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Composite structures such as CFRP offer significant weight reduction over the conventional aluminum alloys for aircraft. Weight reduction improves fuel efficiency of the aircraft by approximately 20% which results in cost savings and simultaneously reduces the operational environmental footprint. However, the new aluminum-lithium alloys offer significant improvements and are viable alternatives to CFRP. Aluminum lithium alloy 2195 with Friction Stir Welding is introduced as a successful alternative to CFRP primary structures. A "thick skin" monocoque design with integral stringers as crack stoppers is discussed. An old Macchi 205 WWII fighter plane has been redesigned both in CFRP and 2195-FSW for comparison. The final designs are comparable in weight, but 2195-FSW is more competitive based on mass production costs, reparability, and environmental impact. Macchi 205 airplane is used due to in-depth experience with the original aircraft geometry and loads. Knowledge gained here can be directly transferred to larger structures, from corporate jets to large transport category airplanes.
2195-FSW, aircraft structures, aluminium alloys, CFRP, composite material
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