Key Factors to Consider When Choosing Materials Used in the Aerospace Industry  

The aerospace industry presents a unique and demanding set of challenges. 

Over the years, airframe materials have undergone remarkable changes, from the Wright brothers’ first powered-flight aeroplane , primarily made of wood and fabric, to modern engineered alloys.

When selecting materials for aerospace applications, engineers must account for factors such as extreme temperatures, pressure fluctuations, weight constraints and long-term durability to ensure optimal performance and safety.

In this article, we’ll explore the key factors that can influence the materials used in the aerospace industry , including high strength-to-weight ratio, temperature tolerance, corrosion resistance and more. 

What Challenges Do Engineers Face When Choosing Materials For Aerospace Applications? 

Due to the industry’s demanding requirements, engineers face numerous challenges when selecting materials for aerospace applications. They must balance the need for a high strength-to-weight ratio while ensuring durability, fatigue and corrosion resistance in extreme environments.

Materials must also withstand wide temperature fluctuations, manage thermal expansion and comply with strict safety regulations and standards.

Additionally, engineers must consider the cost and availability of materials, while ensuring long-term performance and environmental sustainability.

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Current Aerospace Material Trends

As the aerospace industry evolves, several key trends are shaping its future, driven by a demand for greater efficiency, functionality and sustainability. Among these trends are:

1. Lightweight Materials: The pursuit of lighter materials is crucial for improving both performance and fuel efficiency. This requires materials with exceptional strength-to-weight and stiffness-to-weight ratios.
2. Multifunctionality: Aerospace innovation is increasingly focused on integrating multiple functions into a single material or structure. This calls for advanced materials with customisable, tunable properties, as well as smart features that enhance functionality. 
3.  Sustainability: The industry is also prioritising eco-friendly approaches, aiming to minimise environmental impact. This necessitates materials with a lower carbon footprint, higher recyclability and reduced toxicity.

Key Factors to Consider When Choosing Materials Used in the Aerospace Industry  

Strength-to-Weight Ratio

Aerospace components need to be both strong and lightweight. 

Excess weight can reduce fuel efficiency and limit load capacity, while weak materials can compromise an aircraft's structural integrity. 

Aircraft structures often use:

•  Aluminium Alloys: Lightweight, corrosion resistant and relatively inexpensive. 

• Titanium: Stronger than aluminium and can withstand higher temperatures. 

• Carbon Fibre Composites: Known for their extremely high strength-to-weight ratio. 

Aluminium is also suitable for surface treatments and can be recycled without losing its properties; this benefit also ties into the aerospace industry’s commitment to sustainability. 

Temperature Resistance 

Aerospace components often experience extreme temperatures. 

Material used in the aerospace industry must endure the stresses of high temperatures before takeoff, reentry and sustained flight at high altitudes. 

Appropriate materials for ensuring temperature resistance include: 

• High-Temperature Alloys: Nickel-based superalloys are used in turbine engines and other high-stress areas due to their ability to retain strength at high temperatures. 

•  Ceramics: Advanced ceramics are used in heat shields, engine components and brake systems due to their thermal stability. 

Corrosion Resistance 

Aircraft face exposure to a range of harsh environmental conditions, such as moisture and chemicals. Prolonged exposure to these elements can cause corrosion, which affects the integrity of the material and overall safety.
Selecting advanced aerospace materials that can resist corrosion is essential for the longevity of components. 

• Stainless Steel: This alloy contains chromium, which forms a protective oxide layer that shields it from corrosion. 

• Composites and Coatings: Advanced composites and corrosion-resistant coatings are also used to protect vulnerable materials from harsh environmental factors.

Thermal Expansion

Different materials expand and contract at varying rates when exposed to temperature changes. In aerospace applications, where temperature fluctuations are significant, engineers must carefully consider a material’s coefficient of thermal expansion (CTE) to prevent structural warping or failure. 

• Cost & Availability

  
  

  While cutting-edge materials such as carbon fibre composites and titanium offer significant performance advantages, they are often more expensive than traditional materials such as aluminium. Balancing performance with cost-effectiveness is a key challenge for aerospace professionals. 

  
  

  For commercial airliners, where fuel efficiency and low operating costs are essential, manufacturers may prioritise lighter materials that justify their higher upfront costs by reducing fuel consumption over time. 

  Environmental Considerations 

  
  

  Aerospace materials must comply with strict regulations set by aviation authorities. These measures ensure that materials meet safety, durability and environmental standards. 

  
  

  • Eco-Friendly Composites: Innovations in bio-based composites and recyclable materials are being explored to reduce the environmental footprint of aerospace manufacturing. 

  • Noise and Emission Regulations: Materials that help to reduce aircraft noise and improve fuel efficiency are also becoming a priority due to stricter environmental regulations. 

  Need Help Choosing the Right Materials For Aerospace Applications?

  
  

  Selecting the right materials for aerospace applications is a complex process that can significantly impact the performance, safety and cost-effectiveness of aircraft. By considering critical factors such as durability and environmental impact, engineers and manufacturers can make informed decisions that align with both current standards and future innovations. 

  
  

  At Aerospheres, we’re proud to be a trusted aerospace material supplier. We’re dedicated to sourcing, stocking and delivering hard-to-find materials, from sealants and consumables to aviation paint supplies . To find out more about any of our top-quality products, please get in touch with our knowledgeable team today.