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Constellium Bets on lighter recycled aluminum for future planes

Constellium tests lighter alloys as it positions itself to compete with composite materials in future single-aisle aircraft.

Aluminium suppliers, who had lost market share to composites on larger aircraft like Airbus A350 or Boeing 787, have maintained their position in smaller models such as the Airbus A320. This is due to the low-density aluminum alloys, and the familiarity of the industry with mass-produced jets.

After a recent boom in aircraft orders, and as supply chain problems eased, aluminium still has a lot of demand. The metals analyst CRU predicts an 8% annual average growth in aluminum consumption in aerospace across Europe and North America between 2024 and 29.

As attention turns to the new generation of narrow body jets, aluminium and composites will once again be in a battle. Metal suppliers like Constellium, Novelis, and composites manufacturers like Hexcel, will compete with each other.

In order to combine the lightweight properties of thermoplastics with improved production methods, planemakers are focusing on emissions reduction and output rates.

Constellium anticipates that Airbus and Boeing will choose materials for their future single-aisle model around 2029-2030. The supplier also aims to push the aluminium edge in recycling and further progress in alloys.

Hoffmann, speaking at the Paris Airshow, said that the A320 successor is currently on the drawing boards or at least the agenda.

Constellium demonstrated a 20% weight reduction in tests on a new wing concept using new alloys. The process of welding eliminates the need for any rivets.

He added that the use of friction stir weld, which Constellium has used in its work on space programmes will allow for more automation when manufacturing panels.

Constellium believes that aluminium is more reusable than composites and can save 95% of energy compared to virgin metal.

The company is working on better ways to recover scrap metal per alloy, both during production and at the end-of-life of a growing fleet.

He said that aluminum was recycled long before our birth. "They have many qualities, but recycling maturity is not the exact same." Reporting by Gus Trompiz, Editing by Mark Potter

(source: Reuters)