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While There Are Existing Elements Such as Copper, Silicon, Zinc, Manganese, Magnesium and Other Aluminum Alloys, There May be Better Options to Use in Aviation

Briana Mohan, (1) Thomas A Edison Career and Technical Education High School

U.S. Department of the Interior & U.S. Geological Survey. (2023). MINERAL COMMODITY SUMMARIES 2023. Retrieved April 12, 2024, from https://pubs.usgs.gov/periodicals/mcs2023/mcs2023.pdf

The Wright Flyer (U.S. National Park Service). (n.d.). https://www.nps.gov/articles/wrightflyer.htm

Mars, K. (2023, December 14). 120 years ago: The first powered flight at Kitty Hawk - NASA. NASA. https://www.nasa.gov/history/120-years-ago-the-first-powered-flight-at-kitty-hawk/

National Museum of the United States Air Force^TM. (n.d.). Original 1903 Wright Flyer Fabric. https://www.nationalmuseum.af.mil/Visit/Museum-Exhibits/Fact-Sheets/Display/Article/197460/original-1903-wright-flyer-fabric/

Producer Price Index by industry: Aerospace product and parts manufacturing. (2024, April 11). https://fred.stlouisfed.org/series/PCU3364133641

References

An enormous thanks to The Port Authority of NY & NJ, A New JFK, York College, Delta, American Airlines, JFK Millennium Partners and The New Terminal JFK International Airport, whose research grants made this STEM project possible.

Acknowledgements

The hypothesis of new materials being more effective and efficient is possible to achieve, but it may take more time and research.
Furthermore, if new materials are too costly right now, there may be a drop in price due to an increase of supply and demand for these materials. Currently, the most used material for aircrafts are aluminum alloys.

Conclusion

The main focus of this poster is to find a lighter and cheaper material for aircrafts, but it also needs to be strong and durable.

Idea: Lightweight and cheaper

Categories of Aluminium Alloys and Their Elements

During the visionary Renaissance period, there were many ideas for aircrafts. During this time people were fascinated about nature and birds, this soon led to an idea of a bird like machine. These ideas also led to many different concepts on how the aircraft should be constructed. By 1903 the first powered aircraft was flown by Orville Wright.
This aircraft was both lightweight and durable, this machine was also made from spruce and ash wood. The frame was strong and aerodynamic since it was covered with untreated white cotton muslin.(nps.gov, .nationalmuseum.af.mil, nasa.gov).
Although planes may seem different now, they still kept some of the same concepts as before. Some of these concepts would the engine and wings. The material used also needs to be lightweight which was how the first powered aircraft was made.

Background

Over time the alloy cost have increased
Different parts of aircraft’s cost different amounts. This includes varying manufacturing and development cost.
Weight is one consideration for new material effectiveness, but the speed of the resulting aircraft can also be important. Both of these factors will influence cost.

Weight, Speed, and Cost

Some major alloying elements that makes up aircraft are Aluminum, Cooper, Silicon, Zinc, Tin and others but only a few are cheap enough for being light in weight. Currently, the most common material used in aircrafts and aerospace systems is alloys. For lightweight aircrafts, things like wood and fabric were also used. Over the years there has been some improvements but there still hasn’t been an answer to find a better alternative for manufacturing an aircraft.

Major Alloying Elements

Sketches of flying machines by Leonardo da Vinci in the 15th century include various ornithopters

Figure 1

In Figure 1, the graph shows how the cost of materials for aircrafts increase over the years. As you can see the prices haven’t decreased at all which means that the materials are getting more and more expensive each year.

Cost of Materials Over Years

Series Number	Alloying Element	Alloy Category
1XXX	Aluminum	Commercially Pure
2XXX	Copper	Heat-Treatable
3XXX	Magnesium	Non Heat-Treatable
4XXX	Silicon	Non Heat-Treatable
5XXX	Magnesium	Non Heat-Treatable
6XXX	Magnesium & Silicon	Heat-Treatable
7XXX	Zinc	Heat-Treatable

While constructing an aircraft, this image shows what material is used and where that material is applied.

It is clear that composites are used more than the rest of the material because composites are lightweight, durable and cheap.

Materials Used

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While Existing Aluminum Alloys rely on Copper, Manganese, Silicon, Magnesium, Zinc and Tin,

other Materials, Metals, Elements and Alloys may provide better alternatives for Aviation

Briana Mohan(1), Akshara Gupta(1), Andrew M Singh(2), Isaiah Jamna(3), (1) JFKR Aviation and Aeronautics Academy, (2) York College of CUNY, Geology Discipline, Jamaica, NY, & JFKR Aviation and Aeronautics Academy (3)Sophie Davis CUNY School of Medicine, Manhattan, NY & JFKR Aviation and Aeronautics Academy

U.S. Department of the Interior & U.S. Geological Survey. (2023). MINERAL COMMODITY SUMMARIES 2023. Retrieved April 12, 2024, from https://pubs.usgs.gov/periodicals/mcs2023/mcs2023.pdf

The Wright Flyer (U.S. National Park Service). (n.d.). https://www.nps.gov/articles/wrightflyer.htm

Mars, K. (2023, December 14). 120 years ago: The first powered flight at Kitty Hawk - NASA. NASA. https://www.nasa.gov/history/120-years-ago-the-first-powered-flight-at-kitty-hawk/

Producer Price Index by industry: Aerospace product and parts manufacturing. (2024, April 11). https://fred.stlouisfed.org/series/PCU3364133641

References

Acknowledgements

It may be possible to achieve this hypothesis of new materials that can be more effective and efficient, but it will take time and more research.
Further, even if new materials are too expensive right now, there may be a drop in cost as both demand for, and supply of such materials increase in the future.
For now, Aluminum alloys are still very effective for aircraft.

Conclusion

Ideal materials would be both cheaper and have lower density than existing alloys, while maintaining strength and durability.

Possibilities: Cheaper and Lighter

Beryllium: Critical to Aerospace and defense (U.S. DoI and USGS)

During the visionary Renaissance period, there were signs of ideas for aircrafts. Over time people were inspired by nature and birds so they wanted to build a machine that is similar to a bird. There were many different concepts on how to build it. By 1903 the first powered aircraft was flown by Orville Wright.
It was lightweight yet durable, made from spruce and ash wood. The frame was covered in untreated white cotton muslin, which was strong and aerodynamic (nps.gov, .nationalmuseum.af.mil, nasa.gov).
Currently, the planes we have now may appear very different, but many of the same concepts like wings and engines must be kept. Any new materials and components also need to be light, strong, and aerodynamic.

Background

Alloy costs have increased over time.
Different parts of aircraft’s cost different amounts. This includes varying manufacturing and development cost.
Weight is one consideration for new material effectiveness, but the speed of the resulting aircraft can also be important. Both of these factors will influence cost.

Weight, Speed, and Cost

Some major alloying elements that makes up aircraft are Aluminum, Cooper, Silicon, Zinc, Tin and others but few are cheap enough while being light in weight. Metal materials are commonly used for making aircraft and aerospace systems currently. Wood and fabric were also used in lightweight aircrafts. There have been improvements over the years for these aerospace materials. Some industries use carbon fibers because they are low density. This may help produce higher speeds for aircrafts needs.

Major Alloying Elements

Sketches of flying machines by Leonardo da Vinci in the 15th century include various ornithopters

Producer Price Index by Industry: Aerospace Product and Parts Manufacturing (fred.stlouisfed.org after U.S. Bureau of Labor Statistics)

Private manufacturer claims comparing their trademarked forged aluminum against officially designated series (2xxx, 6xxx, 7xxx).

Their proprietary alloy may not be permitted for some official uses.

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Abstract - we need a 1500 characters or less summary

As aircrafts have evolved, there has been some changes in them, but this doesn't mean they changed everything. Since aircrafts were inspired by nature and birds, it was given the idea of bird like machines which are now the aircrafts known today. This design was first powered in 1903, which was made by Orville Wright. He used spruce and ashwood which was soon evolved into different materials. They kept things like the wings and engines but manufacturing a aircraft can be costly. After examining alloys, there has been an increase of cost for the materials needed. Although cheap and lightweight material is needed, each material needs to be durable and efficient to be used as the aircraft needs to be safe for everyone on board. There can be other materials that are cheap and lightweight which can be used during manufacturing but they would also need to be aerodynamic. To add on, different parts of these aircrafts would cost different amounts based on where this material is going to be placed and with the manufacturing cost. As aircrafts have evolved, there has been some changes in them, but this doesn't mean they changed everything. Since aircrafts were inspired by nature and birds, it was given the idea of bird like machines which are now the aircrafts known today. This design was first powered in 1903, Orville Wright. They kept things like the wings and engines but manufacturing a aircraft can be costly. After examining alloys, there has been an increase of cost for the materials needed. Although cheap and lightweight material is needed, each material needs to be durable and efficient to be used as the aircraft needs to be safe for everyone on board. There can be other materials that are cheap and lightweight which can be used during manufacturing but they would also need to be aerodynamic. Since materials are expensive right now, there could be a price drop for these materials, but for now the search for these cheaper materials are still there, but in the meantime aluminum alloys are the best source for now.

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GSA Abstract potentially

There have been many improvements over the years in aerospace materials. Metal materials are commonly used for making aircraft and aerospace systems. Wood and fabric were also used in lightweight aircrafts. In 1903 the first powered aircraft flown by Orville Wright was lightweight yet durable, made from spruce and ash wood. The planes we have now may appear very different, but many of the same concepts like wings and engines must be kept. Any new materials and components also need to be light, strong, and aerodynamic. Ideal materials would be both cheaper and have lower density than existing alloys, while maintaining strength and durability. When examining alloys in aviation, we find that alloy costs have increased over time. Different parts of the aircraft cost different amounts for manufacturing and development. Weight is one consideration for new material effectiveness, but the speed of the resulting aircraft can also be important. Both of these factors will influence cost. It may be possible to develop new materials that can be more effective and efficient, but it will take time and more research. Further, even if new materials are too expensive right now, there may be a drop in cost as both demand for, and supply of such materials increase in the future. For now, Aluminum alloys are still very effective for aircraft.

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