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<p>The aerospace engineering sector is undergoing a transformative shift toward lightweight materials, driven by the relentless pursuit of enhanced performance and efficiency. This review presents, for the first time, a quantitative comparative framework for process–structure–property relationships across all major aerospace lightweight material classes—composites, aluminum, titanium, and magnesium alloys—integrating recent advances in additive manufacturing, sustainability metrics, and hybrid structure design. Unlike existing literature surveys, this work explicitly benchmarks material selection criteria, quantitative mechanical properties, failure mechanisms, and sustainability considerations within a unified decision framework for aerospace designers. These materials are vital to aircraft design, mission success, and fuel economy. This study systematically classifies lightweight materials into composites, metallic alloys, and polymers, and provides in-depth analysis of their properties, manufacturing techniques, and aerospace applications. Advanced alloys including titanium, aluminium, and high-strength steel are examined alongside sophisticated polymers and nanocomposites. The review documents the superior specific strength of aerospace composites (CFRP: ~200–250 kN·m/kg; Ti-6Al-4&#xa0;V: ~196 kN·m/kg; Al 7075-T6: ~208 kN·m/kg), the latest innovations in metallic alloy processing, and the growing role of polymeric materials and nanocomposites in lightweight structural design. Manufacturing technologies including additive manufacturing and precision machining are critically evaluated for their role in weight reduction. Structural durability, corrosion mechanisms, and fatigue failure thresholds are discussed with quantitative context. A dedicated analysis of sustainability, recyclability, and green manufacturing practices is included. Practical performance benchmarks and documented case studies are provided throughout. Concluding with a forward-looking perspective, the study outlines specific future advancements and research priorities anchored in current literature gaps, underscoring the transformative role of lightweight materials in shaping the future of aerospace engineering.</p> Graphical Abstract <p></p>

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Investigating the functional integration of lightweight alloys in aerospace systems

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月20日

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  • Nandagopal Kaliappan,
  • R. Venkatesh,
  • K. Premnath,
  • Habtamu Alemayehu

摘要

The aerospace engineering sector is undergoing a transformative shift toward lightweight materials, driven by the relentless pursuit of enhanced performance and efficiency. This review presents, for the first time, a quantitative comparative framework for process–structure–property relationships across all major aerospace lightweight material classes—composites, aluminum, titanium, and magnesium alloys—integrating recent advances in additive manufacturing, sustainability metrics, and hybrid structure design. Unlike existing literature surveys, this work explicitly benchmarks material selection criteria, quantitative mechanical properties, failure mechanisms, and sustainability considerations within a unified decision framework for aerospace designers. These materials are vital to aircraft design, mission success, and fuel economy. This study systematically classifies lightweight materials into composites, metallic alloys, and polymers, and provides in-depth analysis of their properties, manufacturing techniques, and aerospace applications. Advanced alloys including titanium, aluminium, and high-strength steel are examined alongside sophisticated polymers and nanocomposites. The review documents the superior specific strength of aerospace composites (CFRP: ~200–250 kN·m/kg; Ti-6Al-4 V: ~196 kN·m/kg; Al 7075-T6: ~208 kN·m/kg), the latest innovations in metallic alloy processing, and the growing role of polymeric materials and nanocomposites in lightweight structural design. Manufacturing technologies including additive manufacturing and precision machining are critically evaluated for their role in weight reduction. Structural durability, corrosion mechanisms, and fatigue failure thresholds are discussed with quantitative context. A dedicated analysis of sustainability, recyclability, and green manufacturing practices is included. Practical performance benchmarks and documented case studies are provided throughout. Concluding with a forward-looking perspective, the study outlines specific future advancements and research priorities anchored in current literature gaps, underscoring the transformative role of lightweight materials in shaping the future of aerospace engineering.

Graphical Abstract