and metallics, and ensures that an overall airframe always will feature an optimum balance of both materials. As a result, the company continues to research and develop advanced ultra-light alloys in parallel to composites –Footwear