Pros and Cons of Composite Materials on Aircraft

Composite materials have revolutionized the manufacturing sector of the aviation industry, presenting a variety of new avenues for bolstering aircraft durability and fuel efficiency. Engineered from two or more constituent materials with significantly different physical or chemical characteristics, composites often make up 50–70% of recent aircraft by weight, competing with traditional options. In this blog, we will examine the most notable benefits and limitations of composite materials, helping you evaluate their suitability for specific aerospace applications.

Common Types of Composites Used in Aircraft

Fiberglass

Fiberglass consists of fine strands of glass woven into a fabric and embedded within a polymer resin, offering moderate strength, good corrosion resistance, and excellent flexibility. While it is heavier and less stiff than carbon fiber, fiberglass is significantly more cost-effective and easier to repair. As such, it is widely used in light aircraft, radomes, fairings, and secondary fuselage structures.

Glass Fiber Reinforced Polymer (GFRP)

Similar to fiberglass, GFRP uses glass fibers embedded in a resin matrix, but it is typically manufactured with more uniform and controlled weaves to improve its structural consistency. Due to its excellent dielectric properties, GFRP is used in parts like antenna covers and interior panels that demand electrical insulation.

Carbon Fiber Reinforced Polymer (CFRP)

CFRP is composed of carbon fibers, which are known for their high stiffness and tensile strength, set within a thermosetting resin matrix. The matrix binds the fibers and transfers stress between them, whereas the carbon fibers bear most of the load, a dynamic that works well for primary structural components such as wings, fuselage panels, and tail assemblies.

Aramid Fiber Composites

Aramid fiber-reinforced composites, commonly associated with the Kevlar® brand, are made by embedding strong aramid fibers into a resin matrix, typically epoxy. With a low density yet exceptional impact resistance and fatigue performance, aramid composites are used in areas vulnerable to foreign object damage and bird strikes, such as wing leading edges, engine nacelle components, cargo liners, and bulkheads.

Fiber-Reinforced Matrix Systems

This category encompasses a range of composite structures made by embedding strong fibers, usually carbon or glass, into thermosetting resins. Fiber-reinforced matrix systems are optimized for stiffness, strength, and environmental durability, and they are also able to be tailored through fiber orientation and matrix type to meet specific structural requirements.

Thermoplastic Composites

Thermoplastic composites typically combine carbon or glass fibers with a polymer matrix such as polyether ether ketone (PEEK), polyphenylene sulfide (PPS), or polyetherimide (PEI), becoming soft and moldable when heated and harden upon cooling. With this characteristic, they can be rapidly processed, reshaped, and sometimes even welded. Furthermore, these materials display high impact resistance, damage tolerance, chemical resistance, and recyclability.

Though these materials are usually only employed in aircraft interiors, access panels, and clips, advancements in automated fiber placement and welding technologies have enabled a growing use in structural applications like brackets, wing ribs, and fuselage stiffeners.

Why Composites Are Increasingly Used in Aircraft

Different composites carry distinct benefits, but for the most part, their use is in the pursuit of:

1. A Lightweight Nature: Less weight translates into:
   • Better fuel efficiency
   • Greater payload capacity
   • Improved maneuverability
2. A High Strength-to-Weight Ratio: Some composites, like carbon fiber, are much stronger than aluminum while remaining lighter.
3. Corrosion and Fatigue Resistance: Composites generally do not corrode as easily as most standard metals and tend to flex under pressure rather than crack, resisting wear.

Disadvantages of Composite Materials

1. Difficult Damage Detection: Identifying internal delamination, fiber breakage, or matrix cracking that does not visibly manifest on the surface can be challenging with some composites, particularly carbon fiber and glass fiber variants. Often, impact damage can only be identified with non-destructive inspection techniques like ultrasonic testing, thermography, or shearography.
2. Complex and Costly Repairs: While they tend to have a longer lifespan, the upfront time and labor put into composite repairs can be significantly higher than for metals, often requiring:
   • Specialized materials and tooling
   • Precision curing processes (such as vacuum bagging and heat application)
   • Certified technicians trained in composite restoration
3. Heat Sensitivity: The polymeric resin matrices used in most composite structures have defined temperature limits. For many, mechanical performance begins to degrade around 150°F, and structural integrity may be compromised at 250°F to 300°F. Additionally, some options can emit toxic gasses and microparticles that pose respiratory harm. As such, heat-resistant coatings, compartmentalization, and limits to the use of certain composites in high-temperature applications need to be strategically implemented or considered.

Secure a Wide Array of Composite Components on ASAP Aviation Procurement

In all, composite materials offer incredible benefits in terms of weight reduction, fuel savings, and durability, but like any material, their drawbacks must be managed. Along with careful selection and smart design, the success of composite integration also depends on securing the right components from reliable avenues. This is where ASAP Aviation Procurement, an ASAP Semiconductor purchasing platform, steps in as a go-to source.

Here, we present an expansive, high-quality inventory of composite aviation parts and other such items from renowned manufacturers and suppliers from around the world. Additionally, with easy navigation on our website, rapid responses to quote requests, and efficient delivery, we make it convenient to shop with us. With this being said, be sure to check out our selection and connect with our experts to see how we can serve you with competitive, curated procurement options.