In the highly competitive field of aerospace-materials development it is important to show the potential of material developments and manufacturing process' by means of structural analysis. The conceptual approach composites have taken shows the possibilities of composite developments in aircraft the metal‑alloy community has neglected. The development of structural analyses tools by CRD&T alongside the development of aluminum alloys by Aleris approaches this conceptual design philosophy.
Using the structural analyses tools, concepts are evaluated comparing different material solutions. Not just showing the potential of alloys developments, also taking into account possible production advantages. One of the examples is the conceptual design of a wingbox. Using global dimensions, the wingbox loading can be evaluated for different design concepts, e.g. monolithic, built-up or CFRP solutions. At this stage different materials can be assessed showing the advantages of the Aleris alloy developments. Alloy 7081 in both T7451 and T7651 shows enormous potential for wingbox applications. Higher stresses, lower weight or cost can then be the design driver. These concepts show high weight savings (15%) without a major increase in cost for 7081-T7451 as an integral lower wing solution. If a higher stressed lower wing skin is required, the 7081-T7451 alloy can offer great damage tolerance solutions as a spar alloy.
Similar conceptual steps can be taken for the fuselage, combining static and damage tolerant analysis in different concepts, e.g. riveted, bonded or welded structures. Taking into account at an early stage the production advantages solutions can offer in performance and/or cost. In competition with composites AlLi alloys are developed as a weight saving solution. The Aleris AlMgSc development provides similar results for fuselage applications with improved impact and fatigue performance with the additional advantage of cost savings by the application of innovative manufacturing methods. Several results will be shown to support these statements.