Aircraft materials - The aluminium alloys that we use on aircraft structures

Aluminium alloys are the main materials used on aircraft structures. This material is used from 50 to 70% of the complete aircraft structure.Why we use aluminium alloys? Aluminium is the material with the best properties to use for aircraft structures. We can find the best relation between cost, density and strength. Other major advantages of aluminium is the easy manufacturing and metalwork capability of this material, the abundance and easy recycling of this metal is other great advantages. The aluminium alloys are a mixing of pure aluminium and other elements. The additional elements that we add to pure aluminium defines the classification and numbering system of the alloys. The alloys are numbered with four numbers. The fist number defines the main element added to the aluminium. We can find the following numbering system: 1XXX- pure aluminium 2XXX- main element added to aluminium = Copper 3XXX- main element added to aluminium = Manganese 4XXX- main element added to aluminium = Silicon 5XXX- main element added to aluminium = Magnesium 6XXX- main element added to aluminium = Magnesium+Silicon 7XXX- main element added to aluminium = Zinc 8XXX- main element added to aluminium = others elements

The three numbers after the main number defines the percentage of main element added and the additional elements of the alloy. The rest of the numbering system is of importance for the Material Engineer. For the aircraft design engineer we need to now the main aluminium alloys used on aircraft, its properties and when to use them. The alloys used in aircraft structures are the followings: Aluminium alloy 2024, this alloy is one of the main alloys used in the aircraft. The 2024 is the best material for structures where fatigue and damage tolerance is a problem. Therefore the material used for the fuselage and part of the wing and stabilizers is the 2024 aluminium alloy. Do not forget, use this material when you are working with fatigue critical structural parts.The fuselage skin, frames, stringer, doublers, splices and other structural elements that belong to the fuselage, are made of 2024 aluminium alloy.

Because pressurization load in the fuselage is a fatigue critical load. Aluminium alloy 2524, this alloy is an evolution of the 2024 alloy, improving the fatigue and damage tolerance properties of the alloy. Is used in the fuselage skin, frames or other critical fatigue part. Use when properties vs. cost is improved regarding 2024 alloy. Aluminium alloy 7075, this alloy is from the 7XXX series alloys. This series is used where strength is required. Use where fatigue is not the critical load. In this case 7075 is the best material to use in sheets or plate applications. You can find this material in the upper wing panels, machined frames, formed frames, stringers, longerons, extruded parts, etc...mainly applicable to fuselage, stabilizers and wing areas where the ultimate strength is the design feature. Aluminium alloy 7050, this is also a 7XXX series alloy, strength is the dominated design feature. This alloy is mainly required to extruded, machined and forged aircraft parts. If the requirement is a forged or machined block, where the maximum strength is the target then you must use this alloy. Used in fittings and connecting elements between fuselage and wing or stabilizers, extruded stringers, machined or forged frames,etc.

Aluminium alloy 7475, this alloy is from the 7XXX series. 7475 alloys represent the evolution of the 7075 alloy improving fatigue properties. The main advantages of this alloy is the increasing fatigue properties. The best 7XXX series alloy to use in fatigue critical areas. You can find an excellent combination between strength and fatigue properties. Use this alloy when these properties are required. They are used in fuselage frames, stringers and critical fatigue connections parts. Aluminium alloy 6061, this alloy is not structural. Is mainly used in secondary structures where the welding property is required. If you need to use a material where welding is required, use 6061 alloy. Do not use this alloy in primary structures, strength capability is very low regarding the other alloys. These are the alloys that you must use in the design, repair or modifications in the aircraft. Select the material according to the requirements of the design, strength or fatigue are the dominant criteria to use in the selection of the material.