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Engineer's Toolbox:
Carbon fiber composite brackets replace heavy metal ones in next-gen aircraft

With the aerospace industry focusing on reducing aircraft weight and lean manufacturing, engineers are searching for reliable solutions such as thermoplastic composites that can perform with at least the same assurance as traditional metals and thermosets.

In response to these requirements, Tri-Mack Plastics Manufacturing Corp., a molder of high-temp engineering thermoplastics located in Bristol, RI, has developed VICTREX PEEK composite manufacturing capabilities and produced brackets for use in aircraft structural applications.

Because VICTREX PEEK polymers have been used in injection-molded aerospace components for more than 25 years, Tri-Mack specified the material due to its excellent technical features and proven track record in the industry.

Based on current fuel prices and studies, the removal of 1 kg (2.2 lb) of weight from a short-range aircraft can save airlines up to $100 in annual fuel costs. "Assuming that [using many multiples of] composite brackets can remove 100 kg (220.5 lb) of weight, an airline with 500 short-range aircraft could save up to $5 million per year in fuel costs by making the switch from metal," says Ralf Weidig, composites business leader at Victrex.

Besides over 70 percent weight savings compared to metals such as stainless steel, aluminum, and titanium, the innovative composite manufacturing process used by Tri-Mack provides several benefits leading to faster part manufacturing cycle times compared to thermosets.

"Thermoset composite parts typically take several hours to complete," says Tom Kneath, director of sales and marketing at Tri-Mack. "The VICTREX PEEK composite brackets have manufacturing cycle times measured in minutes. That speed, paired with the ability to recycle the material for other applications, takes us to a whole new level of processing efficiency that isn't achievable with thermosets."

Component integrity is also critical to keeping aircraft in service in order to minimize maintenance and downtime. Thermoplastic composites made from VICTREX PEEK can provide the chemical and corrosion resistance to jet fuel, hydraulic fluid, de-icing solution, salt, steam, water, and other commonly used service fluids that would typically undermine the longevity of metals.

"VICTREX PEEK composites can offer between four and five times higher fatigue strength, specific stiffness, and specific strength when compared to traditional metals such as aluminum," says Weidig. "These mechanical properties, along with vibration- and noise-dampening improvements, make VICTREX PEEK composites an attractive and viable solution for engineers looking to replace heavy metals and thermosets."

To learn more about VICTREX PEEK for composites, go to www.victrex.com.

Source: Victrex

Published April 2012

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