Composite materials are getting increased attention from airframe manufacturers due to their typically outstanding strength-to-weight characteristics. And according to Mick Wallis, president, Alcoa North American Rolled products, who is responsible for the aluminum materials sold into the aircraft industry, the choice was understandable: “In hindsight it was the right decision for the time—when advanced aluminum solutions were not as developed—but our technology solutions have made quantum leaps since those decisions.”

Alcoa has developed a number of materials and processes that it claims can provide up to 10% weight savings over composite-intensive planes. What’s more, they see that it can build planes that are up to 30% less costly to manufacture, operate and repair. And, in the case of short-range aircraft, provide a 12% fuel efficiency boost.

Among the materials are aluminum lithium alloys that provide 7% lower density in structural applications while providing corrosion resistance. Through the use of forged, extruded, and rolled products for structures, there is the ability to have an increased wing aspect ratio, which benefits fuel savings; the parts have 10 times the damage tolerance compared with conventional alloys; and there can be increased cabin pressurization for improved passenger comfort.

And once the aircraft is retired, as Eric Roegner, president of Alcoa Forgings and Extrusions, points out, “Aluminum’s infinite recyclability puts it head and shoulders above other materials in that it can be turned back into useful products again and again.”

Lighter, cost-effective, and green. Sort of a triple win for airframe developers.