Core Materials for Aircraft Structures

Evonik Industries offer a full line of ROHACELL^® foam products which, due to their impressive mechanical strength, wide temperature range, and excellent temperature resistance, can provide for a range of application requirements. In particular, ROHACELL^® HERO foam is ideal for use as aircraft structural parts and has been qualified by AIRBUS under AIMS 04-11-011 and ABS5955 standard since 2017. Ultimately, ROHACELL^® HERO allows aircraft manufacturers to design innovative components that are lightweight, strong and efficient to produce.

Putting Rohacell^® HERO to the Test

In order to examine the technical performance of aircraft parts made from ROHACELL^® HERO, two aircraft structures, leading edge and nose landing gear door, were built and tested. The outcome confirmed both technological and economic benefits in utilizing a ROHACELL^® HERO core in structural aircraft parts.

Proven Technical and Economic Advantages

The bird strike impact test was used to examine the technical performance of the leading edge and landing gear door. This test simulates the effects of an airborne bird impact, which can result in significant damage to aircraft components and equipment, as well as danger to human life. It was discovered that the ROHACELL^® HERO foam core passed the tests, confirming its structural feasibility for use as aerospace structures.

In addition, the economic case evaluation also displayed ROHACELL^® HERO in a positive light. For example, the nose landing gear door was found to cost up to 25% less per part using the foam core, with weight savings of up to 19% per part. The overall savings achieved from using ROHACELL^® HERO are thought to result from shorter processing times during multiple production steps, as compared to traditional honeycomb/prepreg methods.

AIRBUS Group and ROHACELL^® HERO

Due to the positive results from these tests, Evonik announced the signing of a procurement frame contract with AIRBUS Group in November 2016, founding joint agreement on development, manufacture and supply of structural foams and plastic products for aircraft applications.

This agreement forms the basis for a sustainable and long-term partnership with the aircraft OEM and Tier 1 suppliers.

This information has been sourced, reviewed and adapted from materials provided by Evonik Industries - ROHACELL.

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