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" WHY ALUMINIUM IS PREFERRED AS AN AIRCRAFT FUSELAGE MATERIAL: A

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 “WHY ALUMINIUM IS PREFERRED AS AN AIRCRAFT FUSELAGE
MATERIAL: A REVIEW”

1.
Ikonyat Festus (150110119128) 2. Professor Ela Jha
Second Year Mechanical Engineering Student Associate Professor
G.H.Patel College of Engineering and Technology G.H.Patel College of Engineering and Technology
Gujarat Technological University (GTU) Anand, Gujarat
Anand, Gujarat elajha@gcet.ac.in
ikonyatfestus@gmail.com

Abstract—The main objective of the paper is to cause awareness

to future and current engineers on the subject of design materials
for any engineering design project. Many a time engineers come
up with great ideas which sometimes may not be accomplished.
The underlying reason for this is that they begin a project
without putting much emphasis on the materials they are to use.
In the end they don’t achieve the results intended because of the
poor material choice. Due to that, they waste their precious time
and money which otherwise wouldn’t occur with proper material
selection. This causes depression and loss of interest to such
brilliant minds. For this particular article, Aluminium is taken as
a case study for its frequent use in Aircrafts. It is to be compared
to other materials such as Beryllium and Magnesium with almost Figure 1: Unsuccessful Remote controlled Aircraft
the same properties like it and why it is preferred to those due to poor material
particular materials.

Index Terms—aircraft, Aluminium, Beryllium, Magnesium

I. INTRODUCTION
Material selection for design engineering is one of the most
challenging things to an Engineer. The consumers of any
designed product are interested in the durability and strength of
the products produced. So to be able to out-compete the many
products of the similar nature in the market, an Engineer must
bear in mind the materials that will give him/her the best output
that fits the desires of consumers

In G.H.Patel College of Engineering and Technology

(GCET is one of the colleges of Gujarat Technological
University), three first year students ventured into the
designing of a remote solar powered aircraft. Their aircraft is
designed to be used in agriculture for spray of crops and
surveillance of farms by mounting a camera on it. The biggest
challenge these students faced was material selection. They
ended up building four trial models due to poor material
selection. They spent four times the amount they were to
initially spend if only they had taken time to study and come up
with the right material for their design. This same problem
frequently occurs to many engineers as well. Engineers should
learn to take time to study the materials they need for their
designs in order to save costs and time.
Figure 2: Successful Aircraft design due to better
material Used
II. AIRCRAFT DESIGN MATERIALS
Aircraft design materials have evolved over time. The first
successful heavier-than-air powered aircraft was The Wright
[1]
Flyer or mostly known as Flyer I. It was designed and
built by the Wright Brothers in 1903 in North Carolina US.
This first aircraft was entirely built using giant Spruce wood
 as the construction material. During that time the science of
materials had not yet penetrated many Engineering fields.
Figure 3:The Flyer 1 built by the Wright Brothers
A. Construction Materials
After the Wright Brothers laid the foundation for aviation,
later aircrafts needed to be designed from materials that suit
the current functionality of space vehicles. In today’s aircraft
technology, material selection must be based on corrosion
behaviour, physical properties e.g. density, manufacturability,
availability and mechanical properties that include stiffness,
strength, and hardness.
[2]
The common aircraft body materials used by Engineers
include graphite epoxy compounds, titanium, wood, steel and
Aluminium alloys. Out of all these materials, Aluminium was
the primary metal to usher in the dawn of the all-metal
aircraft. However it is important to note that no single aircraft
in use today is made from a single material. In the designs of
aircrafts, engineers are more focused on loading conditions i.e.
fatigue and buckling that maximize aircraft life and minimize
weight.
[3]
Alongside Aluminium, steel fuselages were also built in
the 1930s, but its heavier weight prevented it from becoming a
popular fuselage material. In comparison with Aluminium,
steel is four times stronger and three times stiffer but it is also
three times heavier than Aluminium. However it is used to
make certain parts of an aircraft. Its strength and stiffness
make it ideal for the manufacture of landing gears in the
[4]
process known as carburization. Carburizing is a
casehardening process in which carbon is added to the surface
of low carbon steel. Thus, carburized steel has a high carbon
surface and a low carbon interior. When the carburized steel is
heat treated, the case is hardened while the core remains soft
and tough. Due to carburization of steels, landing gears are
able to absorb shock when the aircraft lands.
Titanium fuselages are among the best for aircrafts. The
strength of Titanium and titanium alloys is the same as steel
and much lighter. They also resist corrosion better than
aluminium and steel but however the production of airplanes
with these materials is very costly which prohibits wide
commercial use of titanium airplanes.
Graphite epoxy compounds are also becoming common in
the design of Aircraft bodies. However currently their
application is limited to the following; • Flight control
surfaces • Landing gear doors • Leading and trailing edge
panels on the wing and stabilizer • Interior components • Floor
beams and floor boards • Vertical and horizontal stabilizer
primary structure on large aircraft • Primary wing and fuselage
structure on new generation large aircraft • Turbine engine fan
[5]
blades • Propellers
I. ALUMINIUM
Figure 4: Aluminium
As already discussed above, Aluminium was the first
material to be used in conventional aircrafts in the 1920s and
30s. Aluminium is used on most types of aircrafts because of
its lightweight and strength. Aluminium alloys don’t corrode as
readily as steel but because of their loss of strength at high
temperatures, they cannot be used for skin surfaces that
become very hot on airplanes that fly faster than twice the
speed of sound.
Commercially pure aluminum is a white lustrous metal
which stands second in the scale of malleability, sixth in
ductility, and ranks high in its resistance to corrosion.
Aluminum combined with various percentages of other metals
forms alloys which are used in aircraft construction. The
[6]
common Aluminium alloys used in aircrafts today are 7000
[7]
series Aluminium (the most preferred), and 2000 series
Aluminium which was commonly used in the original aircrafts.
The main focus of this article is to bring out the reasons
why Aluminium has been a preferred material in the largest
part of aircraft designs. Some materials like magnesium and
Beryllium almost have the same qualities like Aluminium but
they are rarely used in aircraft designs.

PROPERTIES OF ALUMINIUM THAT MAKES IT
IDEAL FOR AIRCRAFT FUSELAGES
Figure 5: Purely Aluminium aircraft fuselage
[7]
The properties of Aluminium are divided into weight,
strength, linear expansion, machining, formability,
conductivity, reflectivity, joining, corrosion resistance and
toxicity.
a) Weight
Light weight is the best known property of Aluminium. It
has a density that is one third of steel, i.e. 2,700kg/m3. This
property is very useful in Aircraft designs.
Figure 6: Aluminium Fuselage of Aircraft
b) Strength
Unlike steel, Aluminium does not become brittle at low
temperatures. In fact its strength increases at low temperatures.
At high temperatures, Aluminium’s strength decreases. Its
high strength is sufficient for aircraft designs
c) Linear expansion
Aluminium has large coefficient of linear expansion. That
means the size of Aluminium changes very little per increase in
temperature
d) Machining
It’s easy to work on Aluminium using different machining
methods. E.g. milling, drilling, cutting, punching, bending and
many others
e) Malleability
This property of Aluminium is exploited in the rolling of
strips and foils, as well as in bending and other forming
operations.
f) Conductivity
Aluminium is a good conductor of heat and electricity and
it weighs as half as much as copper with the same conductivity.
g) Joining
Features facilitating easy jointing are often incorporated
into profile design. Fusion welding, Friction Stir Welding,
bonding and tapping are also used for joining
h) Reflectivity
Aluminium is a good reflector of both visible light and
radiated heat.
i) Corrosion resistance
Aluminium reacts with oxygen to form an extremely thin
layer of aluminium oxide which provides excellent corrosion
protection. The layer is also self-repairing if damaged.
j) Toxicity
Aluminium element has zero toxicity to our health.
METALS THAT HAVE SAME PROPERTIES LIKE
ALUMINIUM BUT NOT FREQUENTLY USED IN AIRCRAFT
DESIGNS
As mentioned earlier on, magnesium and Beryllium which
are group II earth metals have same properties like aluminium
but less used in aircraft fuselage designs. Let’s examine the
reasons why they are not used as fuselage materials.
 II. MAGNESIUM
Figure 7: Magnesium
[8]
Magnesium is the ninth most abundant element in the
universe and it is the eleventh most abundant element by mass
in the human body. It is the lightest metal and it is the third-
most-commonly-used structural metal, following iron and
aluminium.
Earlier on magnesium was one of the main aerospace
construction metals and was used extensively for German
aircraft in the World War II due to its low weight. However as
time passed, the usage of aluminium in aircrafts was restricted
to engine related components largely because of fire and
corrosion hazards.
With new studies into magnesium alloys, their usage in
aircraft construction is being incorporated.
PROPERTIES OF MAGNESIUM
The properties are sub-divided as done earlier on with
aluminium
a) Weight
Magnesium is the lightest metal and its density is two thirds
that of Aluminium.
b) Reaction with air
Magnesium slightly tarnishes when exposed to air
c) Reaction with water
Magnesium reacts with water at room temperature. In
powder form, it reacts rapidly
d) Reaction with acids
Magnesium reacts with acids to produce a metal chloride
and hydrogen gas.
e) Flammability
Magnesium is highly flammable when in powder form,
though it is difficult to ignite in mass or bulk. Flame
temperatures can reach up-to 31000C
f) Corrosion
The presence of iron, nickel, copper and cobalt in
magnesium strongly activates corrosion.
Historically there has been a limited use of magnesium
alloys largely due to its corrosion, creep at high temperatures
and combust.
g) Safety precaution
Magnesium metal and its alloys can be explosive hazards;
they are highly flammable in their pure form when molten or in
powder or ribbon form. Burning or molten magnesium reacts
violently with water. When working with powdered
magnesium, safety glasses with eye protection are employed
because burning magnesium produces ultraviolet light that can
permanently damage the retina of a human eye.
h) Behavior of magnesium at varying pressure
and temperature
Here we discuss the unary phase diagram of magnesium.
Phase Diagram is a graphic representation showing the phase
or phases present for a given composition, temperature and
[4]
pressure. We make use of Gibbs phase rule using the
equation 2+C = F+P. whereby 2 represents two varying
parameters, i.e. temperature and pressure, C represents number
of chemically independent components (here C will be 1 i.e.
pure magnesium), F represents degrees of freedom and P
represents number of phases.
Figure 8: Unary phase diagram of magnesium
As shown in the diagram above, magnesium undergoes
varying phases when pressure and temperature is varied. At
point A, in the diagram, magnesium is all liquid meaning the
number of phases P is one, C is one as mentioned earlier on. PROPERTIES OF BERYLLIUM
Applying Gibb’s phase rule; i.e. 2+C = F+P, (P=1, C=1). So
we get degree of freedom F as 2. This means we change the
a) Weight
pressure, temperature, or both, and still be in an all-liquid
portion of the diagram. Beryllium is the lightest member of the alkali earth metals

Likewise degrees of freedom at point B and X can be b) Toxicity

determined just as explained above. Point X is the triple point
Beryllium is one of the most toxic chemicals known. It is
i.e. degrees of freedom at this point is zero. At this point
very harmful when breathed in and leads to damage to the
magnesium exists in the solid, liquid and gaseous phases in
lungs causing pneumonia.
equilibrium.

c) Strength and hardness

In the analysis of the above results, solid magnesium is not
recommended as an aerospace vehicle component. In space
the pressure is very low. Even at relatively low temperatures,
solid magnesium can begin to change to a vapor, causing
metal loss that could damage the vehicle. In addition, solar
radiation could cause the vehicle to heat, increasing the rate of
magnesium loss.
III. BERYLLIUM
[8]
Just as magnesium, Beryllium is also a group II Alkali
Earth metal. Beryllium is a toxic bivalent element, silvery-
white metal, strong, light-weight, primarily used as a hardening
agent in alloys. Its melting point is very high. It resists attack
by concentrated nitric acid and at standard temperature and
pressure; it resists oxidation when exposed to air.
Beryllium alloys are very tough, stiff and lighter than
similar alloys. These alloys are stronger, harder and more
resistant to fatigue. Due to these qualities, a new alloy known
as Beralcast is being developed for use in helicopter
construction.
d) Corrosion
Beryllium has high corrosion resistance similar to
Aluminium.
e) Conductivity
Beryllium is good at heat and electrical conductivity almost
as well as copper.
COMPARISON OF ALUMINIUM, BERYLLIUM AND
MAGNESIUM

Sr.
Comparison of the three elements
No:
Aluminium Beryllium Magnesium
1. Boils at 24940C Boils at 27700C Boils at 11070C
2. low density lower density lowest density
high strength, high strength,
superior high rigidity
strong, brittle and
3. malleability and and structural
lightest in weight
easy machining stability at high
temperatures
Toxic in high
4. Non-toxic Highly toxic quantity in the
body
Highly
5. Non-flammable Flammable
flammable
Maintains its Relative
Obeys unary
6. structure at high stability at high
phase diagram
temperatures temperatures
Relative
Resistant to
7. resistance to Highly corrosive
corrosion
corrosion
Does not react
Reacts with Reacts with
8. with water and
water and acids Water and acids
Figure 9: Beryllium acids
 CONCLUSION REFERENCES
As described in the article, Aluminium becomes the preferred [1] The Wright Brothers – The Invention of the Aerial Age –
metal for construction of an aerospace vehicle although it is Smithsonian National Air and Space Museum –
https://airandspace.si.edu/exhibitions/wright-brothers/online/
slightly denser than Magnesium and Beryllium. Aluminium is
non-toxic and has good strength and can be re-used making it [2] What kind of Materials is used to make Aircraft? – Smithsonian
National Air and Space Museum –
environmentally friendly.
http://howthingsfly.si.edu/ask-an-explainer/what-kinds-
materials-are-used-make-aircraft
Magnesium is not at all suitable even when it clearly has the
[3] Aircraft Construction and Materials – Integrated Publishing Inc
lowest density. In space, the pressure is very low. The – http://www.tpub.com/air/1.htm
temperature also drops in space. Due to the low pressure and
[4] The Science And Engineering of Materials – Donald R.
temperature, solid Magnesium can begin to change to vapour Askeland, Pradeep P. Phule
as described in the unary phase diagram causing metal loss
[5] Advanced Composite materials –
that could damage the space vehicle. In cases where https://www.faa.gov/regulations_policies/handbooks_manuals/ai
magnesium is used, aircraft companies incur more costs in rcraft/amt_airframe_handbook/media/ama_ch07.pdf
maintaining the aircraft fuselage. [6] The Aluminium Association –
http://www.aluminum.org/resources/industry-
Likewise Beryllium is not a good aircraft material because of standards/aluminum-alloys-101
its toxicity though it has outstanding strength compared to [7] Aircraft Metals – Federal Aviation Administration –
Magnesium. https://www.faa.gov/regulations_policies/handbooks_manuals/ai
rcraft/amt_handbook/media/FAA-8083-30_Ch05.pdf
[8] The Periodic Table – http://www.rsc.org/periodic-
table/element/4/beryllium
ACKNOWLEDGMENT
[9] Smita Joshi, Ikonyat Festus, Parth Gohil, Vicek Nampothiri –
Dr. Himanshu Soni, Principal G.H.Patel College of Design and development of small scale solar powered aircraft
Engineering and Technology and Dr. Darshak Desai, Head of
Mechanical Department. Dr. Smita B. Josh, Associate
Professor Applied Science and Humanities.

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