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In aerospace engineering, weight reduction is the name of the game. With hundreds of thousands of intricate components working in tandem with one another to send massive shuttles through the atmosphere, every little bit of resistance that can be reduced is worth its weight (or lack thereof) in gold. To that end, material choice serves an indispensable role in the design and manufacturing of aerospace assemblies like airplanes, shuttles, satellites, and much more. In today’s article we’ll be weighing in on significant challenges, top metal choices, and precision manufacturing methods of lightweight aerospace materials.
The Challenges of Lightweighting
Although the benefits of lightweight materials for aerospace manufacturing are plentiful and well-documented, such a distinct collection of advantages does not come without its fair share of challenges.
Supply Chain Stability
Like most metals in today’s global market, lightweight alloys can be subject to supply chain instability issues. As material availability fluctuates, it can become difficult for aerospace manufacturers to find a reliable source. With this in mind, it’s not uncommon for manufacturers to partner with a network of suppliers rather than just one.
Material Costs
According to market research experts at The Business Research Company, the aerospace titanium market is projected to grow from $2.83 billion to $3.06 billion in 2024 in the United States alone. This upward trend is expected to continue as aerospace and defense demands continue to rise globally. As a result, the cost of titanium material will continue to trend upward simultaneously, presenting a potential challenge against manufacturing budget constraints.
Quality & Integrity
With the cost of lightweight materials showing no signs of slowing down, it’s only natural that more suppliers will want to capitalize on the demand. Some companies may turn to unscrupulous tactics, delivering materials that don’t quite match what was promised on paper. While this may be harmless for cosmetic materials, function is prioritized over form in nearly all aerospace applications. Using a material of dubious origin can have devastating consequences when its strength does not live up to what was anticipated. When shopping for quality aerospace materials, it’s best to err on the side of caution– if a price seems too good to be true, it will likely come at the expense of poor machinability and unreliable performance down the line.
Looking for a material supplier that you can rely on? Contact Boston Centerless to learn more about how we provide peace of mind with quality certifications and material validation.
Top Materials for Lightweight Aerospace Manufacturing
Aerospace Aluminum Alloys
Aluminum alloys are ideal for aerospace applications where light weight is the highest priority. The aerospace grade aluminum alloys offered by Boston Centerless include:
- 2024 Series (all tempers)
- High yield strength and fatigue resistance
- 6061 - T6, T651, T6511
- Excellent machinability
- 7075 - T6, T651, T6511
- Strength comparable to steel
While aluminum displays a higher strength-to-weight ratio than stainless steel, its strength capacity overall is far less. In addition, its thermal instability and poor corrosion resistance make it a material that is less suited to structural applications, but great for internal components that are not load-bearing.
Titanium Alloys
The highest strength-to-weight ratio of all known metals is one of the key properties that makes titanium a coveted material for aerospace manufacturing. A couple of alloys that are most commonly used for aerospace applications include Ti 6Al-4V, and its high-purity counterpart Ti 6Al-4V ELI. These particular alloys demonstrate excellent resistance to fatigue, corrosion, and fracturing, which makes titanium rods a leading choice for critical structural applications.
It is important to note that commercially pure titanium (CP titanium) is not a suitable substitute for titanium alloys in this context. CP titanium rods, while useful in medical and dental implants for their excellent biocompatibility, do not display the high strength that is required for aircraft components.
Want to learn more about the materials we can supply? Discover our full range of materials, only on the Boston Centerless website.
Precision Manufacturing Methods for Aerospace Components
A material’s weight is just one piece of the puzzle. Of similar importance is the material’s machinability. Aluminum alloys can generally be machined quite easily, while titanium presents more of a challenge due to its physical properties. In either case, two of the most common precision manufacturing methods for aerospace components include multi-axis CNC machining and Swiss CNC Machining.
Multi-Axis CNC Machining
Multi-axis CNC machining is the premier manufacturing process of the A&D world. While traditional CNC machines can simply move a workpiece in one direction at a time along an X, Y, or Z axis, a multi-axis CNC machine allows for rotation along 1, 2, or more additional axes. This opens up new possibilities for the creation of precise geometries that were previously unachievable.
Swiss CNC Machining
Swiss CNC machining best lends itself to the precision manufacturing of round products, including those machined from rod-shaped materials. Unlike traditional CNC machines, Swiss machines can be programmed to cut with a multitude of pre-loaded tools for complex parts that can be made with minimal downtime. This manufacturing method comes with a learning curve, but the reward is well worth the investment.
Material Prep: Precision Grinding Services
To make the most of these machining methods, not just any light weight material will do. We’re not simply referring to alloy composition– rather, it can be said that precision manufacturing starts with precision material.
When a rod is manufactured, there are parameters like diameter, roundness, and straightness, which can all vary across its length. These variances may be small, but in precision machining even a thousandth of an inch can make an immense difference in machining time, tool wear, scrap rates, and of course the costs associated with all of these. At Boston Centerless, we support the precision manufacturing world with high-quality materials shaped through the process of centerless grinding. Through this process we can supply all kinds of lightweight materials for aerospace manufacturing to the most exacting specifications with a level of consistency and reliability that is near impossible to match using other methods.
Whether you’re looking for aluminum or titanium rod, it’s possible to secure your supply of lightweight materials today. Contact Boston Centerless to find out how.