Plastic Parts in Aerospace Applications
Polymers are made by joining together many monomers and create large molecules. Plastics are composed of chains of polymers; they may be shaped when soft, but once hardened, they are no longer malleable. Some of the different types of plastic include polyethylene terephthalate (PETE or PET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene or styrofoam (PS), polycarbonate, polylactide, acrylic, acrylonitrile butadiene, styrene, fiberglass, and nylon. Polymers are resistant to chemicals, they are heat and electricity insulators, they are light, have varying degrees of strength, and can be processed in many different ways. Some of the ways that plastics are used in aerospace industry to increase efficiency are in the creation of aftermarket components, aircraft interiors, aircraft exteriors, and 3D printing.
Plastic composites are plastics that are reinforced with another material such as fibers, particulates, or powders. Composite materials often improve strength, stiffness, and reduce weight. Some examples of polymer and plastic composites are epoxy, polyacetal or polyoxymethylene (POM), PEEK or polyether ketone, fluoropolymers, and phenolics. A resin is the raw material used for manufacturing plastics.
Using plastic in aftermarket components reduces the cost and complexity of manufacturing. They are also created from computer aided designs (CAD) and therefore are easier for OEMs to share
Plastic is used for many components in the cabin. Butadiene styrene (ABS plastic) is used in airplane panels and luggage compartments because it is good for vacuum forming and can be molded into many different shapes. It is also strong and light. Acrylic and polycarbonate plastics have a high degree of thermal stability and are used in ventilation ducts and seals. Plastics are also used in technical components such as wiring conduits, bushings, and bearings. The varieties of plastics and the ability to easily mold them also make it easier for aircraft designers to be creative in developing different interior aircraft designs. Some of the structural components, such as ribs and spars are also constructed with plastic.
Aircraft doors and some other parts of the fuselage are made out of plastic because they are resistant to corrosion and radiation; they are lightweight; they can withstand high levels of pressurized water or steam; and they are resistant to varying temperatures. The fuel tank cover, landing gear hubcaps, pylon fairings, and randomes are made out of plastic material. Heat resistant and non-corrosive plastics can replace metal fasteners and screws. Brackets, gaskets, guides, seals, spacers, and washers are also made out of certain plastics that are provide thermal stability, insulate, zero flammability, and resistance to chemicals.
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