Have a light flight
Decreasing the weight of aircraft components could lead to lighter, more eco-friendly planes in the skies. The EU-funded project 'Integrated design and product development for the eco-efficient production of low-weight aeroplane equipment' (IDEA) aimed to substitute aluminium and other parts with cast magnesium ones. This would reduce weight, improve noise dampening, minimise pollution and lower fuel consumption. The project worked on developing advanced lightweight magnesium alloys that resisted corrosion and were easily casted. It wanted to develop coating, identify the optimal casting techniques, develop simulation tools to test components, and outline a design manual for cast magnesium parts. After thorough testing, IDEA chose two alloys for prototype production. It then determined corrosion properties of the new alloys compared to commercial magnesium ones and developed new coatings for these alloys. The project experimented with sand casting, gravity die-casting, investment casting and high-pressure die-casting (HPDC) processes to enable production of thin-walled components made with magnesium alloys. This involved thorough computer verification and simulation models to predict microstructure and defects. One of the two key prototype components or castings produced by the project was the housing, a box that handles motion transfer from the cockpit to tail through pressure bulkhead. The other key component was the rudder pedal which transmits pilot control inputs to other parts of the plane such as brake control. All the results emerging from tests, prototypes and observations were collated in a design manual for aviation engineers so they could exploit the new technology and results. This holds much promise in advancing aeroplanes to create lighter, more efficient models for future air transport.
