Beyond Aerospace Tubing: SWA Forging’s Unmatched Strength for Critical Aircraft Components

Are you searching for aluminum solutions that go beyond standard tubing for your aerospace needs, demanding unparalleled strength and integrated 3D structures? Let's explore how forging excels where others can't.

For critical aircraft structural components demanding the highest strength-to-weight ratios, fatigue resistance, and integrated 3D geometries, forged aluminum alloys¹ like those expertly crafted by SWA Forging often outperform standard tubing or other formed materials.

The aerospace industry is synonymous with demanding material requirements. When it comes to structural components, the relentless pursuit of lighter weight coupled with maximum strength, fatigue resistance, and reliability is paramount. While aluminum tubing and various formed aluminum parts are certainly used in aerospace for applications like fluid lines, interior elements, and some structural framing, they often reach their limits in mission-critical areas. These areas require components that can withstand extreme stress, vibration, and temperature fluctuations without failure. Standard manufacturing processes for tubing can sometimes result in material inconsistencies or limitations in achieving complex, optimized geometries. At SWA Forging, our expertise in closed-die forging allows us to create aluminum alloy components with superior material integrity. By carefully controlling the metal flow during the forging process, we refine the grain structure, eliminate internal defects, and produce parts with exceptional strength and durability, often in integrated 3D shapes that are impossible to achieve with simple extrusion or bending. This makes forged components the preferred choice for critical structural applications where performance and safety are non-negotiable.

Which metal is most commonly used for aircraft structural components?

Aluminum alloys are the most commonly used metals for aircraft structural components due to their excellent strength-to-weight ratio, corrosion resistance, and relative ease of manufacturing.

Aluminum alloys, particularly those in the 2000, 7000, and sometimes 6000 series, are predominantly used for aircraft structural components because they offer the best balance of low weight, high strength, good fatigue resistance, and cost-effectiveness for widespread application.

When building an aircraft, material selection is a critical decision, influencing everything from fuel efficiency to safety. Aluminum has long been the workhorse of the aerospace industry for structural applications, and for good reason. Its primary advantage is its exceptional strength-to-weight ratio. Aircraft need to be incredibly strong to withstand the stresses of flight, but also as light as possible to improve fuel efficiency and performance. Aluminum alloys deliver this crucial balance. Specific alloys like 2024 (aluminum-copper) and 7075 (aluminum-zinc) are highly favored for primary structures such as fuselage skins, wing structures, and critical internal frames because of their high tensile strength and fatigue resistance. While titanium and advanced composites are also used for highly specialized or extreme-performance applications, aluminum remains the most common choice for the bulk of the aircraft structure due to its proven track record, cost-effectiveness, and versatility. At SWA Forging², we specialize in high-strength aluminum alloys, understanding their unique metallurgical properties that make them ideal for these demanding roles.

Common structural metals in aircraft:

• Aluminum Alloys: Most prevalent due to strength-to-weight, corrosion resistance, cost.
  • Key alloys: 2024, 7075, 6061 (used in various structural and secondary components).
• Titanium Alloys: Used for higher temperature applications, critical components where aluminum strength is insufficient, and corrosion resistance is paramount.
• Steel Alloys: Primarily for landing gear and high-strength fasteners due to extreme strength and wear resistance, but heavier.
• Composite Materials: Increasingly used for wings, fuselage sections, offering very high strength-to-weight and design flexibility.

Aluminum alloys are the backbone of aircraft structures due to their optimal balance of properties.

Which of the following are common materials used in aircraft construction?

Common materials used in aircraft construction include aluminum alloys, titanium alloys, high-strength steel alloys, and advanced composite materials³ like carbon fiber reinforced polymers.

Key materials in aircraft construction are aluminum alloys (for general structure), titanium alloys (for high-temp and high-strength areas), steel alloys (for landing gear, fasteners), and composites (for lightweight strength and aerodynamic shaping), each chosen for specific performance needs.

The complexity of an aircraft means that a single material cannot meet all design challenges. Therefore, engineers select from a range of advanced materials to optimize performance, safety, and efficiency. As previously mentioned, aluminum alloys are foundational, used extensively for airframes, wings, and fuselage due to their excellent strength-to-weight ratio. However, for components exposed to higher temperatures or requiring even greater strength, titanium alloys are employed, particularly in engine components and high-stress airframe areas. High-strength steel alloys are still critical for components like landing gear struts and critical fasteners where sheer strength and durability are essential, despite their higher weight. More recently, composite materials, such as carbon fiber reinforced polymers (CFRP), have become increasingly significant, especially in modern aircraft designs like the Boeing 787 and Airbus A350. Composites offer exceptional strength and stiffness at very low weights, allowing for more complex aerodynamic shapes and further weight savings. At SWA Forging, our focus is on high-performance aluminum alloys, providing solutions that leverage the unique benefits of aluminum for demanding aerospace applications where our forging expertise can provide superior material integrity.

Material categories in aircraft construction:

• Aluminum Alloys: Fuselage, wings, ribs, skins, frames.
• Titanium Alloys: Engine components, landing gear parts, high-temperature structural elements.
• Steel Alloys: Landing gear, engine mounts, fasteners, high-stress fittings.
• Composite Materials: Wings, fuselage sections, control surfaces, interior components.

A blend of aluminum, titanium, steel, and composites builds modern aircraft.

What metal is used in aerospace?

While various metals are used, aluminum alloys are the most prevalent in aerospace due to their favorable strength-to-weight ratio, corrosion resistance, and cost-effectiveness, though titanium and specialized steel alloys are also crucial for specific high-performance applications.

Aluminum alloys are the primary metals used in aerospace for airframes and many structural components, with titanium and specialized steel alloys being critical for high-temperature, high-stress, or high-strength requirements in engines, landing gear, and critical structural elements.

The term "aerospace metals" encompasses a range of materials, each chosen for its unique performance characteristics. At the forefront is aluminum, particularly alloys like 2000 and 7000 series, which form the bulk of the aircraft structure. Their low density combined with high strength makes them ideal for reducing overall aircraft weight, directly impacting fuel efficiency and payload capacity. Titanium alloys are also vital, especially for parts that experience higher temperatures, such as engine components, or require exceptional strength and corrosion resistance, like certain airframe structures or landing gear. Titanium offers a higher strength-to-weight ratio than most aluminum alloys and can withstand higher operating temperatures, but it is significantly more expensive. Steel alloys, especially high-strength steels, are used in areas that demand extreme hardness, strength, and wear resistance, such as landing gear, engine shafts, and fasteners. While heavier than aluminum or titanium, their sheer robustness makes them indispensable for these critical components. SWA Forging specializes in advanced aluminum alloys, providing forged components that meet the rigorous demands of aerospace applications, offering superior material integrity compared to basic formed shapes.

Key metals in aerospace:

• Aluminum: Airframes, wings, fuselage, general structures.
• Titanium: Engines, high-stress airframe parts, landing gear components.
• Steel: Landing gear, fasteners, engine mounts, high-strength fittings.

Aluminum is dominant, but titanium and steel are vital for specific critical functions.

What is the difference between aluminum pipe and aluminum tube⁴?

The fundamental difference lies in their intended use and manufacturing standards: aluminum pipes are typically specified by their internal diameter (schedule) and used for fluid or gas transport, while aluminum tubes are usually specified by their outside diameter and wall thickness and used for structural or mechanical purposes.

Aluminum pipes are designed for conveying fluids or gases and are specified by internal diameter (schedule) and wall thickness, whereas aluminum tubes are primarily for structural or mechanical applications, specified by outside diameter and wall thickness, and often offer greater design flexibility and tighter tolerances.

When discussing aluminum with clients, especially those coming from different engineering backgrounds, the distinction between "pipe" and "tube" is important. While they might seem interchangeable, they have distinct technical definitions and applications. Aluminum pipes are generally manufactured to standards like ASTM B373 or similar, with dimensions based on a nominal pipe size (NPS) and a wall thickness designated by a "schedule." The internal diameter is the primary reference. Pipes are intended for transporting fluids and gases under pressure, so wall thickness and pressure rating are key considerations. Aluminum tubes, conversely, are typically specified by their outside diameter (OD) and wall thickness. They are manufactured to ASTM B210 or B221 standards, among others, and are often used for structural applications, mechanical components, heat exchangers, or decorative elements where precise dimensions, formability, and surface finish are more critical than pressure rating. The ability to form complex shapes, as in extrusion or forging, is more common with tubes. For example, the complex, integrated 3D structures we produce at SWA Forging are inherently "tubes" or tubular components designed for maximum structural efficiency and strength, not for fluid transport under pressure in the same way a standard pipe would be.

Pipe vs. Tube distinction:

• Aluminum Pipe:
  • Application: Fluid/gas transport.
  • Dimensioning: Internal diameter (Schedule).
  • Standards: e.g., ASTM B373.
• Aluminum Tube:
  • Application: Structural, mechanical, heat exchange.
  • Dimensioning: Outside diameter and wall thickness.
  • Standards: e.g., ASTM B210, B221.
  • Manufacturing: Extrusion, drawing, forging.

Pipes are for fluid transport; tubes are for structure and mechanical uses.

Conclusion

For mission-critical aerospace applications demanding superior strength, fatigue resistance, and complex integrated structures, SWA Forging’s advanced aluminum alloy components offer unparalleled performance beyond standard extruded tubing.