Engineering material for weight savings of up to 50 per cent

Citation

(2001), "Engineering material for weight savings of up to 50 per cent", Aircraft Engineering and Aerospace Technology, Vol. 73 No. 1. https://doi.org/10.1108/aeat.2001.12773aad.011

Engineering material for weight savings of up to 50 per cent

Engineering material for weight savings of up to 50 per cent

Keywords: BFI OPTiLAS, Alloys, Casting

BFI OPTiLAS has announced the availability of Beralcast®, a range of light-weight, high-stiffness aluminium beryllium alloys that can be investment cast into complex "near net shapes". Beralcast is said to be significantly lighter and stiffer than aluminium, has higher ductility than pure beryllium, with a specific modulus several times greater than aluminium, magnesium or aluminium based composites. Beralcast 363 grade is stated to be 31 times stiffer than aluminium, yet 22 per cent less dense. According to BFI this combination of properties often enables designers to further optimise design and achieve weight savings of up to 50 per cent over conventional aluminium casting with design-to-cost affordability.

Manufactured by Starmet, Beralcast claims a set of physical and mechanical properties significantly superior to castings manufactured from more conventional materials. BFI believes that Beralcast offers the design engineer a lower density, higher stiffness, lower CTE, high thermal conductivity and near net shape alternatives. In addition it considers that Beralcast is inherently isotropic and stable in nature and offers exceptional vibration damping characteristics.

Starmet uses investment casting technology developed specifically for these alloys to produce the Beralcast range. Beral-castings for high performance applications can be heat-treated or hot isostatically pressed to improve strength and ductility. Starmet offer a rapid prototyping service, said to be ideal for evaluation before building tools with geometrically complex features. Techniques available include stereo-lithography, selective laser sintering, laminated object manufacturing, solid ground curing and laminated ground curing.

In the manufacturer's opinion Beralcast is ideal for use in aerospace products including satellite components, avionics packaging and aircraft/missile systems. Critical elements to the design of such products are low mass, high stiffness, damping capacity, thermal expansion and heat load management.

Satellite components

Struts, booms, deployment mechanisms, fittings, fasteners, heat pipes, electronic packaging and battery housings.

Avionics packaging

Chassis, heat-sinks, electronics racks, cold plates, antenna and wave guide components.

Aircraft/missile systems

Guidance components, electro-optics, sensors, housings, gimbals and mirrors.

BFI OPTiLAS work with European fabrication sources to offer Starmet Beralcast components fully machined and finished, so the customer does not need to arrange for any special facilities. Castings can be produced in a wide range of size and complexity – up to 12kg in weight and 1m in diameter.

Details available from: BFI OPTiLAS Ltd. Tel: +44 1622 882467; Fax: +44 1622 882469; Web site: www.bfi.avnet.com