The Importance of High-Temperature Materials
Excellent aircraft operations rely on durable materials that can withstand high heat and rigorous conditions. As the aerospace industry becomes more and more advanced, the demand for high-temperature materials continues to grow.
High-temperature alloys and materials are critical to the aerospace industry for several reasons:
Extreme Operating Environments
An airplane that takes off from a well-groomed runway for a scheduled domestic flight is not insulated against extreme operating conditions. Domestic fleets and rugged military aircraft alike may be subjected to high heat, severe cold, mechanical stresses and pressures, corrosion, radiation, and thermal shock while in operation.
With this in mind, there are two benefits to choosing high-temperature alloys for aerospace components. First, the materials can withstand high heat throughout the flight. Second, the materials can maintain their vital performance attributes even when subjected to high heat, which ensures reliable endurance against the rigors listed above.
Performance and Safety
High-temperature materials and aerospace alloys allow aerospace manufacturers to improve fuel efficiency and other parameters. For example, turbine efficiency can be increased by 5-6% by boosting the service temperature of the aircraft by 200°C. By leveraging high-temperature materials, aircraft can be operated at higher temperatures, and with the appropriate thermal barrier coatings and cooling systems, the aircraft can achieve better fuel efficiency.
High-temperature materials often have greater flexibility, radar absorption, and flutter suppression than their counterparts, along with high strength-to-weight ratios. This leads to greater stability throughout the aircraft.
Enabling Advanced Designs
The performance attributes of high-temperature materials and their compatibility with advanced manufacturing methods will likely translate to tremendous advancements in aerospace manufacturing and performance in the coming years. High-temperature materials may allow aerospace engineers to solve long-standing challenges and unlock new innovations in aerospace technology by raising the ceiling on operating temperatures.
High-Temperature Alloys and Other Materials for Aerospace
High-temperature materials range from alloys and polymers to composites featuring fibers and matrices. Examples of aerospace alloys and other high-temperature materials include:
Nickel Alloys
Nickel alloys are commonly used in aerospace applications, thanks to their excellent resistance to corrosion and temperature fatigue, caused by repeated exposure to heating and cooling cycles during flight. Nickel alloys are strong and easy to fabricate.
Titanium Alloys
Like nickel alloys, titanium alloys are highly resistant to corrosion and temperature fatigue. Additionally, titanium alloys are quite lightweight, a desirable attribute for manufacturers for whom lightweighting is a priority.
Copper Alloys
Copper alloys boast a few key performance attributes, including resistance to oxidation and creep, long low-cycle fatigue, and excellent strength at high temperatures. Some copper aerospace alloys are especially well suited to complex shaping, due to low thermal expansion.
Ceramic Matrix Composites (CMCs)
CMCs combine ceramic fibers with a ceramic matrix, resulting in a class of material that demonstrates excellent thermal stability, strength, and toughness. CMCs are a popular choice when lightweighting is a concern, since they are much lighter than metal alloys. CMCs are often used for jet engine components and heat shields.
Carbon-Carbon Composites
Carbon-carbon composites, made of carbon fibers embedded in a carbon matrix, are exceptionally well suited to endure the tremendous thermal load of reentry. These materials offer superb thermal conductivity and mechanical properties and are often used for heat shields.
Carbon-carbon composites offer inferior thermal shock and oxidation resistance to other high-temperature materials.
High-Temperature Polymers
Thanks to tremendous leaps in polymer composite research and high-temperature polymerization, high-temperature polymers with incredible performance attributes are becoming increasingly popular for aerospace applications. High-temperature polymers retain their thermal stability at high temperatures and are highly resistant to a wide range of chemicals. These materials demonstrate incredible tensile strength while weighing less than metal aerospace alloys. Additionally, the excellent thermal insulation properties of high-temperature polymers make them a popular choice for parts designed to protect sensitive aircraft systems and components from heat and electromagnetic interference.
Future Directions for High-Temperature Materials
The future of high-temperature materials is incredibly promising, with valuable research occurring in several key areas:
- The next generation of aerospace alloys may outperform existing superalloys at ultrahigh temperatures. This has the potential to allow for tremendous innovation in turbine blade design.
- Combining high-temperature materials with advanced manufacturing methods, such as additive manufacturing and powder metallurgy, may allow aerospace manufacturers to achieve more complex geometries.
- The use of high-temperature polymers and ceramics is contributing to ongoing lightweighting efforts throughout the aerospace industry, which has a direct impact on the fuel efficiency and payload capacity of a given aircraft.
Partner with NMG Aerospace
High-temperature materials are bringing about significant innovation in the aerospace industry, allowing aircraft companies to explore new possibilities in flight. Tapping into the tremendous potential of these materials may require the support of an experienced aerospace manufacturer.
With decades of proven success in aerospace manufacturing and a strong record of compliance with Standards, Processing, and Air Agency certifications and approvals, NMG Aerospace has a long history of driving innovation across the industry.
We have earned the trust of countless aerospace companies, serving as their partner in innovative aerospace design and manufacturing. From expert fabrication and assembly to quality testing, NMG Aerospace can help you develop the next generation of your components and systems, so you can stay ahead of the competition.
To learn more about NMG Aerospace and our materials experience, contact us.
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