It’s a lab. It’s a flying lab. It’s a flying lab made of aluminium! Yes, Airbus recently debuted a futuristic laboratory - using futuristic lightweight metal - and named it DisruptiveLab.
The lab will test new technologies to improve aircraft performance and reduce carbon emissions. Quite true to its name, DisruptiveLab marks yet another disruptive technological advancement in the global commercial aerospace industry in the last decade.
The engineering novelty displayed by Airbus’ DisruptiveLab
An aerodynamic aluminium-composite fuselage is among the technologies being tested on the platform. It helps in reducing drag, resulting in improved fuel efficiency. Additionally, it has a parallel hybrid propulsion system that enables onboard battery recharging in flight.
As part of DisruptiveLab's demonstration, propeller blades are integrated into the aircraft's rotor, which will make its maiden flight later this month. Consequently, the rotor head is smaller, and the drag is even lower. It also features a streamlined Fenestron tail rotor that improves performance.
Airbus Helicopters’ DisruptiveLab is a step towards developing a sustainable aerospace industry and reducing the environmental impact of its helicopters. A brand new demonstrator could only test the innovative architecture and the fully parallel hybrid propulsion system to verify the combined CO2 reduction potential of up to 50%.
A part of the funding for this project comes from the French Civil Aviation Authority (DGAC), as it falls within the CORAC’s roadmap. The DisruptiveLab demonstrator is also part of the French Stimulus Plan, which is part of the European Plan, the Next Generation EU, and the France 2030 Plan.
The DisruptiveLab demonstrator follows Airbus’ FlightLab, which debuted in 2020. FlightLab used an H130 aircraft, while DisruptiveLab is an entirely new vehicle designed to improve performance and reduce the vehicle’s carbon footprint.
The role of aluminium in the aerospace materials market
Aerospace materials are substances used by aircraft OEMs and component manufacturers to produce various aircraft parts. The materials used in aircraft construction are constantly evolving. Today’s aircraft are primarily made of aluminium with some steel construction, unlike earlier aircraft that were initially built of ash and spruce wood with wings covered in muslin. Aluminium is cheaper and lighter than other composites and gives the aircraft useful modern features.
Increasing demand for new aircraft, technological change, increasing aircraft size, and high replacement rates are the major factors driving the global aerospace materials market growth. Composite materials, aluminium alloys, and titanium alloys are used in aircraft manufacturing.
Components made from aluminium commonly used in aircraft
Aluminium sheets, plates and bars are commonly used to make various aircraft components and parts. In addition, aluminium tubes, pipes, and fabricated shapes offer additional support to the structure.
Aluminium alloy 2024 is the most widely used alloy for aircraft manufacturing. It was developed after experiments, allowing small amounts of cold deformation and a period of natural ageing of the metal that resulted in increased yield strength.
2024 is a high-grade alloy with excellent fatigue resistance. It is used primarily in sheet forms, such as fuselage and wings, due to its high tensile strength of roughly 470 MPa.
AA 6061 alloy is very common in light aircraft, especially homemade ones. It’s easily welded and manipulated, is very light, and is relatively strong, making it ideal for fuselage and wings.
Key producers of the aerospace-grade aluminium
Alcoa (United States), Airbus Group SE (France), Boeing Co. (United States), Honeywell International Inc. (United States), Mitsubishi Heavy Industries, Ltd. (Japan), and ThyssenKrupp AG are some of the most prominent players in the aerospace aluminium industry worldwide.
These companies focus on developing new products and technologies that improve the functionality and reliability of their current offerings. In addition, these companies are spending money on research and development to develop new markets for aerospace aluminium, such as drones and electric aircraft. In the coming years, this is expected to fuel the expansion of the global aerospace aluminium market.
Aerospace parts manufacturing market- an overview
The aerospace parts manufacturing market is expected to reach USD 1608.34 billion by 2029, at a CAGR of 4 per cent during the forecast period. One of the major factors driving the growth of the aerospace parts market is the increasing demand for new-generation lightweight, fuel-efficient aircraft.
The aircraft MRO market is expected to reach USD 107.66 billion by 2029, at a CAGR of 4.9% during the forecast period. The demand for MRO facilities is likely to rise as the number of airlines increases in response to the growing number of passengers opting for air travel.
The Future
Industry experts are optimistic about the future of aluminium alloys in aerospace. It is projected that demand for aluminium will double over the next decade. By 2025, there will be a global demand of 80 million tonnes. For this reason, the aerospace industry is increasingly looking for recycled alloys to satisfy their high demand. There is also a push for innovation in the materials used and the design structure of aircraft.
For instance, aluminium-lithium alloys have been developed for the aerospace industry to reduce aircraft weight and improve the aircraft’s performance. Al-Lithium alloys are advanced materials because of their low density, high specific modulus, and excellent fatigue and cryogenic toughness properties.
As developing countries become more involved in the aerospace industry, and with increased investment, there will be further innovation in aluminium alloys over the years to come.
