Replacing metals in Aerospace

Polymers Replacing Metals in the Aerospace Industry

For decades, metals such as aluminium and titanium have been the backbone of aircraft construction. Known for their strength, durability, and reliability, these metals have supported the aerospace industry through countless innovations.

However, a significant shift is occurring with the advent of high-performance polymers, which are increasingly being adopted due to their exceptional strength, durability, and lightweight properties.

Why High-Performance Polymers?

High-performance polymers, also known as advanced polymers, offer several advantages over traditional metals:

LightweightLightweight: Reducing the weight of aircraft leads to fuel efficiency and lower operating costs.

Corrosion ResistantCorrosion Resistance: Unlike metals, polymers do not corrode, extending the lifespan of components.

High Mechanical StrengthHigh Strength-to-Weight Ratio: Modern polymers can withstand extreme stresses while remaining lightweight.

Eficient prototyping designDesign Flexibility: Polymers can be moulded into complex shapes, allowing for innovative design solutions.

Common High-Performance Polymers in Aerospace  

Polyether Ether Ketone (PEEK): Used in bearings, brackets, and cable insulation.

Example: Boeing and Airbus use PEEK in structural components due to its excellent mechanical properties and resistance to high temperatures.

Polyimides: Used in insulation films, seals, and bushings.

Example: NASA employs polyimides in spacecraft components for their thermal stability.  

Polyphenylene Sulphide (PPS): Used in fuel systems, electrical components, and hydraulic systems.

Example: PPS is favoured in fuel line components due to its resistance to chemicals and heat.

Polytetrafluoroethylene (PTFE): Used in seals, gaskets, and wire insulation.

Example: PTFE is employed in aerospace for its low friction, high temperature resistance, and excellent chemical stability.  

wire plane

Components Made from High-Performance Polymers  

  • Cabin Interiors: Lightweight polymer composites are used in seats, overhead bins, and panels.
  • Structural Components: PEEK and PPS are used in fuselage sections, wing components, and landing gear systems.
  • Electrical Systems: Polymers are used for insulation, connectors, and circuit boards.

Advantages Over Metals  

  • Weight Reduction: A key factor in fuel savings and increased payload capacity.
  • Enhanced Durability: Polymers are less susceptible to fatigue and wear.
  • Cost Efficiency: Lower maintenance costs due to corrosion resistance and longevity.

Conclusion  

High-performance polymers are revolutionising the aerospace industry by offering lightweight, durable, and cost-effective alternatives to traditional metals. As technology advances, the role of these polymers will only expand, paving the way for more efficient and innovative aircraft designs.

To find out how we can help your latest project, contact info@fluorocarbon.co.uk