Why is Space Aluminum Panel Better?

Table of Contents

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1. Introduction
2. The Role of Aluminum Alloys in Aerospace Engineering
   • 2.1 Key Properties of Aluminum Alloys
   • 2.2 Historical Evolution of Aluminum in Aerospace
3. Aluminum in Space Exploration
   • 3.1 Spacecraft Structures
   • 3.2 Thermal Control Systems
   • 3.3 Propulsion Systems
4. Aluminum in Satellite Technology
   • 4.1 Satellite Frames and Panels
   • 4.2 Electrical Conductors and Wiring
   • 4.3 Antenna and Communication Systems
5. Aluminum in Aircraft Design
   • 5.1 Airframe Components
   • 5.2 Engine Parts
   • 5.3 Interior Systems
6. Advancements in Aluminum Alloy Technology
   • 6.1 Lightweighting Innovations
   • 6.2 Enhanced Durability and Strength
   • 6.3 Corrosion Resistance Improvements
7. Case Studies
   • 7.1 The Apollo Program
   • 7.2 International Space Station (ISS)
   • 7.3 Modern Satellite Missions
   • 7.4 Commercial Aircraft Innovations
8. Environmental and Economic Considerations
   • 8.1 Recycling and Sustainability
   • 8.2 Cost-Efficiency in Manufacturing
9. Future Prospects of Aluminum in Aerospace
   • 9.1 Aluminum Composites and Hybrid Materials
   • 9.2 Additive Manufacturing and 3D Printing
   • 9.3 Integration with Smart Technologies
10. Conclusion
11. References
12. Meta Information

Introduction

Aluminum has been a cornerstone in the advancement of aerospace technology, offering a unique combination of lightweight properties, strength, and versatility. From the earliest aircraft to the latest spacecraft, aluminum alloys have enabled engineers to design structures that can withstand the harsh conditions of space and the stresses of high-speed flight. This article delves into the critical role that aluminum plays in aerospace engineering, particularly focusing on its applications in space exploration, satellite technology, and aircraft design. Through well-researched data, detailed tables, and real-world examples, we explore how aluminum continues to push the boundaries of what is possible in aerospace technology.

Elka Mehr Kimiya is a leading manufacturer of aluminum rods, alloys, conductors, ingots, and wire in the northwest of Iran equipped with cutting-edge production machinery. Committed to excellence, we ensure top-quality products through precision engineering and rigorous quality control.

The Role of Aluminum Alloys in Aerospace Engineering

Aluminum alloys have long been favored in aerospace engineering due to their exceptional strength-to-weight ratio, corrosion resistance, and ease of fabrication. These properties make aluminum an ideal material for constructing various aerospace components, from airframes to spacecraft structures. The versatility of aluminum allows it to be used in different forms, including sheets, plates, extrusions, and castings, each tailored to specific aerospace applications.

2.1 Key Properties of Aluminum Alloys

Understanding the fundamental properties of aluminum alloys is essential to appreciating their widespread use in aerospace. The following table highlights a comparison between aluminum alloys and other common aerospace materials:

Table 1: Comparison of Material Properties

Aluminum’s lower density compared to titanium and its superior machinability make it a cost-effective choice for many aerospace applications. Additionally, its high thermal conductivity aids in thermal management, which is crucial in both aircraft and spacecraft environments.

2.2 Historical Evolution of Aluminum in Aerospace

The utilization of aluminum in aerospace dates back to the early 20th century. The Wright brothers’ pioneering flights relied on aluminum components, setting the stage for its future dominance. During World War II, aluminum became indispensable in military aircraft, contributing significantly to advancements in aviation technology. The post-war era saw aluminum alloys becoming standard in commercial aviation, exemplified by iconic aircraft such as the Boeing 707 and the Douglas DC-8.

In space exploration, aluminum alloys played a pivotal role in the Apollo program. The Saturn V rocket, which enabled humans to land on the Moon, was constructed primarily from aluminum alloys, demonstrating their reliability and performance under extreme conditions. Over the decades, ongoing research and development have led to the creation of specialized aluminum alloys tailored for modern aerospace demands, ensuring their continued relevance in cutting-edge technology.

Aluminum in Space Exploration

Space exploration presents some of the most demanding environments for materials, requiring them to endure extreme temperatures, vacuum conditions, and intense mechanical stresses. Aluminum alloys, with their robust properties, are integral to various aspects of space missions.

3.1 Spacecraft Structures

Aluminum alloys form the backbone of spacecraft structures due to their lightweight nature and high strength. Reducing the mass of spacecraft is critical not only for lowering launch costs but also for improving fuel efficiency and payload capacity. For instance, the International Space Station (ISS) utilizes aluminum extensively in its trusses and modules. The ISS’s primary truss structure, known as the Integrated Truss Structure (ITS), incorporates aluminum alloys like and , which provide the necessary structural integrity while keeping the overall weight manageable.

Moreover, aluminum’s ease of fabrication allows for the intricate designs required in spacecraft construction. The flexibility in shaping aluminum components facilitates the integration of various subsystems, such as life support, propulsion, and scientific instruments, into a cohesive structure capable of supporting long-duration missions.

3.2 Thermal Control Systems

Managing temperature in the vacuum of space is a significant challenge. Spacecraft are exposed to extreme temperature fluctuations, from the intense heat of direct sunlight to the frigid cold of space’s shadowed regions. Aluminum’s excellent thermal conductivity makes it ideal for thermal control systems. These systems, which include radiators and heat exchangers, rely on aluminum to efficiently dissipate heat generated by onboard electronics and other equipment.

For example, the thermal radiators on the ISS are made from aluminum alloys, which help maintain a stable temperature environment for both the station’s systems and its crew. Additionally, aluminum’s ability to reflect and emit thermal radiation aids in minimizing unwanted heat absorption and loss, ensuring that the spacecraft’s internal environment remains within operational parameters.

3.3 Propulsion Systems

Aluminum alloys are also used in propulsion systems, particularly in the construction of rocket casings and fuel tanks. The lightweight nature of aluminum contributes to overall propulsion efficiency, allowing rockets to carry more payload or reduce fuel consumption. High-strength aluminum alloys, such as -T87, are preferred for their ability to withstand the high pressures and temperatures encountered during rocket launches and space travel.

An example of aluminum’s application in propulsion is the SpaceX Falcon 9 rocket, which incorporates aluminum-lithium alloy structures in its first stage. These alloys not only reduce the rocket’s weight but also enhance its structural performance, contributing to the rocket’s reusability and reliability.

Aluminum in Satellite Technology

Satellites are critical assets for communication, navigation, Earth observation, and scientific research. Aluminum alloys play a vital role in ensuring satellites are robust, lightweight, and capable of performing their missions effectively.

4.1 Satellite Frames and Panels

The structural framework of satellites, including frames and panels, is predominantly made from aluminum alloys. These components must withstand the mechanical stresses of launch, resist thermal expansion and contraction in space, and support various payloads and instruments. Aluminum’s high strength-to-weight ratio is particularly advantageous in designing satellite frames that are both strong and lightweight.

For example, the structural frames of many geostationary satellites are fabricated from -T6 aluminum alloy. This alloy provides excellent weldability and corrosion resistance, which are essential for maintaining the satellite’s integrity over its operational lifespan.

4.2 Electrical Conductors and Wiring

Aluminum is extensively used in the electrical systems of satellites as conductors and wiring. Its high electrical conductivity ensures efficient power distribution throughout the satellite, minimizing energy loss and maintaining the reliability of critical systems. Aluminum wiring is also favored for its lightweight properties, contributing to the overall mass efficiency of the satellite.

In addition to traditional wiring, aluminum is used in bus bars and power distribution units within satellites. These components facilitate the management and distribution of electrical power generated by solar panels to various subsystems and instruments onboard.

4.3 Antenna and Communication Systems

Aluminum alloys are integral to the construction of antennas and communication systems on satellites. The material’s malleability allows for the precise shaping of antenna components, which is essential for effective signal transmission and reception. Aluminum’s durability ensures that these components can withstand the harsh conditions of space, including micrometeoroid impacts and temperature extremes.

The deployment mechanisms of large antenna arrays, such as those used in communication satellites, often rely on aluminum alloys for their lightweight and strong characteristics. This ensures reliable deployment and stable performance during the satellite’s operational phase.

Aluminum in Aircraft Design

The aviation industry has benefited immensely from the use of aluminum alloys, which have been fundamental in shaping modern aircraft design. Aluminum’s properties facilitate the creation of airframes and components that are both lightweight and robust, enhancing overall aircraft performance and efficiency.

5.1 Airframe Components

Aluminum alloys are the backbone of modern airframe design, forming the structure of wings, fuselages, and other critical components. The combination of strength and lightness allows for larger, more efficient aircraft that can carry greater payloads while maintaining fuel efficiency. For instance, the Boeing 737, one of the most widely used commercial aircraft, utilizes aluminum alloys extensively in its airframe construction.

The use of aluminum in airframes contributes to improved fuel efficiency by reducing the overall weight of the aircraft. This not only lowers operational costs but also reduces the environmental impact by decreasing fuel consumption and associated emissions.

5.2 Engine Parts

In addition to structural components, aluminum alloys are used in aircraft engines. Parts such as pistons, cylinders, and engine casings benefit from aluminum’s ability to withstand high temperatures and pressures. Aluminum’s thermal conductivity also aids in dissipating heat generated during engine operation, enhancing performance and longevity.

High-strength aluminum alloys like and are commonly used in engine components due to their superior mechanical properties and resistance to fatigue. These alloys ensure that engine parts can endure the rigorous demands of high-speed and high-altitude flight without compromising safety or reliability.

5.3 Interior Systems

Aluminum is also employed in the design of aircraft interior systems, including seating, cabinetry, and cabin fittings. Its lightweight nature contributes to overall aircraft weight reduction, while its malleability allows for the creation of ergonomic and aesthetically pleasing designs. Additionally, aluminum’s corrosion resistance ensures that interior components maintain their appearance and functionality over time, even in the harsh conditions of flight.

Modern aircraft interiors often feature aluminum accents and structural elements that provide both durability and a sleek, modern appearance. This not only enhances the passenger experience but also supports the aircraft’s overall performance and efficiency.

Advancements in Aluminum Alloy Technology

The continuous evolution of aluminum alloy technology has been pivotal in meeting the ever-increasing demands of aerospace engineering. Innovations focus on enhancing the material’s strength, reducing its weight, and improving its durability and resistance to environmental factors.

6.1 Lightweighting Innovations

One of the primary areas of advancement in aluminum alloy technology is lightweighting. Reducing the weight of aerospace components is critical for improving fuel efficiency, increasing payload capacity, and enhancing overall performance. Recent developments include the creation of high-strength aluminum-lithium (Al-Li) alloys, which offer superior strength-to-weight ratios compared to traditional aluminum alloys.

For example, the Al-Li alloy used in the SpaceX Falcon 9 rocket’s first stage provides a significant weight reduction while maintaining high structural integrity. These lightweight alloys enable the construction of more efficient and cost-effective aerospace systems, pushing the boundaries of what is achievable in both space exploration and aviation.

6.2 Enhanced Durability and Strength

Modern aluminum alloys are engineered to offer enhanced durability and strength, making them suitable for more demanding aerospace applications. Innovations in alloy composition and heat treatment processes have led to materials that can endure extreme conditions, such as those encountered during space missions or high-speed flight.

Alloys like -T6 and -T have been developed to provide higher tensile strength and better fatigue resistance, which are essential for components subjected to repetitive stress and harsh environments. These advancements ensure that aluminum remains a reliable and robust material for critical aerospace applications.

6.3 Corrosion Resistance Improvements

Corrosion is a significant concern in aerospace engineering, where materials are exposed to varying environmental conditions. Aluminum’s natural corrosion resistance is further enhanced through alloying and surface treatments. Advanced coatings and anodizing processes protect aluminum components from oxidation and other corrosive elements, extending their lifespan and maintaining their structural integrity.

Innovations such as chromate-free corrosion inhibitors and nanostructured coatings have been developed to provide superior protection without compromising the material’s lightweight and high-strength properties. These advancements ensure that aluminum components remain resilient and reliable throughout their service life.

Case Studies

Examining real-world applications of aluminum in aerospace provides valuable insights into its critical role and the tangible benefits it offers. The following case studies highlight significant milestones and contemporary uses of aluminum alloys in space exploration, satellite technology, and aircraft design.

7.1 The Apollo Program

The Apollo program, which culminated in the historic Moon landings, showcased the pivotal role of aluminum in space exploration. The Saturn V rocket, responsible for propelling astronauts beyond Earth’s atmosphere, relied heavily on aluminum alloys for its structural components. The rocket’s first and second stages were constructed using aluminum alloy, chosen for its excellent weldability and high strength-to-weight ratio.

The use of aluminum in the Saturn V rocket was instrumental in achieving the necessary thrust while maintaining a manageable mass. This balance was crucial for the rocket’s success, enabling it to carry the Apollo spacecraft and its crew to the Moon and back. The program demonstrated aluminum’s reliability and performance under extreme conditions, solidifying its status as a fundamental material in aerospace engineering.

7.2 International Space Station (ISS)

The International Space Station (ISS) serves as a prime example of aluminum’s versatility and durability in long-term space missions. The ISS’s primary truss structure is made from aluminum alloys such as and , which provide the necessary structural integrity to support the station’s modules, solar arrays, and other components.

Aluminum’s lightweight nature has been crucial in minimizing the overall mass of the ISS, reducing launch costs and facilitating the assembly of the station in orbit. Additionally, aluminum’s excellent thermal conductivity aids in maintaining the station’s temperature, ensuring a stable environment for both the crew and onboard systems.

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7.3 Modern Satellite Missions

Contemporary satellite missions continue to leverage advanced aluminum alloys to enhance performance and extend operational lifespans. NASA’s James Webb Space Telescope (JWST), for example, employs aluminum components in its structure to benefit from the material’s thermal management capabilities and structural integrity.

The JWST’s primary mirror segments are supported by lightweight aluminum structures, which provide the necessary precision and stability for capturing high-resolution astronomical data. Aluminum’s ability to withstand the harsh conditions of space, including extreme temperature variations and radiation exposure, ensures the telescope’s functionality and reliability throughout its mission.

7.4 Commercial Aircraft Innovations

In the commercial aviation sector, aluminum alloys remain integral to the design and construction of modern aircraft. The Boeing 787 Dreamliner, for instance, incorporates advanced aluminum-lithium alloys in its fuselage and wings to reduce weight and improve fuel efficiency. These lightweight alloys contribute to the aircraft’s overall performance, allowing it to achieve longer flight ranges and lower operational costs.

Additionally, innovations in aluminum manufacturing, such as additive manufacturing and precision casting, have enabled the creation of complex, high-strength components that enhance the aircraft’s structural integrity and safety. These advancements underscore aluminum’s continued relevance and adaptability in the evolving landscape of commercial aviation.

Environmental and Economic Considerations

As the aerospace industry continues to grow, environmental and economic considerations play a significant role in material selection and manufacturing processes. Aluminum’s properties and recyclability make it a favorable choice from both environmental and economic perspectives.

8.1 Recycling and Sustainability

Aluminum is highly recyclable, which aligns with the aerospace industry’s increasing emphasis on sustainability and reducing environmental impact. The recycling process for aluminum consumes significantly less energy compared to producing primary aluminum from bauxite ore. Specifically, recycling aluminum requires only about 5% of the energy needed for primary production, resulting in substantial energy savings and reduced greenhouse gas emissions.

The aerospace sector benefits from aluminum recycling by reducing the demand for raw materials and minimizing waste. Components such as aircraft parts and satellite structures can be reclaimed and reprocessed into new alloys, supporting a circular economy and promoting sustainable manufacturing practices.

8.2 Cost-Efficiency in Manufacturing

Aluminum’s cost-effectiveness is another crucial factor driving its widespread use in aerospace. The material is relatively inexpensive compared to other high-performance alloys like titanium, making it a financially viable option for large-scale aerospace applications. Additionally, aluminum’s ease of fabrication reduces manufacturing costs by minimizing the need for specialized tooling and reducing labor-intensive processes.

Moreover, aluminum’s lightweight properties contribute to long-term cost savings by enhancing fuel efficiency in aircraft and reducing launch costs in space missions. These economic benefits make aluminum an attractive choice for aerospace engineers and manufacturers seeking to balance performance with budgetary constraints.

Future Prospects of Aluminum in Aerospace

The future of aluminum in aerospace looks promising, with ongoing research and development aimed at further enhancing its properties and expanding its applications. Innovations in materials science and manufacturing technologies are set to unlock new potentials for aluminum, ensuring its continued relevance in the aerospace industry.

9.1 Aluminum Composites and Hybrid Materials

One of the emerging trends in aluminum alloy technology is the development of aluminum composites and hybrid materials. By combining aluminum with other materials such as carbon fibers, ceramics, or polymers, engineers can create composites that exhibit superior properties compared to traditional aluminum alloys. These hybrid materials offer enhanced strength, stiffness, and thermal stability while maintaining aluminum’s lightweight characteristics.

For example, aluminum-carbon fiber composites are being explored for use in aircraft structures, where they can provide the necessary strength and rigidity without adding excessive weight. These composites have the potential to revolutionize aerospace design, enabling the creation of more efficient and high-performance aircraft and spacecraft.

9.2 Additive Manufacturing and 3D Printing

Additive manufacturing, commonly known as 3D printing, is transforming the way aerospace components are designed and produced. This technology allows for the creation of complex, lightweight structures that would be difficult or impossible to manufacture using traditional methods. Aluminum alloys are particularly well-suited for additive manufacturing due to their excellent thermal properties and ability to form intricate geometries.

NASA and other aerospace organizations are actively exploring the use of aluminum-based 3D printing to produce lightweight, high-strength components for spacecraft and aircraft. This approach not only reduces material waste but also accelerates the prototyping and production processes, enabling faster innovation and development cycles.

9.3 Integration with Smart Technologies

As aerospace technology advances, the integration of smart technologies with traditional materials like aluminum is revolutionizing the industry. Smart technologies encompass a range of innovations, including embedded sensors, Internet of Things (IoT) connectivity, and adaptive systems that enhance the functionality and performance of aerospace components.

Embedded Sensors and Structural Health Monitoring

One of the most significant advancements is the embedding of sensors within aluminum structures to enable real-time structural health monitoring (SHM). These sensors can detect stress, strain, temperature fluctuations, and other critical parameters, providing invaluable data that can predict potential failures before they occur. For instance, Airbus has implemented SHM systems in their aircraft to monitor the integrity of the airframe during flight, allowing for proactive maintenance and enhancing safety.

Case Study: Boeing 787 Dreamliner

The Boeing 787 Dreamliner incorporates a sophisticated SHM system that utilizes embedded fiber optic sensors within its aluminum and composite structures. These sensors continuously monitor the aircraft’s structural health, detecting anomalies that may indicate fatigue or damage. This integration not only improves safety but also reduces maintenance costs by enabling targeted inspections and repairs.

Adaptive Materials and Morphing Structures

Aluminum alloys are also being combined with smart materials to create adaptive structures capable of changing shape in response to environmental conditions. Morphing structures enhance aerodynamic efficiency by adjusting wing configurations during flight, reducing drag, and optimizing fuel consumption.

Example: NASA’s Adaptive Compliant Trailing Edge (ACTE)

NASA’s ACTE project explores the use of morphing wing technology to improve aircraft performance. By integrating aluminum alloy components with flexible materials, the trailing edges of the wings can bend and twist dynamically, adjusting to varying flight conditions. This adaptability leads to significant improvements in fuel efficiency and maneuverability.

IoT and Data Analytics in Aerospace

The integration of IoT devices with aluminum-based aerospace components facilitates the collection and analysis of vast amounts of data. This data can be leveraged to optimize performance, enhance safety, and drive innovation in design and manufacturing processes.

Implementation: Smart Satellites

Modern satellites are equipped with numerous IoT sensors embedded within their aluminum frames and panels. These sensors monitor various parameters such as structural integrity, thermal conditions, and power usage. The collected data is transmitted to ground stations, where advanced analytics tools process the information to ensure optimal satellite performance and longevity.

Enhanced Manufacturing Processes with AI and Machine Learning

Artificial Intelligence (AI) and Machine Learning (ML) are transforming the manufacturing processes of aluminum components in aerospace. These technologies enable predictive maintenance of machinery, optimize production workflows, and improve quality control through automated inspections.

Example: Additive Manufacturing with AI

Additive manufacturing (3D printing) of aluminum parts is enhanced by AI algorithms that optimize printing parameters in real-time. This integration ensures high precision, reduces material waste, and accelerates production cycles, enabling rapid prototyping and customization of aerospace components.

Smart Coatings and Surface Treatments

Advancements in smart coatings and surface treatments are enhancing the performance of aluminum alloys in aerospace applications. These coatings can provide self-healing properties, reduce friction, and improve resistance to environmental factors such as corrosion and extreme temperatures.

Innovation: Self-Healing Coatings

Researchers are developing self-healing coatings for aluminum alloys that can autonomously repair minor damages caused by scratches or impacts. These coatings contain microcapsules filled with healing agents that are released upon damage, restoring the protective layer and extending the lifespan of aerospace components.

Integration with Autonomous Systems

Autonomous systems in aerospace, such as unmanned aerial vehicles (UAVs) and autonomous spacecraft, benefit significantly from the integration of smart aluminum alloys. These systems require lightweight, durable, and intelligent materials to operate efficiently in complex and dynamic environments.

Application: Autonomous Spacecraft

Autonomous spacecraft utilize aluminum alloys integrated with smart technologies to manage onboard systems, navigate through space, and perform maintenance tasks. Embedded sensors and adaptive structures enable these spacecraft to respond to changing conditions autonomously, enhancing mission success rates.

Future Directions

The convergence of smart technologies with aluminum alloys is paving the way for next-generation aerospace systems. Future developments may include fully integrated smart structures that combine sensing, actuation, and decision-making capabilities within a single material framework. Additionally, advancements in nanotechnology and materials science are expected to further enhance the smart functionalities of aluminum-based aerospace components.

10. Conclusion

Aluminum alloys have been and continue to be, indispensable in the field of aerospace engineering. Their unique combination of lightweight properties, strength, and versatility makes them ideal for a wide range of applications, from spacecraft structures to aircraft engines. As technology advances, aluminum remains at the forefront, enabling innovations that drive the aerospace industry forward.

The integration of smart technologies with aluminum alloys is particularly transformative, ushering in an era of intelligent aerospace systems capable of self-monitoring, adapting, and optimizing their performance in real-time. These advancements not only enhance safety and efficiency but also pave the way for more ambitious missions in space exploration and the development of next-generation aircraft.

Moreover, ongoing research and development in aluminum alloy technology continue to push the boundaries of what is possible, with innovations focused on lightweighting, enhanced durability, corrosion resistance, and sustainable manufacturing practices. The future holds exciting possibilities as new aluminum composites and hybrid materials emerge, further enhancing the capabilities of aerospace systems.

Elka Mehr Kimiya stands at the forefront of this dynamic field, contributing to the advancement of aerospace technology through the production of high-quality aluminum products. With a commitment to excellence and a focus on precision engineering, Elka Mehr Kimiya ensures that the aerospace industry has access to the materials necessary to push the limits of innovation and exploration.

In summary, aluminum’s proven track record, combined with its adaptability and the continuous evolution of its alloys, ensures that it will remain a critical material in the pursuit of aerospace excellence. As the industry navigates the challenges of the future, aluminum alloys will undoubtedly play a pivotal role in shaping the next chapter of aerospace technology.

References

According to the Aluminum Association, the history of air and space flight parallels the history of aluminum alloy advancement and production. Next to steel, aluminum sheet is the most commonly used and commercially available metal. Its soft, ductile texture has been fortified with a number of different metals to create alloys that exhibit highly useful qualities that have served the aerospace industry for over 100 years.

First Flight

Aluminum's lightweight and high strength-to-weight ratio make it a good choice for aircraft, which is probably why the Wright brothers chose it to build parts of the engine used for their ground-breaking successful flight back in .

Though the first primitive airplanes were made of lightweight wood, the downside of wood is that it's susceptible to rot. For that reason – and as it became more readily available – aluminum became the go-to construction material for aircraft by the beginning of WWI.

Rise of the Aluminum Industry

A generation later during WWII, the U.S. built almost 300,000 aircraft, both for itself and our allies – with the help of a flourishing aluminum industry.

After the war, the beginning of spaceflight was achieved with the help of aluminum. For instance, the Titan family of rockets used to launch the manned Gemini craft into orbit in the s was made of aluminum.

In use from the s to the s, the Lockheed SR-71 Blackbird reconnaissance plane – one of the fastest aircraft ever built – had an internal aluminum frame
From to , aluminum-skinned supersonic Concorde passenger jets flew across the Atlantic at twice the speed of sound.
The Space Shuttle Discovery, which flew astronauts around the Earth from -, had a backbone of aluminum alloy plate and had an external fuel tank made of aluminum. Its solid booster rockets were powered by aluminum metal mixed with solid ammonium perchlorate.

Modern Age of Aluminum

Still one of the world's most popular jet planes, the Boeing 737 is approximately 80 percent aluminum, with different alloys used for different parts of the aircraft. For example, the fuselage skin, slats, and flaps are made of Aluminum (alloy of aluminum and copper), chosen for its good fatigue performance, fracture toughness, and slow crack propagation rate. Meanwhile, the wing upper skin, spars & beams are made of Aluminum (aluminum alloyed with zinc, magnesium, and copper), known for its high compressive strength-to-weight ratio.
The primary structure of NASA's Orion spacecraft, the next-generation space exploration vehicle which will someday transport people to Mars, is constructed of an aluminum-lithium alloy.

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Aluminum: The Cost-Effective Solution

Though not as strong as titanium or carbon-alloy steel, and heavier than composites, aluminum costs less and has a good balance of strength and low weight that make it a great fit for aircraft. When alloyed with other materials, aluminum exhibits many additional properties beneficial to flight, such as stress corrosion cracking resistance and high tensile strength. Aluminum sheet & plate is as strong as steel at a fraction of the weight. Aluminum sheet & plate is also highly resistant to corrosion, which adds to its overall value. As manufacturing technologies advance, aluminum is sure to stay in the forefront of air and space craft for the foreseeable future.
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