FULLY CIRCULAR METALLIC LIGHTWEIGHT AIRFRAME SOLUTIONS TO ACHIEVE SUSTAINABLE FLIGHT

Future generations of aircraft will need to provide a high-performance level with a low level of CO₂ emission in the use phase and excellent recyclability of the aircraft structure during the manufacturing and end of life phases. For airframes, this translates into significant mass saving and the use of materials which are fully recyclable without loss of performance. Such an improvement can be achieved by enhanced materials integrating circularity aspects from the very beginning of new developments.

Following the life cycle of aluminum parts in an aircraft structure, manufacturing will be discussed step by step, illustrating the progress achieved in decarbonizing the airframe manufacturing. Responsible management of the run-around scrap generated during the semi-finished product manufacturing and the re-introduction of the pre-consumer scrap allow the decrease of primary metal usage, which is a key parameter for rational use of resources and for CO₂ emissions.

The integration of the aircraft end of life recycling is a supplemental brick to achieve a full recycling loop approach with minimum loss of material in the full life cycle of an aluminum airframe structure. Smart material choices and advanced designs are considered to build the basis for aerospace aluminum solutions for a circular economy.