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A Review of Aluminum Alloys in Aircraft and Aerospace Industry

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Journal of Huazhong University of Science and Technology ISSN-1671-4512

A Review of Aluminum Alloys in Aircraft and Aerospace Industry

R. Jini Raj1*, P. Panneer Selvam2, M. Pughalendi3
1
Assistant Professor, Er.Perumal Manimekalai College of Engineering, Hosur and
635117, India
2
Assistant Professor, Er.Perumal Manimekalai College of Engineering, Hosur and
635117, India
3
Assistant Professor, Er.Perumal Manimekalai College of Engineering, Hosur and
635117, India

Abstract: In recent years, Aluminum alloys has been made on the development of aerospace applications.
Over some decades, Aluminum alloys are used as aircraft material structures due to their light weight and
high strength. Aluminum is a less expensive and high performance material, with low manufacturing costs.
This study is about the latest developments of Al-based alloys such as 2000 series, 7000 series and Al-Li
alloys that are developed for aerospace industry with exceptional advantages. The properties and
performance of newly developed 2000, 7000 series aluminum alloys and Al–Li alloys are discussed and it is
compared with traditional alloys commercially in use.
Keywords: Aluminum Alloy, Aerospace, Aircraft, Materials;

1. INTRODUCTION
Aircraft and Aerospace manufacturing industries investments are usually high enough.
The cost of starship rocket under development is approximately $8 billion for full
developed stage. The cost reduction in the manufacturing of aircrafts, rockets and space
shuttle has become a motivating force in many aerospace and aircraft companies. Cost
reduction in production can be achieved by increasing the availability of low cost
materials with high strength and rigidity, less transportation, maintenance cost,
operational costs, and increased fatigue life. Therefore, aircraft and aerospace
manufacturers are indeed of developing their products with new materials at low cost to
meet the requirements. Hence, the task is to develop new materials that can be used in
fuselage, wing construction and also in rockets with high structural performance and life
cycle cost. While considering Aircraft, the effective way of reducing the aircraft weight is
by reducing the material density [1]. It is found that the tensile strength, modulus of
elasticity and tolerance can be increased effectively by decreasing the material density.
The Airframe durability also has direct impact in costs. The service and maintenance cost
for the whole life of the aircraft are estimated to exceed the original purchase price [1].
Therefore, aircraft designers are working in congruence to reduce the weight, improve
tolerance, fatigue and corrosion resistance of the newly developed metallic alloys. The
outcome is in future aircraft structures will show prolonged service life and have reduced
rate of inspections.
Boeing Aircraft shows increased usage of composite materials in aircraft primary
structures (B787, Airbus A380, F35, and Typhoon). Fig. 1 shows the usage of composites
in different types of Boeing aircraft. The desirability of composites in the production of
high performance aircraft structures relies on their high mechanical properties such as
higher specific stiffness, specific strength, fatigue and corrosion resistance compared to
metals. Even though composites are preferably chosen material for wing and fuselage
structures, their complicated mechanical behaviour due to change in environmental
conditions (moisture absorption, getting soft/brittle when exposed to hot/cold
environments) make designers to search alternative material systems. So they proposed
aluminum alloys for fibre metal laminates that becomes a way for recent development of
aluminum alloys in aerospace field [2-17]. Aluminum is the 3rd most abundant element

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on the Earth’s crust after oxygen and silicon and has been used in the aerospace industry

Fig. 1. Composite of materials used in Boeing Aircraft

from as far back as the 19th century. Due to its lightweight, strength and its high corrosion
resistance, it has been most widely used metal in the aerospace industry. Fig 2 shows the
parts where aluminum material is used in aircraft. Although composites are replacing
aluminum to a great extent, aluminum is still being used in the construction of
frameworks. Aluminum still plays a significant role in high performance military
aircrafts.
For example, this metal is used extensively in the J-35 Joint Strike Fighter. It makes up
six forged bulkheads that form the aircraft’s major weight-bearing portion of the airframe
[18]. It is most widely used in its alloy form as pure aluminum does not meet the
industry’s requirements. All modern spacecraft are made of 50% to 90% aluminum alloy.
The most elements that are alloyed with aluminum are copper (Cu), Zinc (Zn), Lithium
(Li), Silicone, Magnesium (Mg), Nickel (Ni), Titanium (Ti), etc.

Fig 2: Alloys used in different parts of the Aircraft structure [43]

The main focus of this review is mainly on the aluminum based alloys that are used in the
aircraft and aerospace industry. Aluminum alloys have been used as the main structural
material for commercial and military aircraft due to their good mechanical behaviour,
ease design and manufacturing processes and inspection techniques. However, the non-

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metallic materials, due to their superior specific strength properties afford a very
competitive substitute, so huge investment is done to improve the thermo-mechanical
properties of the aluminum alloys. Parameters like density, strength, Young’s modulus,
fatigue resistance, fracture toughness and corrosion resistance need to be improved.
In Boeing 777, improvements were made for aluminum in upper-wing structure and
fuselage. However, aluminum alloy in upper wing structure need to have high
compressive yield strength. For the case of fuselage, higher damage tolerance and
durability was needed. Therefore, to meet the requirement aluminum manufacturers
developed the 7055-T7751 plate and 7055-T77511 for the upper wing structure, and
Alclad 2524-T3 sheet and 2524-T351 plate for the fuselage skin. These materials reduced
thousands of pounds of weight for the Boeing 777 [19]. This review article exposes the
recent developments related to aluminum alloys and performance improvements in the
2000, 7000 series aluminum alloys as well as the new generation of Al–Li alloys that
were used in aircraft and aerospace industry.

2. Properties of Aluminum and Aluminum Alloys

To better understand the aluminum alloys, the properties of aluminum are to be first
understood. Aluminum is a silverfish white metal that is light weight, Strong.
High strength-to-weight ratio, Resilient, Ductile at low temperatures, Corrosion resistant,
Non-toxic, Heat conducting and is malleable just like gold. It is easily machined, which
makes it a preferred metal in this industry. The properties of aluminum alloys are High
Strength-To-Weight Ratio, Resilience under Static and Dynamic Loading, Strength at
Low Temperature, Resistant to Corrosion, Non Toxic, Good Heat Conducting,
Reflective Surface, Electrically Conductive, Non Magnetic, Non Sparking, Non
Combustible. The following series of aluminum alloys paves a way to understand
different aluminum alloys used in aerospace field
Table 1. Mechanical properties of some commonly used aluminum alloys in aerospace
industry [45]

Elastic Yield Tensile Fracture

Density
Alloy Temper Modulus Strength Strength toughness
(g/cm3)
(GPa) (MPa) (MPa) (MPa√m)

2014 T6 2.80 72.4 415 485 26.4

2219 T62 2.84 73.8 290 415 36.3

2024 T4 2.77 72.4 325 470 22.0

7050 T74 2.83 70.3 450 510 38.5

7075 T6 2.80 71.0 505 570 28.6

2.1. 2014 Alloy

2014 is a strong, tough metal suitable for joining process like arc and resistance welding.
However, 2014 has poor corrosion resistance capability, so it is used to make the internal

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structure or framework of aircraft. It has high yield strength, high tensile strength but less
fracture toughness

2.2. 2219 Alloy

The 2219 aluminum alloy provides high elastic modulus, maximum strength at high
temperature, and high tensile strength. It was used for the making external fuel tanks.
Weldability is good for 2219 but has less corrosion resistance unless it is heat treated.
2.3. 2024 Alloy

This is an Al-Cu alloy. The 2024 alloy is used in places where high tension is exerted
during operation such as the wing and fuselage structures [20]. It is used when high
strength to ratio is required [20].

2.4. 7050 Alloy

This alloy is the top choice in the aerospace industry because of its greater corrosion
resistance and durability than 7075 [20]. Its ability to resist fracture and corrosion is
because it maintains its strength in wider sections [20].

2.5. 7075 Alloy

This is an Al- Zn alloy. The 7075 has strength that is similar to that of steel, has good
machinability and fatigue strength properties [20]. It is being used in aviation since the
WW II in the Mitsubishi A6M Zero fighter planes [20]

3. Recent development of aluminum alloys in aerospace

Aluminum alloys are identified by a four-digit numbering system. The first digit
represents the alloy group, and the other numbers represent the alloys that are present in
it. The 2xxx series, 7xxx series, and Al-Li alloys are the recent developments in the
aluminum based alloys in the aerospace industry [21], about which this review would
cover.

3.1. 2xxx series of aluminum alloy

The main component in the 2000 series that is alloyed with aluminum is copper. The
solubility of copper in aluminum is 5.65% [1]. These alloys have high strength, and so
their main application is in places where damage tolerance is required [22]. Magnesium is
added to increase the strength of this alloy. This makes the 2000 series alloys that
containing magnesium useful in places where high damage tolerance and high resistance
to fatigue crack growth is required than other Al alloys [21]. One of the most commonly
used 2000 series alloys in the aerospace industry is the 2024-T3 alloy. It is considered as
aircraft alloy because for it high strength and fatigue resistance. 2024 aluminum alloy's
composition roughly includes 4.3-4.5% copper, 0.5-0.6% manganese, 1.3-1.5%
magnesium. Less than a half a percent of silicon, zinc, nickel, chromium, lead and
bismuth are added to overcome the low yield strength in high stress regions. Also due to
the formation of the inter-metallic phase by the copper and magnesium reaction, reduces
the corrosion resistance of the alloy. This is also overcome by the addition of the latter
mentioned small percentage of components. The ultimate tensile strength is 62000 PSI,
and the shearing strength is 40000 PSI. Chemical compositions and mechanical properties
of some of 2xxx series aluminum alloys are shown in Tables 2 and 3 respectively.
Table 2. Chemical Composition of 2xxx series alloy [45]
2000 Cu Zn Mg Mn Fe Si Cr Zr Ti Al

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Series
2024 4.4 - 1.5 0.6 ≤0.5 ≤0.5 0.1 - 0.15 Remainder
2026 3.6– 0.1 1.0– 0.3– 0.07 0.05 - 0.05– 0.06 Remainder
4.3 1.6 0.8 0.25
2224 4.1 - 1.5 0.6 ≤0.15 ≤0.12 - - - Remainder
2324 3.8– 0.25 1.2– 0.3– 0.12 0.1 0.1 - 0.15 Remainder
4.4 1.8 0.9
2524 4.0– 0.15 1.2– 0.45– 0.12 0.06 0.05 - 0.1 Remainder
4.5 1.6 0.7

In fuselage construction 2024-T3 alloy is used which offers yield strength and have better
fracture toughness. The 2024-T3 always remains as the main aircraft structural material.
The drawback is this alloy is not used in highly stressed regions [23]. The 2524-T3 alloy
has a 20% improvement in fracture toughness and has double fatigue crack growth
resistance compared with 2024-T3 [24]. This provides lesser weight savings and longer
service life [25]. In Boeing 777 aircraft the skin of fuselage is made up of 2524 alloy only.
The fatigue strength of this alloy is 25% of the yield strength higher than that of 2024-
T351[26]. The 2224-T351 and 2324-T39 alloys offer higher strength Compared to 2024
for wing skin [27]. Also newly developed 2026 alloy have some additional material
composition like iron and silicon. 2026 offers damage tolerance, good tensile strength,
fatigue performance compared to 2024 and 2224 [28].
Table 3. Mechanical Properties of 2xxx series [45]

2000 Series UTS (MPa) Yield Fracture Elongation

Strength Toughness KIC (%)
(MPa) (MPa m1/2)
2024-T351 428 324 37 21
2026-T3511 496 365 NA 11
2224-T39 476 345 53 10
2324-T39 475 370 38.5-44.0 8
2524-T3 434 306 40(TL) 24

3.2. 7xxx series of aluminum alloy

The main components of 7000 series alloys zinc. The solubility of zinc in aluminum is
31.6%. Zinc has the more solubility in aluminum than any other alloying element [1].
Aluminum and copper are usually combined with zinc which increases the strength of the
alloy [29]. The MgZn2, Al2CuMg, and Al-Cu-Mg-Zn phases formed in aluminum causes
the alloy to have very high strength. The most common among the 7000 series is the 7075
alloy. These are high strength alloys that are used to strengthen aluminum aircraft
structures. It consists of 1.6% of Cu, 2.5% of Mg, 5.6% of Zn. Its ultimate tensile strength
is 33000 PSI and shear strength of 22000 PSI when aluminum is oxide coated, and when
the tempering T6, the ultimate strength is 82000 PSI and the shear strength is 49000 PSI.
Hence the 7075 alloy is used in the construction of parts which are require high strength
such as in aircraft fittings, missile parts, gears and shafts, aerospace and defense
applications. Some of the drawbacks of 7075 alloys include poor resistance to corrosion,
low damage tolerance and is prone to fracture [1]. 7000 series alloys are widely used in
aircraft structures due to their high strength-to-weight ratio and low cost but these alloys
are vulnerable to corrosion that reduces the life of aircraft structures significantly [27].
The 7000 series alloys can be heat treated, and the newly developed combination of Al–

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Zn–Mg–Cu versions afford the maximum strength compared to other aluminum. The
7475 (Al–Zn–Mg–Cu) aluminum alloy is newly developed form of 7075 alloy. The 7475
alloy is developed with a combination of higher strength, higher fracture toughness and
good resistance to fatigue crack propagation in corrosive environment. It is done by
decreasing its contents of iron and silicon in its chemical composition. The total iron and
silicon content in 7475 the total content is 0.22%. These changes give rise to in the
development of the 7475 alloy which is having a highest toughness value. It is also stated
that the corrosion resistance and fatigue behaviour of the 7475 alloy are outstanding.
Overall, its performance is better than other aerospace aluminum alloys such as 7050 and
7075 alloys [23]. Chemical composition of 7xxx series aluminum alloys are given in
Table 4.

Table 4. Chemical Composition of 7xxx series [45]

7000 Cu Zn Mg Mn Fe Si Cr Zr Ti Al
Series
7050 2.3 6.2 2.25 - ≤0.15 ≤0.12 - 0.1 - Remainder
7055 2.0– 7.6– 1.8– 0.05 0.15 0.1 0.04 0.08– 0.06 Remainder
2.6 8.4 2.3 0.25
7075 1.2– 5.1– 2.1– 0.3 0.5 0.4 0.18– - 0.2 Remainder
2.0 6.1 2.9 0.28
7150 1.9– 5.9– 2.0– 0.1 0.15 0.12 0.04 0.08– 0.06 Remainder
2.5 6.9 2.7 0.15
7475 1.2– 5.2– 1.9– 0.06 0.12 0.1 0.18– - 0.06 Remainder
1.9 6.2 2.6 0.25

3.3. Li- Al alloys

Al-Li alloys are utilized for light weight structural application [30]. The Al-Li alloy is the
lightest of all Al-Li alloys [31]. The main purpose of alloying aluminum with lithium is to
reduce the density [1]. The development of Al–Li alloys with improved strength and
fracture toughness with some reduction of weight increases its usage in aircraft
applications. This newly developed Al–Li alloys provides not only weight savings but
also overpowers the drawback of corrosion resistance problem, and increase in
performance of fatigue crack growth, compatible for different manufacturing techniques.
This results in stable, low density and good performance aluminum alloys [1, 32, 33].
Chemical compositions of Al–Li alloys are shown in Tables 4 and the mechanical
properties are shown in Fig 3. With 3% of Li in the alloy, the conventional aluminum
alloy’s density was reduced by 7.8% and the ultimate tensile strength was increased by
62% [30]. But with 1% of Li is added, the density of the alloy is decrease by 3%, and the
Young’s modulus is increased by 6% [31]. Cu is also added to the Al-Li alloy to form
Al2CuLi phase for the improvement of the mechanical property of aluminum [34]. The
2060-T8 alloy, when used for the fuselage skin, 7% of the weight is reduced when
compared to 2524 alloy, and when it is used for the upper wing skin, the weight is
reduced by 14% when compared to 2014 alloy [20].

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Fig 3. Mechanical Properties of Al-Li Alloys [45]

The Al-Cu alloys have low toughness and corrosion resistance [1]. But the newly
developed Al–Cu–Li alloy 2050 in this generation replaced the 2000 series and 7000
series [35]. Al–Li alloy 2198 was developed for aircraft structure application replaced
2024 and 2524. It has a Copper composition up to 3.3% and up to 1.1%. The density of
2198 is superior to 2024. For the same stresses, 2198 was observed to absorb twice energy
to fracture than 2024 [36,37]. Moreover, it was perceived that 2524-T3 offered a higher
fatigue strength and fatigue limit [38]. The next generation Al–Li alloys are 2060 and
2055. Al-Li alloys show good thermal stability and have excellent corrosion performance
compared with aerospace aluminum alloys such as 2024 and 7075. Therefore, for
fuselage, lower wing and upper wing constructions these alloys are better suited. It saves
weight compared with 2000 and 7000 series aluminum alloys. It saves 6-7% weight for
fuselage skin applications, for lower wing skin applications up to 14% weight is saved
and for wing skin and stringer applications, it can save 10% weight [39, 40]. The next
generation Al–Li alloys offers better weight savings less expensive to manufacture,
operate and repair. The improved material properties improved damage tolerance
performance. Al–Li alloys offer improvements in the fracture processes. [41, 42].
Table 5. Chemical Composition of Al-Li alloys [45]
Al–Li Li Cu Zn Mg Mn Fe Si Cr Zr Ti Others
alloys
2050 0.7– 3.2– 0.25 0.2– 0.2– 0.1 0.08 0.05 0.06– 0.1 0.2–0.7
1.3 3.9 0.6 0.5 0.14 Ag
2090 1.9– 2.4– 0.1 0.25 0.05 0.12 0.1 0.05 0.08– 0.15 -
2.6 3.0 0.15

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2098 0.8- 3.2- 0.35 0.25– 0.35 0.15 0.12 - 0.04– 0.1 0.25–0.6
1.3 3.8 0.8 0.18 Ag
2099 1.6– 2.4– 0.4– 0.1– 0.1– 0.07 0.05 0.1– 0.05– 0.1 0.0001
2.0 3.0 1.0 0.5 0.5 0.5 0.12 Be
2199 1.4– 2.0– 0.2– 0.05– 0.1– 0.07 0.05 - 0.05– 0.1 0.0001
1.8 2.9 0.9 0.4 0.5 0.12 Be

4. Conclusion
The present review shows the development of Aluminum alloys used in the aircraft
structural materials. The standards for the aircraft structural materials need the materials
to possess good mechanical properties. Al-based alloys because of their well-known
mechanical behaviour sustained in the field for many years. It has been agreed from this
review that the improvements of aerospace aluminum alloys are due to newly developed
combination of materials to achieve better property balance. In addition to this weight
reduction is one of the important parameter that is improved because of this newly
developed aluminum alloys. It is believed that developments of hybrid materials could
provide chances for aluminum alloys and new material options for the aircraft and
aerospace industry.
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