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Flight numbers plummeted as countries introduced travel restrictions, with Aislelabs reporting a year-on-year decrease of 80% in May.
Many are calling for a fundamental shift in how we treat air travel. Video conferencing has proved its ability to replace most meetings, and there is more awareness than ever about the need to minimise emissions.
While there is added impetus to find new efficiencies, companies are perhaps less likely to spend on radical improvements such as electric flight or alternative fuels as they struggle to pay staff and keep flying.
Instead, the next few years are likely to bring an increased focus on ‘lightweighting’ and the relatively straightforward fuel savings to be had there. Companies have spent much energy and money on metal alloys to reduce weight already, but new composites could help cut even more mass.
Aluminium metal matrix composites from Basingstoke firm Alvant, for example, combine aluminium – a lightweight, high-performance material in itself – with a secondary high-performance material to enhance it further. The aluminium acts as the ‘matrix material,’ like a resin in a carbon composite.
The materials could replace expensive titanium or offer improved fatigue and damage tolerance compared to aluminium, said commercial director Richard Thompson. In one test, an aluminium piece failed after 100,000 cycles, whereas the composite got to 10m cycles before the test was halted.
The company is working with French multinational Safran, investigating its composite’s use in a future landing gear project. Replacing a titanium connecting rod could reportedly cut mass by 40%.
Retrofitting is an appealing option for airlines. “We can save a percentage amount per component and they translate that into passengers, and also fuel savings,” said Thompson. “About 1% weight saving can save 1% fuel.”
He added: “Airlines have invested in their fleet, and if we can bring performance benefits that can have a big impact. People are interested in recyclability and sustainability.”
Unmanned take-off
Lightweighting can also have a big impact on a much smaller scale. A recent report by Protolabs found that 53% of surveyed businesses expect commercial drone deliveries to become ‘commonplace’ over the next three years. The proportion increased more than 10% from February to March as the pandemic took hold.
If drones are to play a part in the supply chain, lighter materials and longer flight times will become more important than ever before. Drone companies might make use of materials such as carbon fibre-reinforced nylon from MakerBot, which can be 3D-printed to shape.
“Your weight is very important, and also the stiffness, and strength of the part as well,” said Johan Broer, MakerBot’s vice-president of product development. “You want to use something strong and lightweight, so then you have to use less energy to actually lift the drone.”
Additive manufacturing of lightweight materials is a promising technology for airliners, but has had limited impact so far. Initial applications in unmanned vehicles could lead the way towards wider integration in aerospace.
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Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers.