Talk Composites - The Forum for Advanced Composites

Composite alternatives to Aluminium

http://www.talkcomposites.com/Topic7793.aspx

By WillRane - 9/12/2013 6:17:20 PM

Hi everyone,

Since its my first post on here; my background is as a Mechanical Engineering student, who spends his summers working in the aviation industry. I have always wanted to set up a small venture with my own capital, and I am simply looking for some friendly technical advice.

I want to know what the best alternative to Aluminium would be, in the composite world. I'm really looking to reduce weight, and perhaps gain some strength. It needs to be durable and relatively resistant to impact. Basically something with similar characteristics to Alu.

I would be using it to make a base sheet, but would like to look at a working a solid profile cut. It doesn't have to be accurate to .000 etc, its fairly bulky stuff. 

I'll be reading into this stuff in my free time, but I'd like to get some direction from some more qualified people than myself.

Thanks for reading,

Will.
By FLD - 9/15/2013 10:10:39 AM

Aluminium is a great material so is quite tough to replace.  Especially if you're wanting lighter whilst retaining strength.  It can be done though Smile  My car had an aluminium undertray / diffuser.  I made a carbon version with spread tow cloth.  Generally laying up carbon to the same thickness as alloy will be similar in weight.  Making it thinner makes it floppy.  If you use a foam core then you get the rigidity and the weight saving (not sure on the weight with soric).  I used a 3mm core and I find this more rigid than alloy.  If you need more rigidity you can use 3D core.  The impact resistance will be partially down to the resin but you could incorporate some Kevlar into your layup.  I've used 1 layer of carbon then the second at 45 degrees.  Your second layer could be Kevlar for the toughness.  I think your main obstacle will be getting CAA approval for any home made parts as composites can vary being had made.  I'll be interested to see how you get on.