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Cellular Structures for Impact Performance

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Making a better aircraft sandwich

Novel materials and technologies have been developed for use in future aircraft structures. These could potentially lead to safer, cleaner and quieter air transport.

Industrial Technologies icon Industrial Technologies

Currently, the wing flaps and overhead lockers in aircraft are made from panels that are sandwich structures. They have two thin covers or skins enclosing a thick but lightweight core. Generally, the materials for the skins are carbon-fibre composites while those for the core are polymer foams or aramid honeycomb structures. More critical components with improved energy absorption may have aluminium skins and cores. However, in all cases the main function of the core is to be low weight and low cost, but rigid enough to maintain the distance between the outer skins that carry the load. The heavier an aircraft weighs, the more fuel it burns, so weight reduction is important. Reducing weight by using novel materials with high strength-to-weight ratios was the focus of the EU-funded 'Cellular structures for impact performance' (Celpact) project. This project worked on the development of new low-weight cores with enhanced properties made of composites and metals. The research included next generation manufacturing techniques for both composite hybrid and metal cellular materials and structures. For example, the project developed core structures using a revolutionary technique called selective laser melting. This method utilises a laser to melt powder particles to form a solid material using stainless steel, titanium and nickel-based superalloys. The technique can be used to manufacture complex core designs that were previously extremely difficult to produce. The new sandwich materials will enable lighter aircraft parts to be fabricated for load-bearing structures such as the fuselage and wing panels. These weight reductions have the potential to reduce both fuel consumption and carbon emissions over the 30-year average lifespan of an aircraft.

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