The usage of composite materials on the Boeing 787 Dreamliner project:

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The usage of composite materials on the Boeing 787 Dreamliner project

The Boeing 787 makes greater use of composite materials in its airframe and primary structure than any previous Boeing commercial airplane. Undertaking the design process without preconceived ideas enabled Boeing engineers to specify the optimum material for specific applications throughout the airframe. 

The result is an airframe comprising nearly half carbon fiber reinforced plastic and other composites. This approach offers weight savings on average of 20 percent compared to more conventional aluminum designs. Without preconceived ideas, Boeing engineers were able to specify the optimum material for specific applications throughout the airframe. The result couldn't be different: the 787 is 50% composites by weight and by 80% volume with each aircraft containing approximately 32,000 kg of CFRP composites. 

Selecting the optimum material for a specific application meant analyzing every area of the airframe to determine the best material, given the operating environment and loads that a component experiences over the life of the airframe. For example, aluminum is sensitive to tension loads but handles compression very well. On the other hand, composites are not as efficient in dealing with compression loads but are excellent at handling tension. The expanded use of composites, especially in the highly tension-loaded environment of the fuselage, greatly reduces maintenance due to fatigue when compared with an aluminum structure. This type of analysis has resulted in an increased use of titanium as well. 

In addition to lowering the overall airplane weight, moving to a composite primary structure promises to reduce both the scheduled and nonroutine maintenance burden on the airlines. In total, the reduced risk of corrosion and fatigue associated with composites combined with the composite repair techniques described will lower overall maintenance costs and maximize airline revenue by keeping airplanes flying as much as possible! 

Source:Managing Composites