Advanced Aluminum and Aluminum-Lithium Solutions for Derivative and Next Generation Aerospace Structures 2012-01-1874

The challenging performance and affordability goals of next generation aircraft have accelerated the demand for advanced structural materials and concepts capable of achieving significant weight and cost (acquisition and operational) reduction. To meet these aggressive weight and structural maintenance reduction targets, future aircraft will require structural solutions that provide increased strength, damage tolerance and corrosion resistance. Alcoa has developed advanced aluminum alloys and third generation aluminum-lithium (Al-Li) alloys with exceptional performance and durability capability.

This presentation first introduces the basic properties of the new 2xxx and 7xxx series aerospace aluminum and third generation Al-Li alloys possessing improved strength, fatigue life, crack propagation, fracture toughness, corrosion resistance, and, in the case of Al-Li alloys, reduced density and increased modulus. Secondly, the results of coupon and structural detail tests combined with trade studies for typical short range transport aircraft demonstrate how the improved properties of the new alloys can be used to provide weight savings and/or maintenance improvements in current, derivative and new aircraft. Lastly, it discusses the feasibility of using conventional aerospace manufacturing techniques such as stretch forming, machining, hole drilling, and fastening.