Chapter 3
Chapter 3
Chapter 3
R.C. Alderliesten
Cover image CC-BY TU Delft is a derivation of two images by: Christopher Boffoli, Big Appetites Studio, Seattle,
Washington, USA, (http://bigappetites.net), who graciously agreed for us to use his Public Domain photograph
of the Boeing 787 fuselage in high resolution, and by Gillian Saunders-Smits, Delft University of Technology with
her photograph of a Fokker F100 Cockpit Structure (CC-BY-SA 4.0). The final cover design was made by Marco
Neeleman, Delft University of Technology Library.
Every attempt has been made to ensure the correct source of images and other potentially copyrighted material
was ascertained, and that all materials included in this book has been attributed and used according to its
license. If you believe that a portion of the material infringes someone else’s copyright, please the author
directly on: R.C.Alderliesten@tudelft.nl
Partly funded by the TU Delft Extension School (online-learning.tudelft.nl) as part of the development of a
Massive Open Online Course in Introduction to Aerospace Structures and Materials.
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3. Material types
3.1 Introduction
The key difference between the structures and materials discipline and other
disciplines related to flight is that this discipline is about materialisation of concepts
also developed within the other disciplines. To create an aircraft or spacecraft one
must use materials. Materials in that sense can thus be defined as substances,
matters, constituents or elements that are used to build parts, components and
structures.
The properties of materials do not depend on their geometry, but on their composition
only. The relation between the composition and the properties of a material can be
further explored, but for the time being, one may consider the properties as an artefact
of materials.
41
42 R.C. Alderliesten
properties, which are the properties divided by the density or weight of the material.
The use of those specific properties will be further discussed in chapter 8.
For application in aerospace structures, one can distinct the following material
categories:
• Metal alloys
• Polymers
• Composites
• Ceramics
These categories are briefly discussed in the following sections. But before
discussing these categories individually, one has to be aware that these materials
have been retrieved from resources like ores (metal) and oil (composites and
polymers). Once retrieved, they are transformed into semi-finished products like
sheets, plates, bars, fibres, powder (polymers), etc. The semi-finished products are
further processed into structural elements. For this transformation a huge number
of processes are available that can be grouped into: casting, forming, machining,
and joining processes. Subsequently, the structural elements are assembled into
structures.
Figure 3.1
Illustration of subsequent production steps from raw material resources to structures (Alderliesten, 2011. Own
Work.)
Introduction to Aerospace Structures and Materials 43
The properties of structures are directly related to the material properties although
they are not identical: structural properties are often influenced by the shape and
geometry (design) too. However, there is also another aspect to be considered when
optimizing between material and structural shape; not every structure or shape can be
made of any material. Consider for example the Eiffel tower, the Parthenon, or a surf
board. The selected materials (resp. metal, marble and composites) and the shapes
of these artefacts are compatible.
This also implies that if the shape is not adapted to or compatible with the material,
the material properties are not optimally used and exploited.
The last relationship to mention is the one between the shape (or structure) and the
manufacturing process. To fabricate a sheet metal wing rib, one may use a forming
process. Replacing the same rib by a machined rib will consequently result in different
details of the wing shape (local radii, thickness, etc). To put it the other way around:
To create a cylindrical shape and a double-curved shape, different manufacturing
processes are needed.
Figure 3.2
Illustration of the relation between Materials, Manufacturing and Design, with the topic of interest in this chapter
highlighted (Alderliesten, 2011. Own Work.)
An alloy is made by adding alloying elements to the purified metal in order to increase
or modify the properties of the pure metal. For example, adding a few percent of
copper and magnesium to aluminium (like in Al-2024) increases the yield strength
and ultimate strength both with a factor of 4 to 6. In general, metal alloys have good
processibility, show plastic behaviour, and are rather cheap.
Metal alloys typically are isotropic materials exhibiting similar elastic properties in
all directions of the material. Because of this isotropic behaviour, the material
specifications and the specifications of physical and mechanical properties are often
given indifferent of the orientation. Only for specific metals that show anisotropic
behaviour, like for example aluminium-lithium alloys, and for rolled sheet material
sometimes properties are specified in two directions. The orientation dependency for
the rolled products is related to the shape of the grains (severely elongated in rolling
direction) as a result of the rolling process.
Introduction to Aerospace Structures and Materials 45
Because metal alloys are ductile materials that yield beyond the yield strength, both
ultimate and yield strength are specified. This value indicates how far the material can
be loaded elastically before permanent plastic deformation may occur.
Table 3.1 gives some mechanical and physical properties of typical steel, aluminium,
titanium and magnesium alloys. It can be observed from the data in this table that
there is some relation between strength and stiffness on the one hand and the density
of the material on the other hand.
Steel exhibits high strength and stiffness, but at the cost of a high density, whereas
magnesium (the lightest alloy in the table) shows the lowest mechanical properties.
Table 3.1
Typical mechanical properties some metals
E G
Metal Alloy
[GPa] [GPa] [MPa] [MPa] [%] [-] [g/cm3]
Typical applications for metals are structures and components that require high
strength both in tension and in compression, see the examples in Figure 3.3. Example
applications for steel alloys are found in aircraft (landing gear components), train
components and rails, bridges, towers and cranes.
Aluminium alloys are for instance applied in the main fuselage and wing structure of
most aircraft, train structures, and car and engine components.
In general, metal alloys are applied in components and products that are produced in
high volumes. Examples here are the cars and cans.
Steel is also often applied as reinforcement material in for example civil applications.
The application of steel cables in suspension bridges is an evident example. But also
concrete is reinforced with steel cables to increase the strength of the structure.
Especially in case of high buildings the steel reinforcement is applied to pre-stress
the structure, i.e. the steel reinforcement is put in tension (because of the excellent
tensile properties), which by equilibrium puts the concrete in compression (for which
concrete is known to perform excellent).
Figure 3.3
Typical applications of metals. Derivative from: Top left NI-CO-LE, (2017), CC0; Top right: Pingstone, (2004), Public
Domain; Bottom left: KarinKarin, (2015), Public Domain; Bottom right: Bender, (2014), CC-BY-SA3.0.
Introduction to Aerospace Structures and Materials 47
3.3 Polymers
In general, polymers are not considered for structural applications. The polymers
have relative low strength and stiffness and can therefore not be used as structural
material. However, they are applied as structural adhesives to join other materials, and
they are applied with additional reinforcement in composites.
Compared to rigid materials like metals, polymers exhibit significant lower stiffness
and strength. Here, it should be noted that the stiffness of many polymers is not
constant during loading. Whereas metals exhibit linear stress-strain behaviour during
elastic deformation of the material, as illustrated in Figure 1.5, the stiffness of
polymers often change with the amount of strain, see Figure 3.4. In case of such
non-linear behaviour, the initial slope of the material is taken to determine the elastic
modulus.
Although the strength and stiffness are generally very low, the elongation at failure
can be quite high. Some rubbers, for example, may strain up to 500% before failure
occurs.
Figure 3.4
Qualitative illustration of the non-linear stress-strain behaviour of polymers (Alderliesten, 2011. 3-4.jpg. Own Work.)
In chapter 2, it has been explained that the temperature has an influence on the
mechanical properties of materials. Although this is in general the case for all
materials, it is quite significant for polymers. Depending on the temperature, materials
48 R.C. Alderliesten
may either behave like brittle materials or like elastic materials. Especially at low
temperature, many polymers show brittle behaviour.
With increasing the temperature a gradual transition can be observed from brittle
to elastic and rubbery behaviour, while further increasing to high temperatures the
material may become viscous or even liquid like.
This transition to the viscous state is important for polymers, because it implies
a significant reduction in the mechanical properties. A well known transition for
polymers is the so-called glass transition temperature.
Figure 3.5
Transition in modulus of elasticity at the glass transition temperature, below the melting temperature (Alderliesten,
2011, 3-5.jpg. Own Work.)
Some polymers exhibit different mechanical behaviour, depending on the rate they are
strained. Glass fibres for example, exhibit higher strengths when loaded at very high
rates. This can be beneficial in case of impact for example.
Because of the wide variety of polymers that exist, the number of applications is
numerous. Some main categories can be distinguished:
• Elastomers
• Plastics
• Fibres
Introduction to Aerospace Structures and Materials 49
Some well known examples of polymer applications are illustrated in Figure 3.6.
Rubbers are elastomers that are typically applied in tires, sealing, coatings and liners.
They are in general characterized by their flexibility and the large strain to failures.
Plastics can be divided into two main categories:
• Thermoplastic
• Thermoset
Figure 3.6
Typical applications of polymers. Derivative from Top left: Saunders-Smits (2018), 3-6-b.jpg. Own Work.; Top right:
Yogipurnama, (2017), CC0; Bottom left: Anon., (2017), CC0; Bottom middle: Pexels, (2016), CC0; Bottom right: Hans,
(2013), CC0.
Thermoplastic polymers melt when heated to certain temperatures and return to their
glassy state when cooled again. These materials are often associated with weak Van
der Waals forces. This means that the material can be melted above their melting
temperature and moulded into components. The process is reversible, as reheating
will melt the material again.
50 R.C. Alderliesten
Thermoset materials however, are cured irreversibly, which means that once the
chains link during curing the process cannot be reversed. These materials usually do
not melt at high temperatures, but may decompose or burn when heated too high.
The difference between these two materials is considered important, especially when
addressing recyclability of the materials. Thermoplastic materials can be recycled
relatively easy by heating above the melting temperature, while thermoset materials
are in general not easy to recycle.
Example applications of thermoset materials are the old bakelite telephones and
the epoxies used in fibre reinforced composites. Here, it should be mentioned that
current developments seem to aim to replace, for certain composite applications, the
thermoset matrix material by thermoplastic matrices.
Examples of fibre types are natural fibres, synthetic fibres and nylon. Application of
these types of fibres in a fibre reinforced composite, implies that different polymers
are combined into a structural material. The fibre is made of another polymer than the
matrix material.
Ceramics are not suitable for structures. They are too brittle and have poor processing
features. However, they are applied in some space applications, for instance for
thermal protection of the metallic or composite structure. Ceramics often consist of
(metal) oxides and metals, in which ionic bonds between the different atoms provide
the material structure.
In general, ceramics are hard and brittle materials that have very limited toughness
due to the lack of ductility (small failure strain). In certain cases a high strength and
stiffness can be achieved, but that depends on the composition of the material and
the level of porosity.
Introduction to Aerospace Structures and Materials 51
The reason why certain ceramics are considered for heat protection is that they
are capable to sustain very high temperatures. Even at those temperature levels the
bonds between the atoms remain very strong. This strong bond also implies that
ceramics are often very resistant to wear.
A variety of typical applications for ceramics can be mentioned here. To start with the
glass application, glass is applied in window panes, lenses, but also in fibres. Glass
fibres are very stable fibres that have high mechanical properties both in tension and
compression. At high strain rate levels, the glass often provides a higher strength than
when quasi-statically loaded to failure.
Another example of ceramics is clay. Porcelain and bricks are well known examples
of these ceramics. In civil applications not only bricks, but also cement and lime are
being applied as ceramic applications.
Other examples are cutting tools and abrasive materials due to its high wear
resistance, armour reinforcement because of its high puncture resistance, and in case
of glass fibres, due to its high impact resistance. The previously mentioned high
heat resistance (1600 – 1700 °C) results in many applications in engine components
and heat protection systems for, for example, the Space Shuttle. A selection of
applications are illustrated in Figure 3.9.
Figure 3.9
Typical applications of ceramics. Derivative from Extreme left: Cjp24, (2007), CC-BY-SA3.0; Left: Torr68, (2005);
CC-BY-SA3.0; Right: Anon.(n.d.), Public Domain; Extreme right: Atkeison, (2003) CC-BY-SA2.0.
52 R.C. Alderliesten
Figure 3.7
Space Shuttle Columbia (left) with indicated location of space debris (centre) and an image of the
accident. Derivative from NASA, (2003), Public Domain.
Figure 3.8
Photos of the ceramic tiles shown intact, with damage, test panel with damage and test set up.
Derivative from Volk, (2008), CC-BY-SA2.0, and NASA, (2003 2007), Public Domain.
Introduction to Aerospace Structures and Materials 53
Composite materials are, as the name already indicates, materials that are composed
of different materials. A more accurate description or definition is given by:
Composites are engineering materials, in which two or more distinct and structurally
complementary substances with different physical or chemical properties are
combined, to produce structural or functional properties not present in any individual
component.
Figure 3.10
Illustration of a fibre reinforced polymer composite ply, and the related stress-strain behaviour of constituents and
lamina (Alderliesten, 2011, 3-10.jpg. Own Work.)
54 R.C. Alderliesten
As is evident from Figure 3.10, the stress-strain behaviour of the fibre reinforced
polymer composite is determined by the constituents of which it is composed. The
stiffness of the lamina is a function of the stiffness of the polymer and the fibre,
which can be estimated by the rule of mixtures, discussed in section 3.6. However,
whereas the stiffness may be directly related to stiffness and volume content of each
constituent in the lamina, the strain to failure is solely determined by the strain to
failure of the fibres. Once the fibres fail, the strength of the remaining polymer is too
low to carry the load.
One should pay attention to the definition given here for ‘composites’, because this
definition states that any type of engineering structural material that satisfies this
definition is considered to be a ‘composite’. These days, people use the wording
‘composites’ often to indicate only one specific type of composites, namely the one
constituted of carbon fibres and polymer. However, one should be aware that this is
an inaccurate use of the definition of composites.
Figure 3.11
Illustration of a fibre metal reinforced polymer composite ply, and the related stress-strain behaviour of constituents
and lamina (Alderliesten, 2011, 3-11.jpg. Own Work.)
Introduction to Aerospace Structures and Materials 55
Due to the high directionality (fibre orientation) these materials enable tailoring to
specific load applications (beams, cables, columns), but require multiple orientations
to cope with bi-axial load applications.
Table 3.2
Qualitative comparison of typical properties of several composites
Glass fibre
reinforced High Medium Low High Medium Low
composite
Carbon
fibre
High Low High High Medium Low
reinforced
composite
Aramid
fibre
High Medium Low High Low Low
reinforced
composite
Fibre Metal
High Medium High High High Medium
Laminate
Typical applications are illustrated in Figure 3.12. Wind turbine blades are commonly
made of glass fibre composites. Other applications are sail planes and pressure tanks
and vessels.
Carbon fibre composites are often applied in automotive and aerospace structures
for their high stiffness. A well known application in sailboats is for example the mast.
But also (motor) bikes are made of carbon fibre composites since the stiffness and
rigidity of the frame is important in such design. Similarly certain sport equipment is
made of these materials.
56 R.C. Alderliesten
Aramid and Kevlar based composites often find applications in armour and bullet
proof protection systems, like bullet proof vests and cockpit doors that should resist
terrorists. Also heat and flame resistant products are often made from aramid fibre
reinforced composites.
Figure 3.12
Typical applications of composites. Derivative from Top row, left: GuentherDillingen, (2012), CC0; Top row, right:
medienluemmel, (2016), CC0; Second row, left: Gnokii, (2011), CC0; Second row, right: Boffoli, (2018), CC0; Third row
left: Saunders-Smits, (2018), 3-12-f.jpg. Own Work.; Third row middle: PMulhalla, (2015), CC-BY-SA3.0; Third row
right: Vinayr16, (2014), CC0; Bottow row: Saunders-Smits, (2018), 3-12-h.jpg and 3-12-i.jpg. Own Work.
Typical applications of the composite Fibre Metal Laminate (FML) concept are
primarily found in aerospace applications. The reason is that these materials are
specifically developed for their high strength and fracture toughness, which increases
the damage tolerance of primary fuselage and wing structures, necessary for
maintaining structural integrity. The FML Glare is currently applied as upper fuselage
skin material and impact resistant empennage leading edges on the Airbus A380. The
material is also applied as high damage tolerant butt strap joint material in the Airbus
A340 fuselage.
Introduction to Aerospace Structures and Materials 57
(3.2)
where indicates the volume fraction of the constituent in the fibre reinforced
laminate. This linear relationship is illustrated for the density of the laminate in Figure
3.13.
Figure 3.13
Rules of mixtures to estimate the composite ply properties based on the matrix and fibre properties relative to their
volume content (Alderliesten, 2011, 3-13.jpg. Own Work.)
Similarly, this rule of mixtures relationship is illustrated in Figure 3.14 for a carbon fibre
composite with various lay-up configurations. Here, it should be clear that the high
fibre volume may improve the properties, but that the different orientations reduce the
overall laminate properties significantly. The grey shaded area in this figure illustrates
the common fibre volume fractions typically applied in composites.
58 R.C. Alderliesten
Figure 3.14
Illustration of the effect of fibre volume fraction of the individual composite plies and lay-up on the overall laminate
stiffness (shaded area is typical range of fibre volume fractions). Alderliesten, (2011). 4-14.jpg. Own Work.
One could assemble a list of requirements for the engineering materials considered.
Comparison between these material requirements and, for example, structural
requirements would reveal a large overlap. However, here one should be careful: there
are significant differences between these two.
Several requirements for structures are also mentioned for materials: high strength,
high stiffness, low weight, durability, and costs. Nonetheless, one should keep in mind
that for compliance to structural requirements the geometry of the structure could be
changed.
For example, to increase the stiffness of a structure, one can select either a material
with a higher stiffness, and/or create a stiffer geometry (shape/design). But, changing
the stiffness of the material, represented by its Young’s modulus, is not possible.
Likewise the density is a material constant. Other properties like the strength and the
durability can be changed by (slightly) changing its composition (another alloy) or
condition (temper).
Therefore, meeting the requirements should be achieved both on a structural level and
material level. Once dominant material requirements are met, discrepancies could
be solved on a structural level. For example, the earlier mentioned differences in
CTE could induce thermal stresses in a structure. This cannot always be solved by
changing one of the applied materials. The structural design solution, i.e. type of joint,
direct contact between materials or separation by intermediate layers, could solve
those specific issues.
Introduction to Aerospace Structures and Materials
Dr.ir. R.C. (René) Alderliesten