Scientists at the Moscow Aviation Institute (MAI) have tested a technology for manufacturing parts from ultrathin composite materials. Elements of the wing frame, fuselage, and aircraft empennage become 20–25% lighter.
According to MAI representatives, the ultrathin composite technology is already used in medicine and electronics, but it has been adapted for aviation parts for the first time. The thickness of a single layer of such material is only 0.05 mm, but its strength is not inferior to a standard composite, a layer of which is 2.6 times thicker. The greatest effect is achieved where every gram matters — in light aircraft with medium and low loads.
What is the technical essence
The composite is assembled from individual monolayers of fiber impregnated with a binder. To make the material strong and rigid in different directions, the layers are laid at different angles. The standard layer thickness is 0.13 mm, and at least seven such layers are needed. If calculations require a composite with a thickness of 0.20 mm, two standard layers must be used, which results in 0.06 mm of excess material and increases the weight of the part. Ultrathin composite allows achieving the desired thickness without overspending.
How it was tested
Nikolay Turbin, head of the MAI laboratory, said that the work was carried out in stages: based on manufacturer data, computer models of the material were developed, samples were manufactured and tested, comparing them with standard ones. Using a tomograph and a microscope, the number of internal defects affecting strength, such as microscopic voids, was checked. The material was also studied under load. Based on the results, the models were calibrated and recommendations for production were formed.
The project involved specialists from the laboratory "Modeling of Composite Structures" of the Institute of Advanced Engineering School and the laboratory "Strength" of the MAI Composite Structures Center.
Where it can be applied
The development is primarily aimed at light aircraft with medium and low loads — this is where weight reduction gives the maximum effect. This refers to elements of the wing frame, fuselage, and empennage. In the future, the technology may find application in larger projects where composites are already used: for example, in the design of the MC-21, the share of polymer composite materials reaches 30–40%, and the wing is made of domestic carbon fiber. However, additional tests and certification are required for highly loaded elements.