Advanced sheet solutions for various aircraft applications

In the past years the need for environmentally friendly structural solutions for fuselage and wing application has significantly increased resulting in the development of advanced and lightweight aluminium alloys. Beyond the environmental aspects also the potential for lower manufacturing and maintenance costs has to be taken into account. Low density alloys allowing for new cost efficient manufacturing methods, advanced design approaches and reduced maintenance are ideal candidates to comply with such challenging requirements.

The advanced AlMgSc alloy AA5028 developed by Aleris offers good damage tolerance properties, a very low density (5% lower compared to 2024) and excellent corrosion resistance (no cladding required).

Due to its high thermal stability achieved via Sc and Zr additions AA5028 allows for both established and unique new manufacturing techniques such as welding and relaxation forming.

This paper gives an overview of the relevant AA5028 properties considering different manufacturing methods which could be applied during a later serial production at the OEMs. Most recent results on demonstrator manufacturing trials will give an insight into these advanced manufacturing possibilities.